333508en K PDF

Mobile Lubrication Library
333508K Komatsu Wheel Loader Installation

Instructions
Instructions for installing a Graco automatic lubrication system on the

Komatsu WA600-8, WA500-8, WA500-7, WA470-8, WA470-7, or
WA380-8, WA380-7.
Part No. 17D273, Series B
Maximum System Working Pressure: 2750 psi (18.96 MPa, 189.6 bar)
Important Safety Information

Read all warnings and instructions in all WARNING
FLUID INJECTION HAZARD
Graco related component manuals and all
Komatsu equipment manuals. Save all Fluid leaks from incorrectly installed or ruptured
instructions. components, and/or failure to verify the compo-
nents are properly installed and tested, can
Related Graco Component Manuals* result in serious injury such as fluid spraying in
the eyes or on skin and fluid injection, or equip-
Manual No. Manual Title ment damage. Installation must be done by a
332291 G3 Pump qualified professional or Komatsu certified tech-
nician and tested prior to use.
3A2960 GLC2200 Controller
312497 MSP Divider Valves
*Refer to these instruction manuals for additional infor-

mation related to the installation and operation of system
components.
The information contained in this document is only a recommendation for an automatic lubrication system and is not intended to
replace the installation and maintenance instructions provided by the original equipment manufacturer.
Table of Contents
Table of Contents
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . 3
Recommended Tools and Supplies . . . . . . . . . . . . 4
Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . 4
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . 6
Zerk Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grease Point Fittings . . . . . . . . . . . . . . . . . . . . . . . . 7
Loader Arm Guards . . . . . . . . . . . . . . . . . . . . . . . . . 9
MSP Divider Valve Assembly . . . . . . . . . . . . . . . . 10
MSP Valve Component Identification . . . . . . . . 10
MSP Divider Valve Assembly . . . . . . . . . . . . . . 10
Weld Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Boom Guard Weld Stud Dimensions . . . . . . . . 14
P-Clamp Weld Studs . . . . . . . . . . . . . . . . . . . . . 18
Loader Arm Anchors . . . . . . . . . . . . . . . . . . . . . . . 19
G3 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installing the G3 Pump . . . . . . . . . . . . . . . . . . . 21
Proximity Switch Cable . . . . . . . . . . . . . . . . . . . . . 29
GLC2200 Controller . . . . . . . . . . . . . . . . . . . . . . . . 30
GLC2200 Controller Wiring . . . . . . . . . . . . . . . . 34
Fuse Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
GLC2200 Controller Programming . . . . . . . . . . . . 39
Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hose Assembly Instructions . . . . . . . . . . . . . . . 42
Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Remote Fill Installation . . . . . . . . . . . . . . . . . . . . . 46
Pump to Master Valve . . . . . . . . . . . . . . . . . . . . . . 50
Master Valve to Secondary Valves . . . . . . . . . . . . 52
Front Secondary to Grease Points . . . . . . . . . . . . 54
Middle Secondary and Rear Secondary to Grease
Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Loader Arm Guarding and Bell Crank P-Clamp . 57
Filling and Purging . . . . . . . . . . . . . . . . . . . . . . . . 58
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Routine Service and Equipment Maintenance . . 59
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 64
2 NOTE: Photographs may include optional equipment.

Installation Checklist
Installation Checklist
The following checklist is provided as a tool to ensure all installation procedures are completed.
Completed Description Page
Grease all zerks, before removal 6

Remove zerks and clean threads 6
Install grease point fittings 7
Cut guarding to length; clean, debur and paint 9
Assemble MSP divider valves 10
Mount supplied weld studs; clean and paint 10
Assemble and mount loader arm anchors 19
Mount MSP divider valves 20
Route the proximity switch cable from the master divider valve to the cab 20
Assemble the G3 pump and fittings 20
Install G3 pump; drill mounting holes 21
Mount GLC2200 Controller 29
Wire GLC2200 Controller 34
Connect to fuse panel 36
Program GLC2200 Controller 39
Cut hoses to length, apply hose wraps and fittings 42
Attach hoses one at a time to front secondary and route to the bearing; DO NOT CONNECT 43
Attach main feed line hose to the pump; DO NOT CONNECT TO MASTER VALVE 55
Attach main feed line hoses to the master valve, route to secondary valves; DO NOT CON- 57
NECT
Mount P-clamp and loader guarding 57
Fill the G3 pump reservoir with grease; purge the main feed line 58
Run test program; verify all connections are tight; verify all points are receiving lubricant 59
NOTE: Photographs may include optional equipment. 3

Recommended Tools and Supplies
Recommended Tools and Supplies

Size/Description
Tool US Metric
Combination wrench* 1/4 in. - 3/4 in. 6 mm - 20 mm
Socket set, standard and deep well with ratchet* 3/8 in. - 3/4 in. 9.5 mm - 20 mm
Screwdrivers: standard and Phillips 1 short; 1 long
Adjustable wrench 1 small; 1 medium
High speed drill (corded or cordless)
Drill bit - steel, high quality 5/16 in., 11/16 in.
Center punch fine point
Pipe taper tap 1/8 in. NPT
Hammer
Angle grinder
Grinding disc Heavy grade grinding disc
Flap disc 60 - 80 grit
Cutoff disc High quality disc
Cutting blade / knife Razor blade cutting tool
Standard pliers Rubber handle
Needle nose pliers Rubber handle
Side cut pliers (diagonal cutters) Rubber handle
Slip joint pliers Rubber handle
Locking pliers Small or medium
Electricians wire striper / crimper General duty wire striper / crimper
Soldering iron 30 watt minimum
Electrical solder
Soldering flux
Shrink tubing Various sizes
Electrical tape Black, small roll
Thread sealant Liquid thread sealant such as Loctite 656
Multi-tester / voltmeter Must test DC/AC/Ohms
Electrical connectors Ring connectors (14 gauge)
Tape measure Standard / metric
Komatsu primer and paint Color should match the Komatsu equipment
Documentation / writing implements Small note pad, pen, pencil, marker
*Both US and Metric sizes of these tools are recommended.

Loctite is a registered trademark of the Henkel Corporation.
All other Trademarks used herein are the property of their respective owners.
Installation Notes
Do not use PTFE tape on fitting threads. Liquid pipe
sealant is recommended for use in lubrication sys-
tems to eliminate the potential for contamination. If
you must use PTFE tape, always skip the first two
threads on the fitting.
Refer to the Installation Checklist provided on page

3 to ensure all installation procedures have been
completed.

Typical Installation
Typical Installation
A
D E
F
Key
A GLC2200 Controller
B G3 Automatic Lubrication Pump
C MSP Master Divider Valve
D MSP Secondary Divider Valve - Front Secondary
E MSP Secondary Divider Valve - Middle Secondary
F MSP Secondary Divider Valve - Rear Secondary
Cycle Timing
Pump On Time: 10 minutes (all models)
Pump Off Time: 1 Hour (all models)
Master Valve Cycles:
WA600 - 10 Cycles
WA500 - 8 Cycles
WA470 - 6 Cycles
WA380 - 5 Cycles

Installation
Installation
Before You Start Zerk Fittings

1. Use a clean cloth or rag to remove excessive
WARNING
Disconnect battery (FIG. 1) before installing
grease, contaminants and dirt from the work area.
2. Remove all grease zerks from their installation loca-
tions (FIG. 2).
the lubrication equipment. Installing
lubrication equipment on powered machinery
could result in serious injury from skin
injection or parts moving unexpectedly.
FIG. 2
3. Use a clean cloth or rag to remove any remaining

grease, contaminants or dirt from the area around
the passage way to the grease points.
FIG. 1: Battery Disconnect
Walk around the machine with a grease gun and verify

that every grease point is accepting grease. (Refer to
FIG. 3, page 7 to identify lubrication points). This will
ensure that the valves can dispense grease to the
grease points by identifying potentially blocked pas-
sages from the grease zerk to the grease point.

Grease Point Fittings

1. Apply thread sealant to supplied grease point fit-
tings.
2. Install fittings in grease points. Refer to FIG. 3 and

the related table for installation locations and parts.
3. Refer to Grease Point Table to determine the

Grease Points on your model.
13 9
1
10 8
11 7 6
4 5
12
FIG. 3

Grease Point Fittings Table
WA5007 WA4707 WA3807

QTY
RefNo. Description WA6008 WA5008 WA4708 WA3808
17G422 Adapter,short,1/8BSPTx1/8NPT X X X X
1 Dumpcylinderrodpin 1
555749 Adapter,4JICX1/8NPT X X X X
2 BucketLinkBellcrankBucketPins 2
556763 Elbow,90,4JICX1/8NPT X X X X
17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X X X
3 CenterBellcrankZBarPin 1
4 LowerBucketPin 2
556763 Elbow,90,4JICX1/8NPT X X X X
5 Liftcylinderrodend 2 555749 Adapter,4JICX1/8NPT X X X X
17K062 Adapter,long,1/8BSPTx1/8NPT X X X
17K062 Adapter,long,1/8BSPTx1/8NPT X
6RH 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X X
SteeringCylinderRodPin 1
Front 555749 Adapter,4JICX1/8NPT X X X X
15K783 Elbow,90Street,1/8NPT X
6LH 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X X X
Front 555749 Adapter,4JICX1/8NPT X X X X
6 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X X X
Rear 555749 Adapter,4JICX1/8NPT X X X X
17G422 Adapter,short,1/8BSPTx1/8NPT X
7 Centerhingepinlower 1 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X
15K783 Elbow,90Street,1/8NPT X X
8 CenterHingePinUpper 1 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X
9LH LiftArmHingePins 1 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X
9RH LiftArmHingePins 1 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X X
17G422 Adapter,short,1/8BSPTx1/8NPT X X
10 LiftArmCylinderPinLH 1 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X X
17G422 Adapter,short,1/8BSPTx1/8NPT X X
17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X
10 LiftArmCylinderPinRH 1
17G422 Adapter,short,1/8BSPTx1/8NPT X X X
11 CenterSupport 1 17K061 Elbow,90Street,Adapter,1/8BSPTx1/8NPT X
12 RearAxlePivotPins(all) 3
13 Bucketcylinderpin 1

Loader Arm Guards
Loader Arm Guards

NOTE: The Loader Arm Guards provided in your kit are designed for use on various sizes of Komatsu equipment. For
some installations they will need to be trimmed to the correct size before installation on the Komatsu equipment.
1. Refer to FIG. 4 to determine where to cut the Loader Arm Guards.
NOTE: No cutting is required for the WA600 Model.

