Komatsu WA400L-Series GALEO WA400-5L Wheel Loader Workshop Service Repair Manual PDF - MKMTSWA400L.zip
A full factory-level service and repair manual, complete with Electrical Wiring Diagrams, covering the Komatsu WA400L-Series Wheel Loaders. It contains everything needed to service, troubleshoot, fix, and rebuild these machines to the standard of trained technicians.
Inside the Komatsu WA400L-Series Wheel Loaders workshop service repair manual you will find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,511 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM009601 - Wheel Loader GALEO WA400-5L Operation & Maintenance Manual.pdf
CEBM010002 - Wheel Loader WA400-5L Shop Manual.pdf
MAIN SECTIONS
CEAM009601 - Wheel Loader GALEO WA400-5L Operation & Maintenance Manual......2
COVER......2
INTRODUCTION......3
FOREWORD......4
SAFETY INFORMATION......5
APPROVED AND NON-APPROVED USES......6
NON-APPROVED......6
PRODUCT IDENTIFICATION......7
MACHINE SERIAL NUMBER......7
ENGINE SERIAL NUMBER AND EMISSION LABEL......8
SERVICE METER LOCATION......8
SERIAL NUMBERS AND DEALER INFORMATION......9
CONTENTS......10
SAFETY......23
GENERAL SAFETY RULES AND PRECAUTIONS......24
GENERAL SAFETY RULES......24
SAFETY FEATURES......25
PERSONAL PROTECTIVE EQUIPMENT......25
UNAUTHORIZED MODIFICATIONS......26
LEAVING OPERATOR’S COMPARTMENT......26
MOUNTING AND DISMOUNTING......27
WASTE HANDLER APPLICATIONS......27
FIRE PREVENTION FOR FUEL AND OIL......28
DUST HAZARD PRECAUTIONS......28
CRUSH OR PINCH POINT DANGERS......29
FIRE EXTINGUISHER AND FIRST AID KIT......29
INSIDE OPERATOR’S COMPARTMENT......30
PRECAUTIONS WHEN USING ROPS......30
PRECAUTIONS FOR ATTACHMENTS......30
STARTING YOUR WORK OPERATIONS......31
WORK SITE HAZARDS......31
AVOIDING DANGEROUS SITUATIONS......31
WORKING CLEARANCES......33
RULES FOR ROAD TRAVEL......34
TRAVELING IN REVERSE......34
TRAVELING ON ICY OR SNOW-COVERED SURFACES......34
WORKING ON LOOSE OR UNSTABLE GROUND......34
TRAVEL ON SLOPES......35
PARKING THE MACHINE......36
PRECAUTIONS DURING MAINTENANCE OPERATIONS......37
WARNING TAGS......37
EQUIPMENT STORAGE......37
WORKING UNDER THE MACHINE......38
USING DROP LAMPS......38
KEEPING THE MACHINE CLEAN......39
RUNNING THE MACHINE DURING MAINTENANCE......39
RULES FOR REFUELING THE MACHINE......40
COOLING SYSTEM PRECAUTIONS......40
BATTERY PRECAUTIONS......41
STARTING THE MACHINE......41
HIGH PRESSURE HOSES......42
HIGH TEMPERATURES AREAS......42
DISPOSAL OF WASTE MATERIALS......42
INFLATING TIRES......43
ACCUMULATOR......43
CRITICAL PARTS......43
VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED......43
SAFETY AND WARNING DECALS......44
LOCATION OF THE SAFETY DECALS......44
LOCATION OF SAFETY LABELS......45
SAFETY LABELS......45
OPERATION......53
GENERAL VIEW OF MACHINE......54
OUTSIDE VIEW OF THE MACHINE......54
INSIDE VIEW OF THE CAB......55
DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS......56
INSTRUMENT BEZEL......56
SWITCH PANELS......57
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM......58
INSTRUMENT BEZEL......58
TYPES OF WARNING......59
MACHINE ELECTRONIC MONITORING DISPLAY......60
MONITOR MODE SELECTOR SWITCHES......60
MODE SELECTOR SWITCH 1......61
MODE SELECTOR SWITCH 2......61
MONITOR DISPLAY INFORMATION......61
