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Komatsu WA400-5 Wheel Loader Operation & Maintenance Manual SN 70001 and up – PDF DOWNLOAD
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Komatsu WA400-5 Wheel Loader Operation & Maintenance Manual
SERIAL NUMBERS: SEAM047401T
MACHINE MODEL SERIAL NUMBERS
WA400-5 70001 and up
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Description
Komatsu WA400-5 Wheel Loader Operation & Maintenance Manual
FILE DETAILS:
Komatsu WA400-5 Wheel Loader Operation & Maintenance Manual
Model Specification: KOMATSU WA400-5 WHEEL LOADER
Language: English
File Format: PDF
Total Pages: 312
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU WA400-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL SN 70001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA400-5 Wheel Loader Operation & Maintenance Manual
FOREWORD:
This manual provides rules and guidelines which will help you use this machine safely and effectively. The precautions in this manual must be followed at all times when performing operation and maintenance. Most accidents are caused by the failure to follow fundamental safety rules forthe operation and maintenance of machines. Accidents can be prevented by knowing beforehand conditions that may cause hazard when performing operation and maintenance.
TABLE OF CONTENTS:
Komatsu WA400-5 Wheel Loader Operation & Maintenance Manual
COVER................................................................................................ 1 FOREWORD............................................................................................. 2 FOREWORD......................................................................................... 3 SAFETY INFORMATION............................................................................... 6 INTRODUCTION..................................................................................... 8 FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE.................................................. 8 NECESSARY INFORMATION............................................................................ 9 MACHINE SERIAL NO. PLATE AND POSITION........................................................ 9 ENGINE SERIAL NO. PLATE AND POSITION......................................................... 9 POSITION OF SERVICE METER.................................................................... 10 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.................................................... 10 CONTENTS............................................................................................. 11 SAFETY............................................................................................... 14 SAFETY........................................................................................... 15 SAFETY LABELS.................................................................................... 18 LOCATION OF SAFETY LABELS.................................................................... 18 SAFETY LABELS................................................................................ 19 GENERAL PRECAUTIONS.............................................................................. 24 SAFETY RULES................................................................................. 24 IF ABNORMALITIES ARE FOUND................................................................... 24 CLOTHING AND PERSONAL PROTECTIVE ITEMS....................................................... 24 FIRE EXTINGUISHER AND FIRST AID KIT.......................................................... 24 SAFETY FEATURES.............................................................................. 24 KEEP MACHINE CLEAN........................................................................... 25 INSIDE OPERATOR'S COMPARTMENT................................................................ 25 ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT............................................... 25 HANDRAILS AND STEPS.......................................................................... 26 MOUNTING AND DISMOUNTING..................................................................... 27 NO PEOPLE ON ATTACHMENTS..................................................................... 27 DO NOT GET CAUGHT IN ARTICULATED PORTION..................................................... 27 PREVENTION OF BURNS.......................................................................... 27 FIRE PREVENTION.............................................................................. 28 ACTION IF FIRE OCCURS........................................................................ 29 WINDOW WASHER LIQUID......................................................................... 29 PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)................................. 29 PRECAUTIONS FOR ATTACHMENTS.................................................................. 30 UNAUTHORIZED MODIFICATION.................................................................... 30 SAFETY AT WORKSITE........................................................................... 30 WORKING ON LOOSE GROUND...................................................................... 30 DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES....................................................... 31 ENSURE GOOD VISIBILITY....................................................................... 31 BE CAREFUL ABOUT ASBESTOS DUST............................................................... 31 CHECKING SIGNALMAN'S SIGNALS AND SIGNS....................................................... 32 EMERGENCY EXIT FROM OPERATOR'S CAB........................................................... 32 VENTILATION FOR ENCLOSED AREAS............................................................... 32 PRECAUTIONS FOR OPERATION........................................................................ 33 STARTING ENGINE.............................................................................. 33 CHECKS BEFORE STARTING ENGINE............................................................ 33 PRECAUTIONS WHEN STARTING................................................................ 34 PRECAUTIONS IN COLD AREAS................................................................ 34 OPERATION.................................................................................... 35 CHECKS BEFORE OPERATION.................................................................. 35 PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE......................................... 35 PRECAUTIONS WHEN TRAVELING............................................................... 36 TRAVELING ON SLOPES...................................................................... 