Komatsu GALEO WA450-5L WA480-5L Wheel Loader & WA450-3LL Log Loader Workshop Repair Service Manual PDF - MKMTSWA450LLWA480L.zip

A full service and repair manual featuring Electrical Wiring Diagrams for the Komatsu Wheel Loader GALEO WA450-5L, WA480-5L and Log Loader WA450-3LL, packed with the technical detail needed to service, troubleshoot, fix and rebuild these machines the way expert technicians do.

Covering the Komatsu Wheel Loader GALEO WA450-5L, WA480-5L and Log Loader WA450-3LL, this workshop service and repair manual contains:

* 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: 3,683 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

CEBM009601 - Wheel Loader GALEO WA450-5L, WA480-5L Shop Manual.pdf

CEBM009605 - Wheel Loader GALEO WA450-5L, WA480-5L Shop Manual.pdf

SEBM009904 - Log Loader WA450-3LL Shop Manual.pdf

CEAM008901 - Wheel Loader GALEO WA450-5L Operation & Maintenance Manual.pdf

CEAM009001 - Wheel Loader GALEO WA480-5L Operation & Maintenance Manual.pdf

MAIN SECTIONS

CEAM008901 - Wheel Loader GALEO WA450-5L Operation & Maintenance Manual.......2

COVER.......2

INTRODUCTION.......8

FOREWORD.......9

SAFETY INFORMATION.......11

APPROVED AND NON-APPROVED USES.......12

NON-APPROVED.......12

PRODUCT IDENTIFICATION.......13

MACHINE SERIAL NUMBER.......13

ENGINE SERIAL NUMBER AND EMISSION LABEL.......14

SERVICE METER LOCATION.......14

SERIAL NUMBERS AND DEALER INFORMATION.......15

CONTENTS.......16

SAFETY.......28

GENERAL SAFETY RULES AND PRECAUTIONS.......29

GENERAL SAFETY RULES.......29

SAFETY FEATURES.......30

PERSONAL PROTECTIVE EQUIPMENT.......30

UNAUTHORIZED MODIFICATIONS.......31

LEAVING OPERATORS COMPARTMENT.......31

MOUNTING AND DISMOUNTING.......32

WASTE HANDLER APPLICATIONS.......32

FIRE PREVENTION FOR FUEL AND OIL.......33

DUST HAZARD PRECAUTIONS.......33

CRUSH OR PINCH POINT DANGERS.......34

FIRE EXTINGUISHER AND FIRST AID KIT.......34

INSIDE OPERATORS COMPARTMENT.......35

PRECAUTIONS WHEN USING ROPS.......35

PRECAUTIONS FOR ATTACHMENTS.......35

STARTING YOUR WORK OPERATIONS.......36

WORK SITE HAZARDS.......36

AVOIDING DANGEROUS SITUATIONS.......36

WORKING CLEARANCES.......38

RULES FOR ROAD TRAVEL.......39

TRAVELING IN REVERSE.......39

TRAVELING ON ICY OR SNOW-COVERED SURFACES.......39

WORKING ON LOOSE OR UNSTABLE GROUND.......39

TRAVEL ON SLOPES.......40

PARKING THE MACHINE.......41

PRECAUTIONS DURING MAINTENANCE OPERATIONS.......42

WARNING TAGS.......42

EQUIPMENT STORAGE.......42

WORKING UNDER THE MACHINE.......43

USING DROP LAMPS.......43

KEEPING THE MACHINE CLEAN.......44

RUNNING THE MACHINE DURING MAINTENANCE.......44

RULES FOR REFUELING THE MACHINE.......45

COOLING SYSTEM PRECAUTIONS.......45

BATTERY PRECAUTIONS.......46

STARTING THE MACHINE.......46

HIGH PRESSURE HOSES.......47

HIGH TEMPERATURES AREAS.......47

DISPOSAL OF WASTE MATERIALS.......47

INFLATING TIRES.......48

ACCUMULATOR.......48

CRITICAL PARTS.......48

VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED.......48

SAFETY AND WARNING DECALS.......49

LOCATION OF THE SAFETY DECALS.......49

LOCATION OF SAFETY LABELS.......50

SAFETY LABELS.......50

OPERATION.......60

GENERAL VIEW OF MACHINE.......61

OUTSIDE VIEW OF THE MACHINE.......61

INSIDE VIEW OF THE CAB.......62

DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS.......63

INSTRAMENT BEZEL.......63

SWITCH PANELS.......64

DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM.......65

INSTRAMENT BEZEL.......65

TYPES OF WARNING.......66

MACHINE ELECTRONIC MONITORING DISPLAY.......67