HOUR METER AND ODOMETER DISPLAY......61
ADJUSTING MONITOR BRIGHTNESS......62
PROGRAMMING TELEPHONE NUMBER......62
ACTION CODE DISPLAY......62
FAILURE CODE DISPLAY......63
SERVICE DISPLAY......64
SELECTING LANGUAGE......65
EMERGENCY STOP WARNING SYSTEM......66
BRAKE PRESSURE WARNING LAMP......66
ENGINE OIL PRESSURE WARNING LAMP......67
BATTERY CHARGE WARNING LAMP......67
STEERING OIL PRESSURE WARNING LAMP......67
CAUTION ALERT WARNING SYSTEM......68
AXLE OIL TEMPERATURE CAUTION LAMP......68
TORQUE CONVERTER CAUTION LAMP......69
COOLANT TEMPERATURE CAUTION LAMP......69
HYDRAULIC OIL TEMPERATURE CAUTION LAMP......69
FUEL LEVEL CAUTION LAMP......69
INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM......70
ENGINE OIL LEVEL CAUTION LAMP......70
RADIATOR COOLANT LEVEL CAUTION LAMP......71
AIR CLEANER CLOGGING CAUTION LAMP......71
MAINTENANCE CAUTION LAMP......71
MODE ALERT LAMPS......72
PARKING BRAKE PILOT LAMP......72
COOLING FAN REVERSE ROTATION PILOT LAMP......73
EMERGENCY STEERING PILOT LAMP......73
OUTPUT MODE PILOT LAMP (POWER MODE)......73
PREHEATING PILOT LAMP......74
JOYSTICK PILOT LAMP......74
SHIFT INDICATOR......74
AUTO-SHIFT PILOT LAMP......74
LOCKUP PILOT LAMP......75
SHIFT HOLD PILOT LAMP......75
SHIFT LEVER POSITION PILOT LAMP......75
TURN SIGNAL PILOT LAMP......75
HEAD LAMP HIGH BEAM PILOT LAMP......76
GAUGE DISPLAY......77
TORQUE CONVERTER OIL TEMPERATURE GAUGE......77
ENGINE TEMPERATURE GAUGE......78
HYDRAULIC TEMPERATURE GAUGE......78
FUEL GAUGE......78
SPEEDOMETER......78
METER DISPLAY PILOT LAMP......79
MACHINE MONITOR......79
DISPLAYING ODOMETER......79
RESET FOR FILTER, OIL REPLACEMENT TIME......79
ENTERING A TELEPHONE NUMBER......80
SELECTING A LANGUAGE......81
ADJUSTING MONITOR BRIGHTNESS......82
MACHINE SWITCHES AND CONTROLS......83
SWITCH LOCATION......83
IGNITION SWITCH......84
POWER MODE SELECTOR SWITCH......84
TRANSMISSION MODE SELECTOR SWITCH......85
TRANSMISSION CUT-OFF SWITCH......85
TRANSMISSION CUT-OFF SET SWITCH......86
LAMP SWITCH......86
TURN SIGNAL LEVER......86
DIMMER SWITCH......87
HORN BUTTON......87
HAZARD LAMP SWITCH......87
PARKING BRAKE SWITCH......87
FRONT WORKING LAMP SWITCH......88
REAR WORKING LAMP SWITCH......88
MONITOR PANEL MODE SELECTOR SWITCH 1......89
MONITOR PANEL MODE SELECTOR SWITCH 2......89
KICKDOWN SWITCH......89
HOLD SWITCH......90
FRONT WIPER SWITCH......90
REAR WIPER SWITCH......90
CIGARETTE LIGHTER......91
CAB LAMP SWITCH......91
REAR DEFROSTER SWITCH......91
E.C.S.S. SWITCH......92
EMERGENCY STEERING SWITCH......92
COOLING FAN REVERSE ROTATION SWITCH......93
TORQUE CONVERTER LOCK-UP SWITCH......93
LOAD METER CANCEL SWITCH......93
LOAD METER SUBTOTAL SWITCH......93
SOUND SYSTEM......94
DIGITAL ESPERIA RADIO COMPONENTS......94
POWER SWITCH/VOLUME......94
TONE CONTROL KNOB......95
DISPLAY......95
CLOCK BUTTON/DISPLAYING FREQUENCY......95
AST......95
PRESET BUTTON......96
SEEK......96
BAND SELECTOR SWITCH......96
TUNING SWITCH......96
LISTENING TO THE RADIO......97
AUTOMATIC TUNING......97
MANUAL TUNING......97
SETTING THE PRESET BUTTONS......97
AUTOMATIC MEMORY......98
AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO......98
ADJUSTING THE TIME......98
BLAUPUNKT CALAIS RADIO COMPONENTS......99
POWER SWITCH/MUTE......99