37 PROHIBITED OPERATIONS.................................................................... 38 PRECAUTIONS WHEN OPERATING............................................................... 38 METHODS OF USING BRAKE................................................................... 39 OPERATE CAREFULLY ON SNOW................................................................ 39 PARKING MACHINE.......................................................................... 40 TRANSPORTATION............................................................................... 41 LOADING AND UNLOADING.................................................................... 41 SHIPPING................................................................................. 41 BATTERY...................................................................................... 42 BATTERY HAZARD PREVENTION................................................................ 42 STARTING WITH BOOSTER CABLES............................................................. 43 TOWING....................................................................................... 44 WHEN TOWING.............................................................................. 44 PRECAUTIONS FOR MAINTENANCE...................................................................... 45 WARNING TAG.................................................................................. 45 KEEP WORK PLACE CLEAN AND TIDY............................................................... 45 APPOINT LEADER WHEN WORKING WITH OTHERS...................................................... 45 MAINTENANCE WITH ENGINE RUNNING.............................................................. 46 TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING........................................... 47 INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF................................. 47 PROPER TOOLS................................................................................. 48 ACCUMULATOR.................................................................................. 48 PERSONNEL.................................................................................... 48 ATTACHMENTS.................................................................................. 48 WORK UNDER THE MACHINE....................................................................... 49 NOISE........................................................................................ 49 PRECAUTIONS WHEN USING HAMMER................................................................ 49 REPAIR WELDING............................................................................... 49 REMOVING BATTERY TERMINAL.................................................................... 49 PRECAUTIONS WITH HIGH-PRESSURE OIL........................................................... 50 PRECAUTIONS FOR HIGH-PRESSURE FUEL........................................................... 50 HANDLING HIGH-PRESSURE HOSES................................................................. 50 WASTE MATERIALS.............................................................................. 50 MAINTENANCE OF AIR CONDITIONER............................................................... 51 COMPRESSED AIR............................................................................... 51 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS................................................ 51 PRECAUTIONS WITH TIRES........................................................................... 52 HANDLING TIRES............................................................................... 52 PRECAUTIONS WHEN STORING TIRES............................................................... 52 OPERATION............................................................................................ 53 GENERAL VIEW..................................................................................... 54 GENERAL VIEW OF MACHINE...................................................................... 54 GENERAL VIEW OF CONTROLS AND GAUGES.......................................................... 55 EXPLANATION OF COMPONENTS........................................................................ 58 MACHINE MONITOR.............................................................................. 58 SWITCHES..................................................................................... 88 CONTROL LEVERS, PEDALS.......................................................................101 STEERING TILT LOCK LEVER.....................................................................106 CAP WITH LOCK................................................................................107 SAFETY BAR...................................................................................109 TOWING PIN...................................................................................109 GREASE PUMP..................................................................................110 CAB DOOR OPEN LOCK...........................................................................110 CAB WINDOW OPEN LOCK CANCEL KNOB.............................................................110 BACKUP ALARM.................................................................................111 FUSE.........................................................................................111 SLOW-BLOW FUSE...............................................................................113 TAKING OFF POWER.............................................................................113 CAR RADIO....................................................................................114 AIR CONDITIONER..............................................................................120 HANDLING CAB WIPER...........................................................................125 DUST INDICATOR...............................................................................125 OPERATION........................................................................................126 CHECK BEFORE STARTING ENGINE, ADJUST.........................................................126 STARTING ENGINE..............................................................................140 OPERATIONS AND CHECKS AFTER STARTING ENGINE..................................................144 STOPPING ENGINE..............................................................................146 CHECK AFTER STOPPING ENGINE..................................................................146 MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING............................................146 TURNING......................................................................................156 OPERATION