Re
WA380 Model measure from the first tab; trim to here

(approximately 41 inches / 1041 mm)
WA470 / WA500 Model Measure from end to the first recess

(approximately 50 inches / 1270 mm)
FIG. 4
2. Refer to Figure FIG. 5 to determine where to cut the Bucket Link Guard.
NOTE: The Bucket Link Guard installed on the WA500 and WA600 models do NOT require cutting.
WA380 Model measure from end; trim to here

(approximately 17.09 inches / 434 mm)
WA470 Model measure from end; trim to here

(approximately 21.8 inches / 553.7 mm)
FIG. 5
3. Use a cutting wheel to cut the Loader Arm Guards

;
and Bucket Link Guard to the correct lengths.
4. WA470 and WA380 models only: Bend up one end

of the Bucket Link Guard as needed to ensure a
good fit as shown in FIG. 6.
FIG. 6: Bent Bucket Link Guard
5. Clean and debur the cut edge. Prime the guarding

with Komatsu primer. When primer has dried, apply
a few coats of matching Komatsu colored paint.

MSP Divider Valve Assembly

The Divider Valve Assembly includes the following com- b. Assemble metering valves to base plates as
ponents: shown in FIG. 8.
MSP divider valve base
MSP divider valve assembly
1/8 in. x 4 JIC straight outlet fittings
Inlet fittings
Cycle indicators
Performance indicators
Proximity switches
Prepare a clean, flat area to assemble the valves.
FIG. 8
MSP Valve Component Identification
2. Remove end plugs and indicator port plugs before
installing performance and cycle indicators in the
MSP block.
B
A 3. Install outlet fittings in ports (FIG. 9).
All outlets use 1/8 in. x 4 JIC straight fittings

(included in kit).
D Outlet
Fitting
E
FIG. 7
Key: FIG. 9
A Valve Section
B Inlet Section 4. Install inlet fittings in ports (FIG. 10).
C Indicator / Port Plug
D End Plug
E End Section Inlet Fitting

1. The MSP metering valves require assembly (FIG. 8).
NOTE: Refer to the MSP Divider Valve Assembly

Location Table (page 12) and divider valve assem-
bly reference illustrations (beginning on page 12) to
verify assembly orientation.
a. Remove components from packaging.
FIG. 10

5. Install grease zerk fittings and zerk cover (FIG. 11). 7. Install cycle indicators into secondary valves into
master valve and proximity switch to each master
valve as shown in FIG. 13).
zerk
FIG. 11
Cycle Indicator
6. Install performance indicators in ports (FIG. 12):
2000 psi (13.79 MPa,137.9 bar) reset indicators

are installed in the master valve (quantity 3).
FIG. 13
1000 psi (6.89 MPa, 68.95 bar) reset indicator
are installed in the secondary valve (quantity 8. Install outlet plugs in all open ports as shown in the
23). divider valve assembly reference photographs (FIG.
14 - FIG. 17) on page 12.
NOTE: Refer to the MSP Divider Valve Assembly
Location Table (page 12) to verify assembly
orientation.
Performance
Indicator
FIG. 12

MSP Divider Valve Assembly Location

Master Master
(WA500/ (WA380/ Front Middle Rear
WA600) WA470) Secondary Secondary Secondary
(FIG. 14) (FIG. 14) (FIG. 15) (FIG. 16) (FIG. 17)
Plug 10S 10S Plug 20T 40T Plug 10S
Plug 15S 15S Plug 30T 40T 20T
Plug 35S 35S Plug 30T 40T 20T
40T 40T 40T
MSP Divider Valve Assembly Reference Illustrations
Master Valve Assembly (FIG. 14) Middle Secondary (FIG. 16)
WA500/WA600 WA380/WA470 ALL
FIG. 14 FIG. 16
Front Secondary (FIG. 15) Rear Secondary (FIG. 17)
ALL WA600 WA500/WA470/WA380

FIG. 17:
FIG. 15

Weld Studs
Weld Studs
NOTE: Weld studs are provided in the installation kit. 3. Adjust installation location for guides and MSP
However, the installer may also use their own weld stud divider valves as needed before spot welding the
welder and weld studs if preferred. weld studs.
4. Clean the surface on the loader arm as needed to

NOTICE prepare it for welding.
To avoid damaging the loader, consult the Komatsu
operations and maintenance manual before welding. 5. Position the guard over the loader arm again and
mark the weld stud locations on the loader arm.
1. Use the loader arm guard and dimensions provided 6. Spot weld studs.
on the MSP Divider Valve and Weld Stud Dimension
Table on page 15 - 17 as a guide to determine 7. Clean the weld with a flap disk or grinding disk.
where to place the weld studs on the loader arm.
8. Prime the weld surface with Komatsu primer. When
2. Use the MSP divider valve assemblies to determine primer has dried, apply a few coats of matching
the installation location of the MSP divider valves on Komatsu colored paint.
the loader arm.
NOTE: Although the guard is shown installed in FIG. 18,
NOTE: Refer to Weld Stud MSP Divider Valve Ref- DO NOT install the guard to the loader arm at this time.
erence Photographs on page 14 to help determine Other equipment must be installed before these parts
the best location for MSP valves. are connected to the machinery.

Weld Studs
Boom Guard Weld Stud Dimensions

(See FIG. 18)
A B C D E F G
Model
inches mm inches mm inches mm inches mm inches mm inches mm inches mm
WA600 8.5 215.9 9.0 228.6 7.0 177.8 2.75 69.85 33.0 838.2 26.0 660.4 2.75 69.85
WA500 5.0 127.0 6.0 152.4 7.0 177.8 2.75 69.85 25.5 647.7 18.5 469.9 2.75 69.85
WA470 6.0 152.4 3.5 88.9 6.0 152.4 2.75 69.85 18.5 469.9 15.7 398.8 2.75 69.85
WA380 6.0 152.4 3.0 76.2 3.0 76.2 2.75 69.85 15.5 393.7 15.7 398.8 2.75 69.85
FIG. 18:

Weld Studs
Weld Stud and MSP Divider Valve Installation Reference Photographs
MSP Divider Valve Weld Stud Dimensions: WA600 Models
A B C D E
inches mm inches mm inches mm inches mm inches mm
2.0 50.8 6.0 152.4 4.0 101.6 3.0 76.2 27.0 658.8
Install MSP divider valves using weld studs. Use the supplied 1/4-20 lock nuts. Refer to FIG. 19 - FIG. 23 for installa-
tion details.
A
D
FIG. 19: Master Left Front Frame E
A
FIG. 22: Rear Secondary
Weld
B Studs
a
a
FIG. 20: Middle Secondary Right Front Frame
C Weld FIG. 23: Front Secondary: Align and center divider

Stud valve weld studs between pads (a) as shown.
FIG. 21: P-Clamp (bell crank)

Weld Studs
MSP Divider Valve Weld Stud Dimensions: WA500 Models
A B C D E F
inches mm inches mm inches mm inches mm inches mm inches mm
1.5 38.1 2.0 50.8 2.5 63.5 3.5 88.9 4.0 101.44 8.5 215.9
Install MSP divider valves using weld studs. Use the

supplied 1/4-20 lock nuts. Refer to FIG. 24 - FIG. 28 for
installation details.
Weld Stud E
Weld
Stud

D
FIG. 24: Master Valves
B
A
FIG. 25: Front Secondary
FIG. 26: Middle Secondary

Weld Studs
MSP Divider Valve Weld Stud Dimensions: WA470 and WA380 Models (FIG. 29 - FIG. 35)
A B C D E F
Model
inches mm inches mm inches mm inches mm inches mm inches mm
WA470 1.5 38.1 6.75 171.4 4.0 101.6 5.0 127.0 18.0 457.2 2.5 63.5
WA380 1.5 38.1 6.0 152.4 4.0 101.6 5.0 127.0 18.0 457.2 2.5 63.5
B
B
C C
FIG. 29: Left Side; Middle Secondary FIG. 31: Right Side; Master Valve
FIG. 30 - WA470-8 Models only: Remove the hose on FIG. 32 - WA470-8 Models only: Remove the remote fill
the left hand side of the machine. Grinding the remote line for the loader arm pivot pin. Grind down the stud on
line anchor is not required unless there is interference the right hand side of the machine.
with the valve.
Weld
Stud
FIG. 32: Master Valve

FIG. 30: Middle Secondary

Weld Studs
P-Clamp Weld Studs

WA600 Models:
Two weld studs are necessary (FIG. 36).
Weld
Stud
FIG. 33: Front Secondary
Weld Stud
F FIG. 36
F
WA500, WA470, WA380 Models:
Install a P-Clamp to the bottom articulation points
(FIG. 37).
Do not install P-Clamp closer than 1.5 inches (38.1

mm) to any mating surface, bearing, edge or frame
weld.
weld stud
E
FIG. 37: P-clamp; bottom articulation points