MONITOR MODE SELECTOR SWITCHES.......67

MODE SELECTOR SWITCH 1.......68

MODE SELECTOR SWITCH 2.......68

MONITOR DISPLAY INFORMATION.......68

HOUR METER AND ODOMETER DISPLAY.......68

ADJUSTING MONITOR BRIGHTNESS.......69

POGRAMING TELEPHONE NUMBER.......69

ACTION CODE DISPLAY.......69

FAILURE CODE DISPLAY.......70

SERVICE DISPLAY.......71

SELECTING LANGUAGE.......72

EMERGENCY STOP WARNING SYSTEM.......73

BRAKE PRESSURE WARNING LAMP.......73

ENGINE OIL PRESSURE WARNING LAMP.......74

BATTERY CHARGE WARNING LAMP.......74

STEERING OIL PRESSURE WARNING LAMP.......74

CAUTION ALERT WARNING SYSTEM.......75

AXLE OIL TEMPERATURE CAUTION LAMP.......75

TORQUE CONVERTER CAUTION LAMP.......76

COOLANT TEMPERATURE CAUTION LAMP.......76

HYDRAULIC OIL TEMPERATURE CAUTION LAMP.......76

FUEL LEVEL CAUTION LAMP.......76

INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM.......77

ENGINE OIL LEVEL CAUTION LAMP.......77

RADIATOR COOLANT LEVEL CAUTION LAMP.......78

AIR CLEANER CLOGGING CAUTION LAMP.......78

MAINTENANCE CAUTION LAMP.......78

BATTERY ELECTROLYTE LEVEL CAUTION LAMP.......78

MODE ALERT LAMPS.......79

PARKING BRAKE PILOT LAMP.......80

COOLING FAN REVERSE ROTATION PILOT LAMP.......80

EMERGENCY STEERING PILOT LAMP.......80

OUTPUT MODE PILOT LAMP (POWER MODE).......81

PREHEATING PILOT LAMP.......81

JOYSTICK PILOT LAMP.......81

DIRECTIONAL SELECTOR LAMP.......81

SHIFT INDICATOR.......82

AUTO-SHIFT PILOT LAMP.......82

LOCKUP PILOT LAMP.......82

SHIFT HOLD PILOT LAMP.......82

SHIFT LEVER POSITION PILOT LAMP.......83

TURN SIGNAL PILOT LAMP.......83

HEADLAMP HIGH BEAM PILOT LAMP.......83

GAUGE DISPLAY.......84

TORQUE CONVERTER OIL TEMPERATURE GAUGE.......84

ENGINE TEMPERATURE GAUGE.......85

HYDRAULIC TEMPERATURE GAUGE.......85

FUEL GAUGE.......85

SPEEDOMETER.......85

METER DISPLAY PILOT LAMP.......86

MACHINE MONITOR.......86

DISPLAYING ODOMETER.......86

RESET FOR FILTER, OIL REPLACEMENT TIME.......86

ENTERING A TELEPHONE NUMBER.......87

SELECTING A LANGUAGE.......88

ADJUSTING MONITOR BRIGHTNESS.......89

MACHINE SWITCHES AND CONTROLS.......90

SWITCH LOCATION.......90

IGNITION SWITCH.......91

POWER MODE SELECTOR SWITCH.......91

TRANSMISSION MODE SELECTOR SWITCH.......92

TRANSMISSION CUT-OFF SWITCH.......92

TRANSMISSION CUT-OFF SET SWITCH.......93

LAMP SWITCH.......93

TURN SIGNAL LEVER.......93

DIMMER SWITCH.......94

HORN BUTTON.......94

HAZARD LAMP SWITCH.......94

PARKING BRAKE SWITCH.......94

FRONT WORKING LAMP SWITCH.......95

REAR WORKING LAMP SWITCH.......95

MONITOR PANEL MODE SELECTOR SWITCH 1.......96

MONITOR PANEL MODE SELECTOR SWITCH 2.......96

KICKDOWN SWITCH.......96

HOLD SWITCH.......97

FRONT WIPER SWITCH.......97

REAR WIPER SWITCH.......97

CIGARETTE LIGHTER.......98

CAB LAMP SWITCH.......98

REAR DEFROSTER SWITCH.......98

E.C.S.S. SWITCH.......99

EMERGENCY STEERING SWITCH.......99

COOLING FAN REVERSE ROTATION SWITCH.......100

DIRECTIONAL SELECTOR SWITCH.......100

DIRECTIONAL SELECTOR SWITCH ACTUATION SWITCH.......101

TORQUE CONVERTER LOCK-UP SWITCH.......101

LOAD METER CANCEL SWITCH.......101

LOAD METER SUBTOTAL SWITCH.......101

EXPLANATION OF RADIO COMPONENTS.......102

POWER SWITCH/VOLUME.......102

TONE CONTROL KNOB.......103

DISPLAY.......103

CLOCK BUTTON/DISPLAYING FREQUENCY.......103

AST.......103

PRESET BUTTON.......104

SEEK.......104

BAND SELECTOR SWITCH.......104

TUNING SWITCH.......104

LISTENING TO THE RADIO.......105

AUTOMATIC TUNING.......105

MANUAL TUNING.......105

SETTING THE PRESET BUTTONS.......105

AUTOMATIC MEMORY.......106