OF WORK EQUIPMENT..................................................................158 WORK POSSIBLE USING WHEEL LOADER.............................................................160 PRECAUTIONS FOR OPERATION....................................................................166 ADJUSTING WORK EQUIPMENT POSTURE.............................................................168 PARKING MACHINE..............................................................................170 CHECKS AFTER COMPLETION OF OPERATION.........................................................172 LOCKING......................................................................................172 HANDLING THE TIRES...........................................................................173 TRANSPORTATION...................................................................................175 TRANSPORTATION PROCEDURE.....................................................................175 LOADING, UNLOADING WORK WITH TRAILERS........................................................175 LIFTING MACHINE..............................................................................177 COLD WEATHER OPERATION...........................................................................180 PRECAUTIONS FOR LOW TEMPERATURE..............................................................180 PRECAUTIONS AFTER COMPLETION OF WORK.........................................................181 AFTER COLD WEATHER...........................................................................182 WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER..........................182 LONG-TERM STORAGE................................................................................183 BEFORE STORAGE...............................................................................183 DURING STORAGE...............................................................................183 AFTER STORAGE................................................................................183 TROUBLESHOOTING..................................................................................184 WHEN MACHINE RUNS OUT OF FUEL................................................................184 TOWING THE MACHINE...........................................................................185 IF BATTERY IS DISCHARGED.....................................................................189 OTHER TROUBLE................................................................................192 MAINTENANCE..........................................................................................197 GUIDES TO MAINTENANCE............................................................................198 OUTLINES OF SERVICE..............................................................................200 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC.......................................200 OUTLINE OF ELECTRIC SYSTEM...................................................................202 WEAR PARTS.......................................................................................203 WEAR PARTS LIST..............................................................................203 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.............................204 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.............................................204 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...................................................209 TORQUE LIST..................................................................................209 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....................................................210 MAINTENANCE SCHEDULE CHART.......................................................................211 MAINTENANCE SCHEDULE CHART...................................................................211 SERVICE PROCEDURE................................................................................213 INITIAL 250 HOURS SERVICE....................................................................213 INITIAL 1000 HOURS SERVICE...................................................................213 WHEN REQUIRED................................................................................214 CHECK,CLEAN,OR REPLACE AIR CLEANER ELEMENT...............................................214 CLEAN INSIDE OF COOLING SYSTEM...........................................................217 CHECK WATER SEPARATOR....................................................................219 CHECK TRANSMISSION OIL LEVEL, ADD OIL....................................................220 CHECK AXLE OIL LEVEL, ADD OIL............................................................221 CLEAN AXLE CASE BREATHER.................................................................223 CLEAN CONDENSER OF AIR CONDITIONER.......................................................223 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID..............................................224 CLEAN RADIATOR FINS AND COOLER FINS......................................................224 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................227 REPLACE BOLT ON CUTTING EDGE.............................................................227 REPLACE BUCKET TEETH.....................................................................228 CHECK AIR CONDITIONER....................................................................229 REPLACE SLOW-BLOW FUSE...................................................................229 SELECTION AND INSPECTION OF TIRES........................................................230 CHECK BEFORE STARTING........................................................................232 EVERY 50 HOURS SERVICE.......................................................................232 DRAIN WATER, SEDIMENT FROM FUEL TANK.....................................................232 EVERY 100 HOURS SERVICE......................................................................232 LUBRICATE REAR AXLE PIVOT PIN............................................................232 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...............................................233 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................233 EVERY 250 HOURS SERVICE......................................................................234 CHECK BATTERY ELECTROLYTE LEVEL..........................................................234 CHECK PARKING BRAKE......................................................................236 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....................................236 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN..................................................237 