Loader Arm Anchors
Loader Arm Anchors

Loader arm anchors are used to contain and protect the
bucket pin routing hoses.
1. Assemble the upper and lower anchors by connect-

ing a 1/8 in. NPT x 4 JIC straight fitting and an 1/8
in. NPT x 4 JIC elbow fitting as shown in FIG. 38.
FIG. 38
2. Adjust the elbow fitting to be approximately 45 from

the center of the anchor as shown in FIG. 39. The
hose fitting will be connect to this fitting later in the
assembly. Wrench tighten securely.
FIG. 39
3. Secure the anchors to the weld studs with the sup-

plied 1/4-20 nylon lock nuts. Verify that the straight
fittings in the anchors are parallel with each other to
allow for proper hose alignment when the hoses are
connected. See FIG. 40.
FIG. 40

G3 Pump
G3 Pump 3. Assemble the pressure relief valve.
a. Apply thread sealant (user supplied) to threads

The G3 Pump includes the following components: of pressure relief valve (a) (FIG. 43).
Pump mechanism with attached reservoir
Pressure relief valve (required to protect system
from damage)
Pressure gauge (used to monitor system perfor-
mance and to assist with troubleshooting). b
Mounting bracket and hardware
CPC power cable a
Zip ties FIG. 43
1. Remove all components from the packaging and b. Install pressure relief valve (a) into banjo fitting
place all parts on a clean, flat surface. (b). Wrench tighten (FIG. 43).
c. Install one washer (c) over end banjo bolt (d).

Then install banjo fitting (b) on banjo bolt, fol-
lowed by the second washer (c) (FIG. 44).
c
d
c
FIG. 41
2. WA600 Model only: Install pump element on the

other side of the pump as shown in FIG. 42.
FIG. 44
.
4. Install banjo bolt (d) into pump element (e) (FIG. 45).
FIG. 42
d
FIG. 45

G3 Pump
5. Use two wrenches to tighten banjo fitting. Place one Installing the G3 Pump
wrench on the pump element (e) and the second
wrench over the end of the banjo bolt (d). ONLY WA600 Models
tighten the banjo bolt (d) while holding the pump
element (e) securely in place. Torque banjo bolt (d) 1. The pump will be installed to the inside of the right
to 35 ft. lbs (45.7 Nm) (FIG. 46). Take care to not hand walk way, near the access steps as shown in
over-tighten. FIG. 48.
NOTE: Do not block the operator egress.
FIG. 48
FIG. 46 2. Position the pump mounting bracket in the recessed

area:
6. Install the pressure gauge fitting, pressure gauge The bolt holes closest to the cab should be
and output fitting in the pressure relief valve as placed 1-7/8 inches from the edge as shown in
shown in FIG. 47. FIG. 49.
The bolt holes closest to the hydraulic tank
NOTE: Hold the pressure relief valve securely in should be placed 1/2 inch from the edge (FIG.
place while installing the pressure gauge assembly. 49).
Mark Holes
FIG. 47
FIG. 49

G3 Pump
3. Mark the hole locations with a paint pen or marker 7. Wrap the CPC power cable with the 1/4 in. cable
(FIG. 49). loom (included in the kit) (FIG. 52).
4. Use a center punch to score drill points in the center

of each of the marks. Then use a 5/16 in. high
speed drill bit to drill out the 4 mounting holes.
5. Install the G3 pump mounting bracket to the G3

pump using the supplied hardware (FIG. 50).
Wrench tighten securely.
FIG. 52
8. Connect the power cable to the pump.
9. Route the power cable underneath the decking to

the cab (FIG. 53).
FIG. 50
6. Use supplied hardware to mount the G3 pump

bracket to the holes drilled in Step 2, page 21 (FIG.
51). Power
Cable
FIG. 53
FIG. 51

G3 Pump
10. Finish the power cable routing by threading the

cable end through the rubber grommet on the floor
of the cab, closest to the accelerator pedal (FIG. 54).
(This is the same routing used for the proximity
switch cable).
FIG. 54
11. Use the zip ties (included in the kit) to secure the
proximity cable in place (FIG. 54).

G3 Pump
WA500 Models
NOTE: For WA500-8 Models only, holes should be 4.5
1. On the right side walk way, locate the recessed area
inches from the edge (c) as shown in FIG. 57.
next to the hydraulic tank as shown in FIG. 55.
Recessed
Area
c
FIG. 57
FIG. 55
3. Mark the hole locations with a paint pen or marker.
2. Position the pump mounting bracket in the recessed
area: 4. Use a center punch to score drill points in the center
of each of the marks. Then use a 5/16 in. high
The bolt holes closest to the cab should be
speed drill bit to drill out the 4 mounting holes (FIG.
placed 1.5 inches from the edge (a) as shown in
58).
FIG. 56.
The bolt holes closest to the hydraulic tank Drilled

should be placed 1 inch from the edge (b) (FIG. Mounting
Drilled Holes
56).
Mounting
Holes
a
FIG. 58
5. Install the G3 pump mounting bracket to the G3

pump using the supplied hardware (FIG. 59).
FIG. 56
FIG. 59

G3 Pump
6. Use supplied hardware to mount the G3 pump 10. Finish the power cable routing by threading the
bracket to the holes drilled in Step 2, page 21 (FIG. cable end through the rubber grommet on the floor
60). of the cab, closest to the accelerator pedal (FIG. 63).
(This is the same routing used for the proximity
switch cable).
FIG. 60
7. Wrap the CPC power cable with the 1/4 in. cable
loom (included in the kit) (FIG. 61).
FIG. 61
8. Connect the power cable to the pump. FIG. 63

9. Route the power cable underneath the decking to 11. Use the zip ties (included in the kit) to secure the
the cab. Follow the existing cabling and use the proximity cable in place (FIG. 63).
anchor points to secure the CPC cable with supplied
zip ties (FIG. 62).
FIG. 62

G3 Pump
WA470 and WA380 Models

1. The G3 pump should be mounted on the deck plate
located outside the cab on the right side as shown in
FIG. 64. a
FIG. 64: WA470 model shown
2. (See FIG. 65).

For WA470 models: Drill bolt holes (a) 1-1/8
inch (28.57 mm) from the back of the deck plate.
Center the mounting bracket between the railing FIG. 65
supports (b) as shown in FIG. 65 3. Mark the hole locations with a paint pen or marker.
For WA380 models: Drill bolt holes (a) 7/8 inch
(22.35 mm) from the back of the deck plate. 4. Use a center punch to score drill points in the center
Measure 5.75 inches (146 mm) in from the edge of each of the marks. Then use a 5/16 in. high
closest to the hydraulic tank. speed drill bit to drill out the 4 mounting holes (FIG.
66).
Be sure the holes have enough clearance for
the 5/16 inch washer to seat properly.
Drilled
Mounting
Holes
Drilled
Mounting
Holes
FIG. 66

G3 Pump
5. Install the G3 pump mounting bracket to the G3 9. Route the power cable around the back of the G3
pump using the supplied hardware (FIG. 67). pump and through the bracket as shown in FIG. 70.
Power Cable
FIG. 67
6. Use supplied hardware to mount the G3 pump

bracket to the holes drilled in Step 2, page 26 (FIG.
68).
FIG. 70
10. Secure the power cable to the deck grating with a

zip tie as shown in FIG. 71
FIG. 68
7. Wrap the CPC power cable with the 1/4 in. cable
loom (included in the kit) (FIG. 69).
zip tie
FIG. 71
FIG. 69
8. Connect the power cable to the pump.

G3 Pump
11. For the WA470 model only: Finish the power cable For the WA380 model only: Finish the power cable
routing by threading the cable end through a hole in routing by running the cable along the side of the G3
the deck grating. Follow a path below the deck and pump and then between the deck grating and cab.
under the cab as shown in FIG. 72. Follow a path below the deck and under the cab as
shown in FIG. 73.
Power Cable
Power
Cable
FIG. 73
12. Finish the power cable routing by threading the

cable end through the rubber grommet on the floor
Power Cable of the cab, closest to the accelerator pedal (FIG. 74).
Routing (This is the same routing used for the proximity
switch cable).
FIG. 72
FIG. 74
13. Use the zip ties (included in the kit) to secure the
cable in place (FIG. 74).

Proximity Switch Cable
Proximity Switch Cable

The proximity switch is used to monitor the system.
1. Wrap the proximity switch cable with the 1/4 in.

cable loom (included in the kit). Allow sufficient
cable length to allow for steering articulation.
2. Route the cable through the center of the machine.

Follow the existing electrical and/or hydraulic
cables.
3. Finish the cable routing by threading the cable end

through the rubber grommet on the floor of the cab, Prox
closest to the accelerator pedal. Cable
4. Use the heavy duty zip ties (included in the kit) to

secure the proximity cable in place. Refer to FIG. 75
- FIG. 76 for installation details.
Prox
Cable
FIG. 75
WA600 Power Cord and Prox Cable

FIG. 76

GLC2200 Controller
GLC2200 Controller
The GLC2200 Controller includes the following compo-
nents:
GLC2200 Controller
2 inches
Mounting bracket and hardware
GLC2200 cable
Zip ties
Remove all components from the packaging and place
all parts on a clean, flat surface.
GLC 2200 Mounting Bracket Installation Bend 45

The mounting bracket kit includes the following compo-
nents: FIG. 78
Ref Description Qty 3. Install bracket fasteners (g) to mounting bracket (a)
a Mounting Bracket 1 using bolts (b), washers (c) and nuts (d) as shown in
b Mounting Bolts 6 FIG. 79. Fasten loosely to allow for final adjustment
c Washers 14 when installed to the Komatsu equipment.
d Nuts 6
e Mounting Base Plate 1
f Mounting Plate 1 b
g Mounting Bracket to Cab 2
h Washer, nylon 2
j Screw, pan head 2 g
k Nut 2
c
WA600 Models
1. Remove bolts and washers (w) located on the right d a
hand side of the operators window (FIG. 77). Keep c
washers (w). They will be used for GLC2200 instal-
lation.
FIG. 77
2. Secure long bracket in a vise. Measure down

approximately 2 inches from each end. Bend the
bracket at the 2 inch marks to a 45-degree angle as FIG. 79
shown FIG. 78.