AUTOMATIC SWITCHING RECEPTION OF MONAURAL/STEREO.......106

ADJUSTING THE TIME.......106

PRECAUTIONS WHEN USING.......106

LOCATIONS AND FUNCTION OF AIR CONDITIONER CONTROL PANEL.......107

FAN SWITCH.......108

TEMPERATURE CONTROL SWITCH.......108

MONITOR PANEL.......109

AIR CONDITIONER SWITCH.......109

METHOD OF OPERATION.......109

MANUAL OPERATION.......110

STOPPING MANUAL OPERATION.......111

MODE SELECTOR SWITCH.......111

RECIR/FRESH SELECTOR SWITCH.......111

WHEN NOT USING THE AIR CONDITIONER REGULARLY.......112

COOL BOX.......112

PRECAUTIONS WHEN USING THE COOLING.......112

CONTROL LEVERS, PEDALS.......113

SPEED CONTROL LEVER.......113

DIRECTIONAL LEVER.......115

SPEED CONTROL LEVER STOPPER.......115

SAFETY LOCK LEVER.......116

BUCKET CONTROL LEVER.......116

LIFT ARM CONTROL LEVER.......117

BRAKE PEDAL.......117

ACCELERATOR PEDAL.......118

STEERING TILT LOCK LEVER.......118

SECURITY AND LOCKS.......119

IGNITION KEY LOCKED AREAS.......119

CAB DOOR LOCKS.......119

ENGINE ACCESS DOORS.......119

REAR GRILL.......120

FUEL CAP.......120

PADLOCKED AREAS.......121

BATTERY AND TOOL BOX.......121

TRANSFER CASE.......121

UPPER HOOD ACCESS PANNEL.......121

SAFETY FEATURES.......122

PASSIVE SAFETY FEATURES.......122

ROLL-OVER PROTECTIVE STRUCTURE (ROPS).......122

CAB FRONTAL GUARD (WASTE HANDLER APPLICATION ONLY).......122

BACKUP WARNING ALARM.......122

ACTIVE SAFETY FEATURES.......123

SAFETY BAR.......123

SEAT BELT.......123

EQUIPMENT LOCK LEVER.......124

MACHINE FEATURES.......125

CAB DOORS.......125

OPEN LOCK.......125

ELECTRICAL.......125

FUSE.......125

FUSE CAPACITY AND NAME OF CIRCUIT.......126

SLOW BLOW FUSE.......127

AUXILIARY POWER.......127

MACHINE CAB AND CHASSIS.......128

SEAT ADJUSTMENT.......128

HANDLING CAB WIPER.......130

DUST INDICATOR.......130

GREASE PUMP.......130

PRECAUTIONS BEFORE STARTING WORK OPERATIONS.......131

PRE-OPERATIONAL CHECKS.......131

PERFORM A WALK AROUND CHECK OF YOUR MACHINE.......131

UNDER THE HOOD.......131

CHECK COOLANT LEVEL.......132

CHECK ENGINE OIL LEVEL, ADD OIL.......133

REAR-VIEW MIRROR ADJUSTMENT.......133

IN THE OPERATORS CAB.......134

SEAT BELT ADJUSTMENT.......134

LEVER STAND ADJUSTMENT.......135

LEVER STAND ANGLE ADJUSTMENT.......135

START-UP PROCEDURES.......136

CHECK FUEL LEVEL, ADD FUEL.......136

CHECK THE BRAKE PEDALS.......137

CHECK THE PARKING BRAKE.......137

STARTING THE ENGINE.......138

OPERATIONS AND CHECKS AFTER STARTING ENGINE.......141

BREAKING IN THE MACHINE.......141

NORMAL START-UP AND WARM-UP.......141

STOPPING THE ENGINE.......142

TRAVELING, STOPPING AND PARKING THE MACHINE.......143

TRAVELING.......143

TURNING ON SLOPES.......145

CHANGING GEAR SPEED RANGES.......145

CHANGING DIRECTION.......146

WHEN USING AUTO-SHIFT.......147

USING THE SWITCH TO CHANGE DIRECTION.......147

STOPPING AND PARKING THE MACHINE.......149

TRANSMISSION CUT-OFF SWITCH.......151

ADJUSTING THE TRANSMISSION CUT-OFF.......151

STOPPING WHEN TRANSMISSION CUT-OFF IS ON.......152

TURNING.......152

EMERGENCY STEERING.......153

USING THE EMERGENCY STEERING.......153

EMERGENCY STEERING SELF-CHECK FUNCTION.......154

STARTING YOUR WORK OPERATIONS.......155

WORK EQUIPMENT.......155

LIFT ARM LEVER.......155

BUCKET LEVER.......156

SCOOPING A LOAD OR CUTTING A GRADE.......157

LOADING PILED SOIL OR BLASTED ROCK.......157

CUTTING A GRADE ON LEVEL GROUND.......159

LEVELING OPERATIONS.......160

PUSHING OPERATION.......160

LOAD AND CARRY OPERATIONS.......160

LOADING OPERATIONS.......161

CROSS DRIVE LOADING.......161