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER....................................237 LUBRICATING..............................................................................238 EVERY 500 HOURS SERVICE......................................................................239 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE........................239 REPLACE FUEL FILTER CARTRIDGE............................................................240 EVERY 1000 HOURS SERVICE.....................................................................241 CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER....241 CLEAN TRANSMISSION CASE BREATHER.........................................................242 LUBRICATING..............................................................................242 CHECK TIGHTENING PARTS OF TURBOCHARGER...................................................243 CHECK PLAY OF TURBOCHARGER ROTOR.........................................................243 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT....................................243 REPLACE CORROSION RESISTOR CARTRIDGE.....................................................243 EVERY 2000 HOURS SERVICE.....................................................................243 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...........................243 REPLACE HYDRAULIC TANK BREATHER ELEMENT..................................................245 CHANGE AXLE OIL..........................................................................246 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER............246 CLEAN PPC CIRCUIT STRAINER...............................................................247 CLEAN ENGINE BREATHER ELEMENT............................................................247 CHECK ALTERNATOR, STARTING MOTOR.........................................................247 CHECK ENGINE VALVE CLEARANCE, ADJUST.....................................................247 CLEAN AND CHECK TURBOCHARGER.............................................................248 CHECK INJECTOR...........................................................................248 CHECK ACCUMULATOR GAS PRESSURE...........................................................248 CHECK VIBRATION DAMPER...................................................................248 CHECK BRAKE DISC WEAR....................................................................248 EVERY 4000 HOURS SERVICE.....................................................................249 LUBRICATING..............................................................................249 CHECK WATER PUMP.........................................................................250 CHECK AIR CONDITIONER COMPRESSOR, ADJUST.................................................250 REPLACE INJECTOR ASSEMBLY................................................................250 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP,HARDENING OF RUBBER........................251 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,HARDENING OF RUBBER.......................251 EVERY 8000 HOURS SERVICE.....................................................................251 REPLACE HIGH-PRESSURE PIPING CLAMP.......................................................251 REPLACE FUEL SPRAY PREVENTION CAP........................................................251 SPECIFICATIONS.......................................................................................252 SPECIFICATIONS...................................................................................253 ATTACHMENTS, OPTIONS.................................................................................254 SELECTING BUCKET AND TIRES.......................................................................255 HANDLING LOAD METER..............................................................................256 GENERAL LOCATIONS............................................................................256 LOAD METER FUNCTIONS.........................................................................258 HANDLING LOAD METER DISPLAY..................................................................261 METHOD OF SETTING TIME ON CLOCK..............................................................276 PRINTER OUTPUT...............................................................................278 HANDLING TORQUE CONVERTER LOCK-UP................................................................281 GENERAL LOCATIONS............................................................................281 METHOD OF OPERATION..........................................................................282 WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED.....................................................283 HANDLING AUTO-GREASING SYSTEM....................................................................284 METHOD OF OPERATING AUTO-GREASING SYSTEM.....................................................284 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...............................................290 TROUBLESHOOTING..............................................................................290 HANDLING JOYSTICK STEERING SYSTEM................................................................291 EXPLANATION OF COMPONENTS....................................................................291 STRUCTURE AND FUNCTION OF JOYSTICK STEERING..................................................293 GETTING IN OR OUT OF OPERATOR'S CAB..........................................................295 ADJUSTMENT OF JOYSTICK CONSOLE...............................................................295 OPERATION METHOD OF JOYSTICK STEERING SYSTEM.................................................296 HANDLING EPC WORK EQUIPMENT LEVER................................................................299 OPERATIONAL FEATURES.........................................................................299 SWITCHES.....................................................................................299 SEMI AUTO DIGGING OPERATIONS.................................................................300 METHOD OF REMOTE POSITIONER..................................................................302 HANDLING MULTI-FUNCTION LEVER....................................................................304 EXPLANATION OF COMPONENTS....................................................................304 USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE.......................................307 INDEX................................................................................................309
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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