GLC2200 Controller
4. Install the GLC200 mounting plate (f) to the mount- 5. Install the GLC200 controller on the mounting plate
ing base plate (e) using bolts (b), washers (c) and (f) using screws (j), and nuts (k) as shown in FIG. 81.
nuts (d) as shown in FIG. 80. Be sure washer (h) is Tighten mounting bolts just enough to secure the
installed between the mounting plate (f) and mount- controller in the bracket. Adjust the GLC2200 con-
ing base plate (e) on the top an bottom. Wrench troller for the best viewing angle then wrench tighten
tighten nuts securely. bolts securely.
a
j k
b
c
h
c
f e GLC2200
FIG. 81
FIG. 80 6. Adjust bracket fasteners (g) (installed in Step 3) for

installation on the Komatsu loader; matching the
bracket to the location of the bolt holes available
after removing bolts in Step 1 (page 30).
7. Wrench tighten nuts (d) to secure bracket fasteners

(g) to bracket (a).

GLC2200 Controller
8. Use bolts (b) and washer (w) to secure bracket fas- WA500, WA470, WA380 Models
teners (g) to Komatsu loader in bolt holes available
after removing the bolts and washers in Step 1 1. Remove bolt covers, bolts and washers (w) located
(page 30) (FIG. 82). next to the glove box in the cab frame cover pan-
els(FIG. 84). Keep washers (w). They will be used
for GLC2200 installation.
w
b
g
Bolt
Covers
a
FIG. 84
2. Install the GLC2200 mounting base plate (e) to the

mounting bracket (a) using bolts (b), washers (c)
and nuts (d) as shown in FIG. 85. Wrench tighten
nuts securely.
3. Install bracket fasteners (g) to mounting bracket (a)

using bolts (b), washers (c) and nuts (d) as shown in
FIG. 85. Fasten loosely to allow for final adjustment
when installed to the Komatsu equipment.
d
FIG. 82 g
9. Connect GLC2200 wiring harness to the GLC2200 a
controller (FIG. 83). c
b
FIG. 85
FIG. 83

GLC2200 Controller
4. Install the GLC200 mounting plate (f) to the mount- 6. Adjust bracket fasteners (g) (installed in Step 3) for
ing base plate (e) using bolts (b), washers (c) and installation on the Komatsu loader; matching the
nuts (d) as shown in FIG. 86. Be sure washer (h) is bracket to the location of the bolt holes available
installed between the mounting plate (f) and mount- after removing the bolt cover and bolts in Step 1,
ing base plate (e) on the top an bottom. Wrench page 32.
tighten nuts securely.
7. Wrench tighten nuts (d) to secure bracket fasteners
(g) to bracket (a).
b 8. Use bolts (b) and washer (c) and washer (w) to
c secure bracket fasteners (g) to Komatsu loader in
f bolt holes available after removing the bolt covers,
h bolts and washers (w) in Step 1, page 32 (FIG. 88).
c
d w
a
g
e
c
FIG. 86
5. Install the GLC200 controller on the mounting plate

(f) using screws (j), and nuts (k) as shown in FIG. 87.
Tighten mounting bolts just enough to secure the
controller in the bracket. Adjust the GLC2200 con-
troller for the best viewing angle then wrench tighten
bolts securely.
FIG. 88
a j 9. Connect GLC2200 wiring harness to the GLC2200
controller.
GLC2200
f
FIG. 87

GLC2200 Controller
10. Route the GLC2200 wiring harness cable behind 2. Cut back and tape any wires that will not be used in
the cab paneling and under the cab floor mat (FIG. the lubrication system (FIG. 91).
89).
FIG. 91
Each wire connection should be assembled using

the following Wire Splicing procedure:
Refer to the Wiring Table (below) for wire connection
between the GLC2200 controller, G3 pump, proximity
switch, and main power.
FIG. 89
GLC2200 Wiring Table
GLC2200 Harness Prox Pump
GLC2200 Controller Wiring
Color Description +/- Color Color
Blue Pump - Blue Black
NOTICE
Purple Unused (cut) -
To avoid damaging the loader:
Brown Low Level Input - Orange
Turn off and disconnect power at the battery White Prox Switch Signal - Black
before installing equipment.
Black Voltage Input 24VDC -
All electrical wiring must be done by a qualified
professional or Komatsu certified technician. Orange Pump + Brown Red
Green Unused (cut) +
Yellow Low Level Input + White
1. Use a wire stripper to remove 3 inches of wire
sheath from the each of the wiring harnesses (FIG. Gray Unused (cut) +
90). Red Voltage Input 24VDC +
Wire Splicing
1. Remove 1 inch of wire sheath using a wire stripper
(FIG. 92).
FIG. 92
FIG. 90

GLC2200 Controller
2. Slide 1.5 inches of shrink tubing over end of one

piece of wire (FIG. 93).
FIG. 93
3. Connect two (or more) wire ends together by twist-

ing the stripped wire ends of wires together (FIG.
94).
FIG. 94
4. Solder connection with a soldering iron.
5. Slide the shrink tubing over the soldered wires. Use

a heat gun to contract the shrink tubing (FIG. 95).
FIG. 95
6. Repeat Steps 1 - 5 for all wires.
7. Wrap wiring assembly with electrical tape or cable

loom to protect connection.

Fuse Panel
Fuse Panel
1. Remove fuse and relay panel covers (FIG. 96). cable
routing
WA600 Model Only: Remove the fuse panel and
relay panel on the right hand side of the machine
near the operators seat (FIG. 98).
cover
FIG. 99: WA500, WA470, WA380 - The 3 downward
pointing arrows point to the secondary operator
egress door.
3. Locate the wiring on the right rear side of the seat

and through the bottom, toward the door of the sec-
ondary operator egress door. (Refer to the arrow
FIG. 96: WA500, WA470, WA380 Models shown in FIG. 99 and FIG. 100)
cable
routing
FIG. 100
4. Feed cable through the cutout and into the back cor-
ner of the relay panel (FIG. 101).
FIG. 97: WA600 Model
2. Lift the floor mat and route the wiring assembly from
the grommet under the bulkhead panel (FIG. 97 and
FIG. 99).
FIG. 101
FIG. 98: WA600 Model

Fuse Panel
5. Pull the cable through the back of the relay panel, 6. Attach a ring terminal to the controller ground wire
into the fuse panel and out through the panel cover (FIG. 104) (Instructions for wiring and splicing are
(FIG. 103 and FIG. 102). included in the GLC2200 Controller Wiring section,
page 34).
FIG. 104
7. Attach an ATM fuse splice connector to the power

wire of the controller (FIG. 105). Install a 5 Amp fuse.
FIG. 105
8. Remove a bolt from the relay rail closest to the fuse

panel and connect the grounding ring to the bolt.
Re-tighten bolt (FIG. 106).
FIG. 102: WA600
FIG. 106
FIG. 103: WA500, WA470, WA380

Fuse Panel
9. In the fuse box locate the fuse labeled Eng Control 12. Reinstall the fuse cover over the top of the fuse
Key SW Acc (FIG. 107 and FIG. 108). panel and the Add-A-Fuse.
13. Reinstall the relay and fuse panel covers.
NOTE: The fuse should be located on the bottom
left side of the fuse panel.
FIG. 107: WA500, WA470, WA380
FIG. 108: WA600 Auto Grease (OPT) fuse location
10. Remove the 5 Amp fuse installed in the fuse panel

labeled Eng Control Key SW Acc. Install the fuse
into the Add-A-Fuse slot (FIG. 109).
FIG. 109
11. Connect the Add-A-Fuse with both 5 Amp fuses

installed into the fuse panel slot labeled Eng Con-
trol Key SW Acc.

GLC2200 Controller Programming

Component Identification Display (E)
Keypad, Display, and Icons A blinking field on the display indicates the controller
is in SETUP MODE.
NOTICE In RUN MODE field of numbers on the display will

To prevent damage to soft key buttons, do not press not blink.
the buttons with sharp objects such as pens, plastic
cards, or fingernails. Alarm LED (F)
Illuminates when any alarm is detected. When an alarm
B C is active an error code displays and an audible alarm
also sounds.
ON OFF RIGHT Direction Arrow / MANUAL RUN / ENTER (G)
In SETUP MODE, saves entry, moves cursor in
A D display one field to the right or to the next setup
step.
HH MM SS ##
In RUN MODE activates the pump for one com-
plete ON cycle if actuated during the OFF por-
tion of the RUN cycle.
E UP and DOWN Direction Arrows (H)

F
! Press and hold both the UP and DOWN Arrow

keys together for 3 seconds to enter SETUP
G MODE.
In SETUP MODE increase or decrease number
values associated with the various RUN
MODES.
H
J
LEFT Direction Arrow / RESET (J)
In SETUP MODE moves cursor in display one
field to the left.
FIG. 110 In RUN MODE, Pressing RESET starts a PUMP
OFF cycle.
Pump ON LEDs (A, B, C)
In ALARM MODE, Press once to clear buzzer;
A Pressure Control LED: In RUN MODE illuminates
Press and hold for 3 seconds to clear warning
indicating function mode that is currently running.
and switch controller to OFF MODE.
B Cycle Control LED: In RUN MODE illuminates
NOTE: See the GLC2200 Controller Instruction manual
for detailed descriptions of the display features.
C Time Control LED: In RUN MODE illuminates
Pump OFF LED (D)

In RUN MODE this LED illuminates when in the
OFF or RESET portion of the RUN CYCLE.