VOLUME CONTROL......100
FMT CONTROL......100
IR REMOTE CONTROL (OPTIONAL)......100
RDS CONTROL......100
ML CONTROL......101
EJECT CASSETTE......101
CASSETTE COMPARTMENT......101
FF AND RW BUTTONS......101
GEO BUTTON......102
SRC BUTTON......102
AUDIO BUTTON......102
MULTIFUNCTION ROCKER SWITCH......102
MENU BUTTON......103
KEYPAD 1-5......103
TRAFFIC......103
DISPLAY......103
THEFT PROTECTION......104
PRECAUTIONS WHEN USING......104
AIR CONDITIONER CONTROL PANEL......105
FAN SWITCH......105
AIR CONDITIONER SWITCH......106
MODE SELECTOR SWITCH......106
FRESH/RECIRC SELECTOR SWITCH......106
EXTERNAL AIR INTAKE......106
TEMPERATURE CONTROL SWITCH......107
METHOD OF OPERATION......107
WHEN NOT USING THE AIR CONDITIONER REGULARLY......108
COOL BOX......109
PRECAUTIONS WHEN USING THE AIR CONDITIONER......109
CONTROL LEVERS, PEDALS......110
SPEED CONTROL LEVER......110
DIRECTIONAL LEVER......112
SPEED CONTROL LEVER STOPPER......112
SAFETY LOCK LEVER......113
BUCKET CONTROL LEVER......113
LIFT ARM CONTROL LEVER......114
BRAKE PEDAL......114
ACCELERATOR PEDAL......115
STEERING TILT LOCK LEVER......115
SECURITY AND LOCKS......116
IGNITION KEY LOCKED AREAS......116
CAB DOOR LOCKS......116
ENGINE ACCESS DOORS......116
REAR GRILL......117
FUEL CAP......117
PADLOCKED AREAS......118
BATTERY AND TOOL BOX......118
TRANSFER CASE......118
UPPER HOOD ACCESS PANEL......118
SAFETY FEATURES......119
PASSIVE SAFETY FEATURES......119
ROLL-OVER PROTECTIVE STRUCTURE (ROPS)......119
CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY)......119
BACKUP WARNING ALARM......119
ACTIVE SAFETY FEATURES......120
SAFETY BAR......120
SEAT BELT......120
EQUIPMENT LOCK LEVER......121
MACHINE FEATURES......122
CAB DOORS......122
OPEN LOCK......122
ELECTRICAL......122
FUSE......122
FUSE CAPACITY AND NAME OF CIRCUIT......123
SLOW BLOW FUSE......124
AUXILIARY POWER......124
MACHINE CAB AND CHASSIS......125
SEAT ADJUSTMENT......125
HANDLING CAB WIPER......127
DUST INDICATOR......127
GREASE PUMP......127
PRECAUTIONS BEFORE STARTING WORK OPERATIONS......128
PRE-OPERATIONAL CHECKS......128
PERFORM A WALK AROUND CHECK OF YOUR MACHINE......128
UNDER THE HOOD......128
CHECK COOLANT LEVEL......129
CHECK ENGINE OIL LEVEL, ADD OIL......130
REAR-VIEW MIRROR ADJUSTMENT......130
IN THE OPERATOR’S CAB......131
SEAT BELT ADJUSTMENT......131
LEVER STAND ADJUSTMENT......132
LEVER STAND ANGLE ADJUSTMENT......132
START-UP PROCEDURES......133
CHECK FUEL LEVEL, ADD FUEL......133
CHECK THE BRAKE PEDALS......134
CHECK THE PARKING BRAKE......134
STARTING THE ENGINE......135
OPERATIONS AND CHECKS AFTER STARTING ENGINE......138
BREAKING IN THE MACHINE......138
NORMAL START-UP AND WARM-UP......138
STOPPING THE ENGINE......139
TRAVELING, STOPPING AND PARKING THE MACHINE......140
TRAVELING......140
TURNING ON SLOPES......142
CHANGING GEAR SPEED RANGES......142
CHANGING DIRECTION......143
WHEN USING AUTO-SHIFT......144
STOPPING AND PARKING THE MACHINE......145
TRANSMISSION CUT-OFF SWITCH......147
ADJUSTING THE TRANSMISSION CUT-OFF......147
STOPPING WHEN TRANSMISSION CUT-OFF IS ON......148
TURNING......148
EMERGENCY STEERING......149
USING THE EMERGENCY STEERING......149
EMERGENCY STEERING SELF-CHECK FUNCTION......150
STARTING YOUR WORK OPERATIONS......151
WORK EQUIPMENT......151