Programming the GLC200 Controller 6. Program the next field by pressing the
UP or DOWN ARROW until:
Before programming the GLC2200 controller:
0 appears in the next fields for
Restore power to the equipment by engaging WA600 models
the main power switch to the Komatsu WA500-7 8 appears in the next field for
Wheel Loader. WA500 models
Key on the machine to the Acc position. 6 appears in the next field for
WA470 models
1. Press both the UP and DOWN ARROW 5 appears in the next field for WA380 models.
buttons together for three seconds.
7. Press the ENTER button.
The cursor automatically moves to

set up the ON TIME Mode.
2. Use the UP ARROW until on:CY

displays.
The LED below the clock in the ON field lights,
indicating the ON TIME is being programmed.
ON TIME is the amount of time the pump runs
to complete all cycles set up in Steps 1-7.
NOTE: The ON TIME entry is a 4-digit number

setting MM (minutes) and SS (seconds). For this instal-
lation the time is 10 minutes for all Models.
This will allow the controller to 8. Program the first minute field by pressing
count the number of times the the UP or DOWN ARROW button until
master valve cycles to lubricate 1 appears in the first MM (minutes)
the machine. field.
The blinking field indicates the device is ready to
program the number of cycles.
NOTE: The Cycle entry is a 2-digit number and requires 9. Press the ENTER button. The next
a leading zero (0) must be entered in the first field. For MM number field to the right flashes
this installation the master valve entry requires: indicating it is ready for program-
ming.
WA600 models - 10 cycle times per hour
WA500 models - 08 cycle times 10. Repeat steps 8 - 9 to set each of the
WA470 models - 06 cycle times remaining next MM and the SS (sec-
WA380 models - 05 cycle times onds) fields.
4. Program the first field by pressing the UP
or DOWN ARROW until 1 appears in
the first field for WA600 models or 0
appear in the first field for WA500,
WA470 or WA380 models. 11. After pressing the ENTER button to
set the last SS field, all the pro-
grammed Backup Time information is
5. Press the ENTER button. saved.
The cursor automatically moves to The controller automatically switches to the OFF
the next field and flashes. Time SETUP MODE.

The LED below the OFF TIME Symbol Illu-

minates.
OFF
NOTE: The OFF TIME entry is a 4-digit

number setting HH (hours) and MM (min-
utes). For this installation the time is 1 hour
so a leading zero (0) must be entered in the
first HH field.
To set the OFF TIME:
12. Program the first hour field by pressing

the UP or DOWN ARROW button until 0
appears in the first HH (hour) field.
13. Press the ENTER button. The next

HH number field to the right flashes
indicating it is ready for programming.
14. Repeat steps 12 - 13 to set each of the remaining

next HH and the MM (minutes) fields. Press the
ENTER button.
The controller automatically switches to the LOW

LEVEL SETUP MODE.
LOW LEVEL SETUP programs how the low level is

detected by the controller. For this installation the
LOW LEVEL SETUP is programmed to LL:02.
1. Use the UP or DOWN ARROW

until LL:02 displays.
Setup is complete. Listen for an audi-

ble beep signaling the controller is
now programmed and has exited the
SETUP MODE.
NOTE: See the GLC2200 Controller Instruction manual

for detailed programming instructions.

Hose Assemblies
Hose Assemblies
The hose in the kit is provided in bulk and the fittings are field b. Trim the hose spring guard (sg) so it is long
installable; a crimper is not required. enough to cover hose assembly (FIG. 112).
A list of the hose assemblies needed and the assembly
requirements for both 1/8 in. and 1/4 in. hoses is provided in
the Hose Assembly Tables. US Measurements are provided
on page 44 and Metric Measurements are provided on page
45.
NOTE: In the Hose Assembly Table: h
sw
Assembled hose lengths with fittings are shown as Overall sg
Length.
FIG. 112
Use the Cut Length measurement when cutting the hose
from the roll.The 3. Remove two hose fittings from their package and
The hose lengths provided in the Hose Assembly Tables disassemble the two pieces (FIG. 113).
(pages 44 and 45) are for a standard wheel loader. If the
equipment has a high-lift option, the hose lengths pro-
vided for the front secondary valve and feed line from the
master to the front secondary valve are incorrect. Mea-
surements should be made at the time of installation. socket
FIG. 113
Hose Assembly Instructions 4. Connect the socket to the end of the hose. Rotate
1. Wrap or slide spiral wrap (sw) over the end of the the fitting counter-clockwise to thread the hose fit-
cut-to-length hose (h) until the entire length of the ting onto the hose (FIG. 114).
hose is encased in the spiral wrap.
NOTE: A wrench and pliers may be needed to
2. Trim the spiral wrap (sw), leaving approximately 1 assist with this assembly. If socket is difficult to
inch (25.4 mm) of the hose end unwrapped (FIG. install, apply lubricant that is compatible with the
111). hose material.
sw
1 inch
FIG. 114
h 5. Leave approximately 1/16 in. of the hose end before

FIG. 111 completely seating the hose into the fitting. This will
allow enough space for the second half of the fitting
Front Secondary: Lower Bucket Pin Anchor to Pin to be connected (FIG. 115).
LH and RH ONLY
6. Lubricate socket, threads and hose inside diameter.
The Left Hand And Right Hand Front Secondary: Lower
Bucket Pin Anchor to Pin spiral wrapped hose, must
also be protected with a hose spring guard.
a. Slide the hose spring guard (sg) over the end of
the spiral wrapped hose. Feed the hose assem-
FIG. 115
bly into the hose spring guard until the entire
length of the hose is encased in the hose spring
guard.

Hose Assemblies
7. Thread the stud of the nipple clockwise into the

socket installed in the hose until the nipple nearly
Hose Routing
bottoms out against the socket shoulder (FIG. 116). Routing hose lines takes time. It is easier when there
are two people working on the installation together.
NOTE: Two hand wrenches may be needed to
assist with this assembly. Refer to FIG. 135 - FIG. 162 to assist with grease line
routing.
Route hoses by following the path of the already
installed electrical or hydraulic lines.
Route the lines to the grease point but do not con-
FIG. 116
nect the lines to the fittings. Take care to ensure dirt
and/or debris do not get on the grease fitting or
NOTICE introduced into the system.
Do not over tighten the fittings during final assembly.
Secure lines using the supplied zip ties.
After the two fittings are securely connected, stop
tightening the fittings. Over-tightening can damage
the fittings and a new hose assembly will need to be
made.
The nipple should be firm when tightening but not dif-

ficult to install. If the nipple is difficult to install, check
the hose for proper lubrication. Reapply lubricant as
needed. Installation without proper lubrication can
cause damage to the core tube.
8. Repeat Steps 1-7 for all hose assemblies.

Hose Assemblies
Hose Assembly Table - US Measurements (NOTE: Metric measurements are provided on page 45)
Cut Length - inches
Group Lube Point Description Size WA600 WA500 WA470 WA380
Front Secondary Lift Cylinder Rod End Right Side 1/8 in. 26.0 23.0 18.0 19.0
Front Secondary Lift Cylinder Rod End Left Side 1/8 in. 26.0 23.0 24.5 19.0
Front Secondary Center Bellcrank bell crank Pin 1/8 in. 87.0 75.5 67.5 71.5
Front Secondary Upper Bellcrank bell crank Pin 1/8 in. 74.0 78.5 82.0 69.5
Front Secondary Bucket Link Bellcrank Bucket Pin 1/8 in. 172.0 147.5 152.5 141.5
Front Secondary Bucket Link Bellcrank bell crank Pin 1/8 in. 176.0 125.5 126.5 116.0
Front Secondary Lower Bucket Pin Anchor to Pin LH 1/8 in. 26.75 23.5 23.5 23.5
Front Secondary Lower Bucket Pin Anchor to Pin RH 1/8 in. 26.75 23.5 23.5 23.5
Front Secondary Lower Bucket Pin Under Guarding 1/8 in. 63.75 51.0 51.0 42.5
Front Secondary Lower Bucket Pin Under Guarding 1/8 in. 63.75 51.0 51.0 42.5
Front Secondary, steel wrap Lower Bucket Pin Valve to Anchor LH 1/8 in. 61.0 48.0 41.5 40.5
Front Secondary, steel wrap Lower Bucket Pin Valve to Anchor RH 1/8 in. 61.0 48.0 41.5 40.5
Middle Secondary Lift Arm Hinge Pin LH 1/8 in. 81.5 11.0 30.5 31.5
Middle Secondary Lift Arm Hinge Pin RH 1/8 in. 64.25 11.0 120.5 85.5
Middle Secondary Bucket Cylinder Pin 1/8 in. 63.5 11.0 54.0 53.5
Middle Secondary Lift Arm Cylinder Pin LH 1/8 in. 65.0 14.5 7.0 7.0
Middle Secondary Lift Arm Cylinder Pin RH 1/8 in. 65.0 11.0 102.0 113.5
Middle Secondary Steering Cylinder Pin LH 1/8 in. 82.0 14.5 54.0 53.5
Middle Secondary Steering Cylinder Pin RH 1/8 in. 81.5 14.5 54.0 53.5
Middle Secondary Center Support 1/8 in. 82.5 14.5 47.5 53.5
Rear Secondary Rear Axle Pivot Pin - top 1/8 in. 43.75 7.0 16.5 12.0
Rear Secondary Rear Axle Pivot Pin - middle 1/8 in. 45.5 7.0 15.5 11.0
Rear Secondary Rear Axle Pivot Pin - bottom 1/8 in. 37.5 7.0 13.5 10.0
Rear Secondary Steering Cylinder Pin LH 1/8 in. 82.0 19.5 111.0 45.5
Rear Secondary Steering Cylinder Pin RH 1/8 in. 83.0 74.5 175.0 66.5
Rear Secondary Center Pivot Pin 1/8 in. 127.0 57.5 149.5 138.5
Rear Secondary Center Pivot Pin 1/8 in. 166.0 121.5 174.5 141.5
Master to Rear Secondary Steering and Rear Axle 1/4 in. 128.25 92.5 151.5 119.5
Master to Front Secondary Cylinder Lift Pins 1/4 in. 216.0 147.5 151.5 162.5
Master to Middle Secondary Steering and Pivot Pins 1/4 in. 80.25 67.5 82.5 67.5
Pump to Master Master Valve 1/4 in. 2.65 160.0 119.5 115.5
NOTE: The hose lengths provided in the Hose Assembly Tables are for a standard wheel loader. If the equipment has a high-lift
option, the hose lengths provided for the front secondary valve and feed line from the master to the front secondary valve are
incorrect. Measurements should be made at the time of installation.
Additional hose assembly instructions for this hose are provided in the Front Secondary: Lower Bucket Pin Anchor to Pin LH
and RH section on page 42.
Cut length depends on fitting location. Always measure for accuracy before cutting.

Hose Assemblies
Hose Assembly Table - Metric Measurements

Cut Length - mms
Group Lube Point Description Size WA600 WA500 WA470 WA380
Front Secondary Lift Cylinder Rod End Right Side 3.175 mm 660.4 584.2 457.2 482.6
Front Secondary Lift Cylinder Rod End Left Side 3.175 mm 660.4 584.2 595.3 482.6
Front Secondary Center Bellcrank bell crank Pin 3.175 mm 2210.0 1917.5 1714.5 1816.5
Front Secondary Upper Bellcrank bell crank Pin 3.175 mm 1880.0 1993.5 2082.5 1765.5
Front Secondary Bucket Link Bellcrank Bucket Pin 3.175 mm 4369.0 3746.5 3873.5 3594.5
Front Secondary Bucket Link Bellcrank bell crank Pin 3.175 mm 4470.0 3446.5 3213.5 2946.5
Front Secondary Lower Bucket Pin Anchor to Pin LH 3.175 mm 679.4 596.5 596.9 596.9
Front Secondary Lower Bucket Pin Anchor to Pin RH 3.175 mm 679.4 596.5 596.9 596.9
Front Secondary Lower Bucket Pin Under Guarding 3.175 mm 1619.0 1295.0 1295.0 1080.0
Front Secondary Lower Bucket Pin Under Guarding 3.175 mm 1619.0 1295.0 1295.0 1080.0
Front Secondary, steel wrap Lower Bucket Pin Valve to Anchor LH 3.175 mm 1549.0 1219.0 1054.5 1028.5
Front Secondary, steel wrap Lower Bucket Pin Valve to Anchor RH 3.175 mm 1549.0 1219.0 1054.5 1028.5
Middle Secondary Lift Arm Hinge Pin LH 3.175 mm 2070.0 279.5 774.5 800.1
Middle Secondary Lift Arm Hinge Pin RH 3.175 mm 1632.0 279.5 3060.5 2171.5
Middle Secondary Bucket Cylinder Pin 3.175 mm 1613.0 279.5 1371.5 1358.5
Middle Secondary Lift Arm Cylinder Pin LH 3.175 mm 1651.0 367.5 177.8 177.8
Middle Secondary Lift Arm Cylinder Pin RH 3.175 mm 1651.0 279.5 2590.5 2882.5
Middle Secondary Steering Cylinder Pin LH 3.175 mm 2083.0 367.5 1371.5 1358.5
Middle Secondary Steering Cylinder Pin RH 3.175 mm 2070.0 367.5 1371.5 1358.5
Middle Secondary Center Support 3.175 mm 2095.0 367.5 1206.5 1358.5
Rear Secondary Rear Axle Pivot Pin - top 3.175 mm 1111.0 177.8 419.1 304.8
Rear Secondary Rear Axle Pivot Pin - middle 3.175 mm 1156.0 177.8 393.7 279.4
Rear Secondary Rear Axle Pivot Pin - bottom 3.175 mm 952.6 177.8 342.9 254.0
Rear Secondary Steering Cylinder Pin LH 3.175 mm 2083.0 495.3.9 1904.5 1155.5
Rear Secondary Steering Cylinder Pin RH 3.175 mm 2108.0 1892.5 2819.5 1892.5
Rear Secondary Center Pivot Pin 3.175 mm 3226.0 1460.5 3797.5 3517.5
Rear Secondary Center Pivot Pin 3.175 mm 4216.0 3086.5 4432.5 3594.5
Master to Rear Secondary Steering and Rear Axle 6.35 mm 3258.0 2349.0 3848.5 3035.5
Master to Front Secondary Cylinder Lift Pins 6.35mm 5486.0 3746.0 3848.0 4127.5
Master to Middle Secondary Steering and Pivot Pins 6.35 mm 2038.0 1714.0 2095.0 1714.5
Pump to Master Master Valve 6.35 mm 6731.0 4064.0 3035.5 2933.5
NOTE: The hose lengths provided in the Hose Assembly Tables are for a standard wheel loader. If the equipment has a high-lift
option, the hose lengths provided for the front secondary valve and feed line from the master to the front secondary valve are
incorrect. Measurements should be made at the time of installation.
Additional hose assembly instructions for this hose are provided in the Front Secondary: Lower Bucket Pin Anchor to Pin LH
and RH section on page 42.
Cut length depends on fitting location. Always measure for accuracy before cutting.

Remote Fill Installation

Remote Fill Parts WA500 Models
1. Use an 11/16 inch drill bit to drill a hole in the accu-
Ref* Part No. Description Qty mulator cover (located under the stairs) 6 inches
16 556762 CONNECTOR, #4, JIC, 1/4 PM 1 (152.4 mm) from the bulkhead mounting bolt. See
FIG. 118.
19 556773 FITTING, swivel, fem, SAE #4, 2
JIC
45 557950 BULKHEAD, remote fill 1
46 100840 FITTING, elbow, 1/4 in x 1/4 in. 1
47 557896 STUD, fill, 1/4 inch NPTF (f) 1
48 556408 FITTING, 1/4 x 1/8 inch NPTF 1
Hex
49 555749 CONNECTOR, #4, JIC, 1/8 PM 1
50 15K783 FITTING, elbow 1
FIG. 118
*See Parts, page 63.
WA500-8 Models
Instructions 1. Use an 11/16 inch drill bit to drill a hole in the accu-
WA600 Models mulator cover (located under the stairs) 3.5 inches
down (a) and 3 inches from the right hand bolt (b).
1. Use an 11/16 inch drill bit to drill a hole in the bulk-
See FIG. 119.
head on the right hand side behind the ladder as
shown in FIG. 117.
7.5 in.
(190.5 mm)
3 in. (76.2 mm)
FIG. 117
FIG. 119

WA470-7 or WA380-7 Models

1. Place a piece of scrap cardboard or metal inside the
coolant box to protect the plastic coolant container
from the drill bit.
2.75 in.
Use an 11/16 inch drill bit to drill a hole 2 inches (69.85 mm)
(50.8 mm) from the bottom and 3 inches (76.2 mm)
from the right side of the coolant box as shown in 5.5 in.
(38.1 mm)
FIG. 120.
FIG. 123: WA470-8 models - cover installed
3 in.
(76.2 mm)
2.75 in. (69.85 mm)

2 in.
(50.8 mm) 3 in.
5.5 in. (76.2mm)
(38.1 mm)
FIG. 120
2 in.
WA470-8 and 380-8 Models (50.8 mm)
1. Remove the accumulator cover under the right hand
FIG. 124: WA470-8 - cover off
stairwell (FIG. 121-FIG. 124.
2. Mark a hole approximately 5.5" (38.1 mm) from the
2.75 in. left hand side of the plate and 2.75" (69.85 mm)
(69.85 mm) down from the top edge (See FIG. 121 and FIG. 122
for WA380 models and FIG. 123 and FIG. 124 for
5.5 in. WA470 models).
(38.1 mm)
3. Place a piece of scrap cardboard or metal inside the
coolant box to protect the plastic coolant container
from the drill bit.
Use an 11/16 inch drill bit to drill a hole 2 inches

(50.8 mm) from the bottom and 3 inches (76.2 mm)
FIG. 121: WA380-8 models - cover installed from the right side of the coolant box as shown in
FIG. 124.
4. Install swivel (19) to one end of hose that is left over

2.75 in. from previous cut lengths.
(69.85 mm)
5. Remove the pump fitting installed in the G3 pump
inlet, apply thread sealant to threads of elbow fitting
5.5 in. (46) and install elbow fitting in its place.
(38.1 mm)
6. Apply thread sealant to threads of connector (16)
and install connector to elbow (46) installed in G3
pump in Step 5. Tighten securely.
FIG. 122: WA380-8 models - cover off 7. Connect swivel (19) to connector (16). Hand tighten;
then use a wrench to tighten 1/2 turn more.

For WA500 Models For WA380 Models: Route the end of the hose
along a path between the decking and the cab as
Follow along a similar path as the previously installed shown in FIG. 128 and then under the stair platform
main feed line (see FIG. 125) until it reaches the bulk- to the coolant box.
head and the hole drilled in Step 1.
FIG. 125
8. For WA600 Models see FIG. 126
Remote
Fill Hose
Routing
FIG. 128
FIG. 126
Route the end of the hose through hole in the grated Open the coolant box cover. Route the hose around
floor near the G-3 pump as shown in FIG. 127. the top of the coolant container as shown in FIG. 129
and to the hole previously drilled in Step 3.
46
16
19
FIG. 129
9. Trim the hose to the necessary length.
10. Install the second provided swivel (19) to trimmed

end of hose.
FIG. 127

11. Apply thread sealant to threads of connector (49).

Install bulkhead fitting (45) to the connector (49).
Remove mounting nut.
12. Install bulkhead fitting (45) through bulkhead hole

drilled in Step 1. Reinstall mounting nut over end of
bulkhead fitting to secure bulkhead fitting to loader
(FIG. 130).
NOTE: When installing the bulkhead fitting (45)

make sure connector (49) is oriented upward as
shown in FIG. 130
45 Accumulator
Box
47
49
Mounting
Nut 48
FIG. 130
13. Join connector (49) to swivel (19) (installed in Step

10). Hand tighten; then torque to 10-12 ft. lbs
(13.5-16.2 N.m).
14. Apply thread sealant to I.D. threads of bulkhead fit-

ting (45) and to threads of coupler (48). Install cou-
pler to the bulkhead fitting. Tighten securely.
15. Connect fill stud (47) to coupler (48). Tighten

securely.

Pump to Master Valve

Connect the main feed line from the pump to the
master valve.
Loosely connect the hose to the pump, route the

main feed line hose and connect to the master
valve.
WA600 Models
FIG. 133
WA500/WA470/WA380 Models
FIG. 131
FIG. 134
FIG. 132
FIG. 135

FIG. 136 FIG. 138
FIG. 137 FIG. 139

Master Valve to Secondary Valves

NOTE: Unless otherwise noted, images for Master Valve
to Secondary Valves are shown installed on a WA500-7.
The WA470 and WA380 models are very similar in
appearance and are not shown.
Connect the hoses to the master valve and route to

secondary valves as shown in FIG. 140 - FIG. 147.
Route lines from the master, through the center of
the machine to the secondary valves.
Route the hoses but do not connect to the second-
ary valves.
Valve Label
FIG. 143, FIG. 144 10S Rear Secondary FIG. 142: WA380 and WA470
FIG. 145, FIG. 146 15S Middle Secondary
FIG. 147 35S Front Secondary
FIG. 140: WA600 Master FIG. 143: WA600 Rear Secondary
FIG. 141: WA500 Master
FIG. 144: WA500/WA470/WA380 Rear Secondary

FIG. 146: WA500/WA470/WA380 Middle Secondary
FIG. 145: WA600 Middle Secondary
FIG. 147: All Models Front Secondary

Front Secondary to Grease Points
Front Secondary to Grease Points

Front Secondary (FIG. 148-FIG. 152)
Lift Cylinder 20T Lift Cylinder

Bell Crank Pin 30T Bell Crank Pin
Bucket Link Pin 30T Bucket Link Pin
Bucket Pin 40T Bucket Pin
\
FIG. 148
FIG. 151
FIG. 149
FIG. 150
FIG. 152

Middle Secondary and Rear Secondary to Grease Points
Middle Secondary and Rear Secondary to Grease

Points
Middle Secondary: WA600 Models Middle Secondary: WA470 and WA380
Lift Arm Cylinder (L) 40T Lift Arm Hinge Pin (L) Models
Lift Arm Cylinder (R) 40T Steering Cylinder (L)
Lift Arm Hinge Pin (R) 40T Steering Cylinder (R) Lift Arm Hinge Pin 40T Bucket Cylinder
Bucket Cylinder Pin 40T Center Drive Shaft Support Lift Arm Cylinder 40T Steering Cylinder
Lift Arm Hinge Pin 40T Steering Cylinder
Lift Arm Cylinder 40T Center Drive Shaft Support
FIG. 153
FIG. 155
Middle Secondary: WA500 Models
Lift Arm Hinge Pin 40T Lift Arm Cylinder
Lift Arm Hinge Pin 40T Steering Cylinder
Bucket Cylinder 40T Steering Cylinder
Lift Arm Cylinder 40T Center Drive Shaft Support
FIG. 154

Middle Secondary and Rear Secondary to Grease Points
Rear Secondary: WA600 Models Rear Secondary: WA500 Models

Rear Axel Pivot Top 10S X X 10S Rear Axle
Rear Axel Pivot Mid 20T Rear Axel Pivot Bottom Steering Cylinder 20T Rear Axle
Steering L 20T Steering R Steering Cylinder 20T Rear Axle
Pilot Bearing Bottom 40T Pivot Bearing Top Pivot Bearing 40T Pivot Bearing
FIG. 157
Rear Secondary: WA470 and WA380

Models
X 10S Rear Axle
Steering Cylinder 20T Rear Axle
Steering Cylinder 20T Rear Axle
Lower Pivot Bearing 40T Upper Pivot Bearing
FIG. 156
FIG. 158

Loader Arm Guarding and Bell Crank P-Clamp
Loader Arm Guarding and Bell Crank P-Clamp

1. Attach the Bucket Link hose guard using the sup- 3. Gather the four hoses running through the Bell
plied U-bolts and 3/8-16 nylon lock nuts and wash- Crank including the Bucket Link hoses. Cut a large
ers. Trim excess from U-bolts as needed. (FIG. 159). section of 1/4 in. wire loom and wrap the hoses
together (FIG. 161).
When nearing a lube point, remove the respective

hose from the wire loom. Continue to wrap the other
hoses until nearing the Bucket Link points.
FIG. 159
2. Attach the loader arm guarding to the previously

installed weld studs (page 9) using the supplied
3/8-16 nylon lock nuts and washers (FIG. 160). FIG. 161
4. Attach the supplied P-clamp to the weld stud on the

Bell Crank. Route the banded hoses through the
P-clamp. Secure with the supplied 1/4-20 nylon lock
nut (FIG. 162).
FIG. 160
FIG. 162

Filling and Purging
Filling and Purging

An automatic lubrication system must be free of air 3. Continue to fill the master valve and the grease lines
in order to generate enough pressure to cycle to the secondary valves. Have a colleague identify
grease through the valves. when the lines are filled and air is purged from the
lines. Wrench tighten the inlet hose fittings on the
Take care to ensure dirt and/or debris do not get on secondary valves, securely.
the grease fitting or introduced into the system.
NOTE: Use a waste container to capture excess
1. Connect a pneumatically powered grease gun to the grease from the feed lines.
grease zerk (a) on the G3 pump. Fill the G3 pump
reservoir with grease to the MAX line mark (b) on 4. Connect a pneumatically powered grease gun to the
the front of the reservoir (FIG. 163). grease zerk (d) on the secondary valve to fill the
secondary valves and their grease lines (FIG. 165).
Have a colleague stand next to the grease lines
from the secondary valves to the grease points to
identify when the lines are filled and air is purged
b from the lines. Wrench tighten the secondary lines
to the grease points, securely.
NOTE: Use a waste container to capture excess

grease from the secondary lines.
FIG. 163 FIG. 165

2. Connect a pneumatically powered grease gun to the
grease zerk (c) on the master valve to the pump
(FIG. 164). Have a colleague stand next to the pump
to identify when the main feed line from the pump is
full and the air is purged from the line. Wrench
tighten the fitting on the G3 pump, securely.
FIG. 164

Testing
Testing
Before testing the system:

be sure the G3 pump reservoir is filled,
all supply lines are connected securely,
WARNING
SKIN INJECTION HAZARD
verify all grease point fittings and hose connec- High-pressure fluid from dispensing device, hose
tions are tight, leaks, or ruptured components will pierce skin. This
valves and grease lines are filled with grease may look like just a cut, but it is a serious injury that
and purged of air. can result in amputation. Get immediate surgical
treatment.
1. Turn on the battery disconnect to the machine (FIG. Do not put your hand over the fluid outlet.
166) and key on power in the cab to the Acc posi-
tion. Do not stop or deflect leaks with your hand,
body, glove, or rag.
Follow the Pressure Relief Procedure included
in the pump instruction manual, when you stop
dispensing and before cleaning, checking, or
servicing equipment.
Tighten all fluid connections before operating
the equipment.
Check hoses and couplings daily. Replace worn
or damaged parts immediately.
5. If any of the fittings or connections are leaking,

tighten fittings and/or make adjustments as needed.
FIG. 166
6. Put the machine into service and manually run the
2. Verify the GLC2200 Controller has power. lubrication system.
3. Press the Manual Run button on Articulate all working sections of the machine to
the GLC2200 Controller to run the ensure there is sufficient hose length supplied
lube system through several lube to all lubrication points.
events.
Inspect all pump, valve hose fittings and grease
4. While the pump is running, walk around the point connections to verify there are no leaks,
machine and inspect all pump, valve hose fittings the hoses are secure and that all points are
and grease point connections to verify there are no receiving grease.
leaks in the system.
7. If any of the fittings or connections are leaking,
tighten fittings and/or make adjustments as needed.
Routine Service and

Equipment Maintenance
Every time you complete the vehicle inspection check-
list, walk around the machine to inspect all pump, valve
hose fittings and grease point connections to verify
there are no leaks in the system. This will ensure any
damage to hoses or fittings is identified and repaired
properly.

Troubleshooting
Troubleshooting
NOTE: If the problem is not attributed to the Graco Lubrication System, consult the Komatsu Operations and Mainte-
nance manual or your Komatsu dealer.
Problem Cause Solution
Check that the battery disconnect is

No power to the machine ON and the keyed power is in the
Acc position.
GLC2200 Controller does not turn
on Check to ensure the controller has
GLC2200 Controller not wired cor- been wired correctly by reviewing
rectly the GLC2200 Wiring Table on page
34.
For 3 seconds, hold down the fault
clear button (located on the left side
GLC2200 Controller is in alarm of the controller). Controller fault
Fault is not cleared on controller
mode; will not operate correctly should clear and begin OFF TIME
countdown. See GLC2200 Control-
ler instruction manual.
Refill G3 pump reservoir. After fill-
ing, press and hold the fault clear
GLC2200 Controller goes into fault
G3 pump reservoir is empty button on the GLC2200 controller
mode and displays ER:LL
for 3 seconds. See GLC2200 Con-
troller instruction manual.
To silence the alarm, press the fault
clear button on the GLC2200 Con-
Audible alarm is sounding during troller for one second. Release but-
Machine requires service
machine operation ton. The alarm will silence, but the
system will remain in alarm mode
until the machine is serviced.

Troubleshooting
Verify the GLC2200 Controller is

programmed to the machine
requirements, see page 40. In
colder temperatures, it may be nec-
essary to exceed 10 minutes of run
time to complete the lube cycle.
Adjust to 15 minutes.
The lubrication system failed to If the first solution does not correct
complete a lube event in the allowed the problem, run a manual cycle
10 minute run time. and check the pump relief valve for
discharged grease. The gauge
should display 3000 psi (20.68 MPa,
206.8 bar) when the relief valve dis-
charges. If grease has discharged
from the relief valve, a bearing may
have stopped taking grease, a
GLC2200 Controller is in fault mode grease line may be compromised,
and displays ER:Cy or the MSP valve may be clogged.
Inspect MSP master valve to find
MSP master valve reset indicator reset indicator with a protruding pin.
pin is protruding. Hose is damaged Follow the corresponding hose to
the secondary valve. Replace hose.
If the hose is not compromised,
inspect the corresponding second-
ary valve for a pin protruding from
the secondary valve. Use a grease
MSP master valve reset indicator gun to verify the valve is accepting
pin is protruding. Valve is not grease.
accepting grease and blocked.
If the valve is blocked, replace
valve.
Repeat as needed for all MSP
valves.
Check MSP valve torque. Tighten if
MSP valve not torqued to required not torqued to required specifica-
MSP Valves fail to accept grease
specification or overtightened tion. If overtightened, adjust valve
assembly and retest.

Troubleshooting
Reset the GLC2200 Controller OFF

TIME to a shorter amount of time.
This will engage a lube event more
frequently and increase the amount
of grease the bearings receive in a
day.
Bearings not receiving enough GLC220 Controller OFF TIME set
grease too long. Alternative settings:
45 minutes = 30% increase
See OFF TIME setup beginning
with Step 12, page 41
Verify you are programming the
hours, minutes, and seconds fields
GLC2200 will not allow pro- Hours, minutes or seconds field not correctly. Refer to Programming the
grammed time set correctly on GLC2200 Controller GLC2200 Controller instructions,
page 39 or refer the GLC2200 Con-
troller instruction manual.
The kit comes with extra hoses and
fittings. If a replacement hose is
G3 Pump does not build or hold needed, use these extra parts to
Broken hose
pressure make a replacement or contact your
local Graco distributor to order a
replacement part.

Parts
Parts
Part Description Part Description
96G198 PUMP, G3, 8L 556402 FITTING, 1/4 x 1/8 NPTF, hex
24N468 CONTROL, GLC 2200 556429 FITTING, zerk, 1/8 NPTF
24W981 CABLE, harness, GLC 2200 10 ft 557969 CAP, dust
125910 BRACKET, pump, windmill 556420 FITTING, tee stl 1/4 (m) NPT
563161 VALVE, relief 3000 assy 102814 GAUGE, 3000 psi (20.68 MPa, 206.8
bar) 1/4 NPT b/m dry
571058 KIT, accessory, output adapter
556407 FITTING, tee stl 1/4 (m) NPT
24G485 PLATE, base, 3 section MSP (f) NPS
557950 BULKHEAD, remote fill
24G486 PLATE, base, 4 section MSP (f) NPS
15M045 FITTING, elbow
562712 VALVE, assy MSP 10S
557896 STUD, fill, 1/4 inch NPTF (f)
556408 FITTING, 1/4 x 1/8 inch NPTF Hex
555749 CONNECTOR, #4, JIC, 1/8 PM
562723 VALVE, assy MSP 20T
15K783 FITTING, elbow
17G422 ADAPTER, 1/8 (m) BSPT x 1/8 (f) NPT
17K061 FITTING, elbow, street, 1/8 NPT BSPT
557349 PLUG, dryseal 1/8 (f) NPT
17K062 FITTING, adapter, lg, 1/8 NPT BSPT
556762 CONNECTOR, #4, JIC, 1/4 PM
128661 SWIVEL, hose, 1/8 in I.D. x #4 JIC
555749 CONNECTOR, #4 JIC 1/8 PM
128563 SWIVEL, hose, 1/4 in. I.D. x #4 JIC
556763 FITTING, #4 JIC 1/8 PM
17D688 HOLDER, fuse
556773 FITTING, swivel, fem, SAE #4, JIC
557264 FUSE, 5 Amp
128752 KIT, accessory, hose, 100 ft
17G007 KIT, GLC2200 mounting
128581 KIT, accessory, guard, 80 ft
100840 FITTING, elbow
127013 FITTING, swivel, JIC 37D size #4
128570 KIT, accessory, hose, 200 ft
128579 KIT, accessory, guard, 160 ft
557392 ADAPTER, 1/8 (f) NPT hex
557393 COUPLING,1/8 (f) P x 1/8 (M) P x
1-1/4 ex
126331 HARNESS, wiring, m12(f) to bare wire
24K415 KIT, accessory, prox sensor
563251 INDICATOR, cycle assy soft seal
563257 INDICATOR, reset assy 2000 psi (13.79
MPa, 137.9 bar)
563255 INDICATOR, reset assy 1000 psi (6.89
MPa, 68.95 bar)

Graco Information
Graco Information
For additional information about these Graco products; including Warnings, Troubleshooting, and Technical Data
refer to the Graco instruction manuals included with the equipment or visit the Graco website at www.graco.com to
download the latest versions of Graco instruction manuals.

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Mobile Lubrication Library

333508K Komatsu Wheel Loader Installation

Instructions for installing a Graco automatic lubrication system on the

Important Safety Information

*Refer to these instruction manuals for additional infor-

2 NOTE: Photographs may include optional equipment.

Completed Description Page

Grease all zerks, before removal 6

NOTE: Photographs may include optional equipment. 3

Recommended Tools and Supplies

*Both US and Metric sizes of these tools are recommended.

Refer to the Installation Checklist provided on page

4 NOTE: Photographs may include optional equipment.

NOTE: Photographs may include optional equipment. 5

Before You Start Zerk Fittings

3. Use a clean cloth or rag to remove any remaining

FIG. 1: Battery Disconnect

Walk around the machine with a grease gun and verify

6 NOTE: Photographs may include optional equipment.

Grease Point Fittings

2. Install fittings in grease points. Refer to FIG. 3 and

3. Refer to Grease Point Table to determine the

NOTE: Photographs may include optional equipment. 7

Grease Point Fittings Table

WA5007 WA4707 WA3807

8 NOTE: Photographs may include optional equipment.

Loader Arm Guards

1. Refer to FIG. 4 to determine where to cut the Loader Arm Guards.

NOTE: No cutting is required for the WA600 Model.

WA380 Model measure from the first tab; trim to here

WA470 / WA500 Model Measure from end to the first recess

WA380 Model measure from end; trim to here

WA470 Model measure from end; trim to here

3. Use a cutting wheel to cut the Loader Arm Guards

and Bucket Link Guard to the correct lengths.

4. WA470 and WA380 models only: Bend up one end

FIG. 6: Bent Bucket Link Guard

5. Clean and debur the cut edge. Prime the guarding

NOTE: Photographs may include optional equipment. 9

MSP Divider Valve Assembly

Prepare a clean, flat area to assemble the valves.

All outlets use 1/8 in. x 4 JIC straight fittings

MSP Divider Valve Assembly

NOTE: Refer to the MSP Divider Valve Assembly

10 NOTE: Photographs may include optional equipment.

2000 psi (13.79 MPa,137.9 bar) reset indicators

NOTE: Photographs may include optional equipment. 11

MSP Divider Valve Assembly Location

MSP Divider Valve Assembly Reference Illustrations

Master Valve Assembly (FIG. 14) Middle Secondary (FIG. 16)

WA500/WA600 WA380/WA470 ALL

Front Secondary (FIG. 15) Rear Secondary (FIG. 17)

ALL WA600 WA500/WA470/WA380

12 NOTE: Photographs may include optional equipment.

4. Clean the surface on the loader arm as needed to

NOTE: Photographs may include optional equipment. 13

Boom Guard Weld Stud Dimensions

14 NOTE: Photographs may include optional equipment.

Weld Stud and MSP Divider Valve Installation Reference Photographs

MSP Divider Valve Weld Stud Dimensions: WA600 Models

FIG. 19: Master Left Front Frame E

C Weld FIG. 23: Front Secondary: Align and center divider

FIG. 21: P-Clamp (bell crank)