Komatsu WA400-1 and WA400-5 Wheel Loader Workshop Repair Manual with Wiring Diagrams, PDF Download - MKMTSWA400.zip

A full workshop service and repair guide, complete with Electrical Wiring Diagrams, for the Komatsu WA400 Wheel Loader — everything you need to maintain, troubleshoot, fix, and rebuild your machine to the standard of a trained professional technician.

The Komatsu WA400-Series wheel loader workshop service 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: 2,260 pages

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

Language: English

SEAM047401T - Wheel Loader WA400-5 Operation & Maintenance Manual.pdf

SEBM028006 - Wheel Loader WA400-5 Shop Manual.pdf

SEBM04240106 - Wheel Loader WA400-1 Shop Manual.pdf

MAIN SECTIONS

SEAM047401T - Wheel Loader WA400-5 Operation & Maintenance Manual...2

COVER...2

FOREWORD...3

FOREWORD...4

SAFETY INFORMATION...7

INTRODUCTION...9

FRONT/REAR,LEFT/RIGHT DIRECTIONS OF MACHINE...9

NECESSARY INFORMATION...10

MACHINE SERIAL NO. PLATE AND POSITION...10

ENGINE SERIAL NO. PLATE AND POSITION...10

POSITION OF SERVICE METER...11

TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...11

CONTENTS...12

SAFETY...15

SAFETY...16

SAFETY LABELS...19

LOCATION OF SAFETY LABELS...19

SAFETY LABELS...20

GENERAL PRECAUTIONS...25

SAFETY RULES...25

IF ABNORMALITIES ARE FOUND...25

CLOTHING AND PERSONAL PROTECTIVE ITEMS...25

FIRE EXTINGUISHER AND FIRST AID KIT...25

SAFETY FEATURES...25

KEEP MACHINE CLEAN...26

INSIDE OPERATOR'S COMPARTMENT...26

ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...26

HANDRAILS AND STEPS...27

MOUNTING AND DISMOUNTING...28

NO PEOPLE ON ATTACHMENTS...28

DO NOT GET CAUGHT IN ARTICULATED PORTION...28

PREVENTION OF BURNS...28

FIRE PREVENTION...29

ACTION IF FIRE OCCURS...30

WINDOW WASHER LIQUID...30

PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)...30

PRECAUTIONS FOR ATTACHMENTS...31

UNAUTHORIZED MODIFICATION...31

SAFETY AT WORKSITE...31

WORKING ON LOOSE GROUND...31

DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...32

ENSURE GOOD VISIBILITY...32

BE CAREFUL ABOUT ASBESTOS DUST...32

CHECKING SIGNALMAN'S SIGNALS AND SIGNS...33

EMERGENCY EXIT FROM OPERATOR'S CAB...33

VENTILATION FOR ENCLOSED AREAS...33

PRECAUTIONS FOR OPERATION...34

STARTING ENGINE...34

CHECKS BEFORE STARTING ENGINE...34

PRECAUTIONS WHEN STARTING...35

PRECAUTIONS IN COLD AREAS...35

OPERATION...36

CHECKS BEFORE OPERATION...36

PRECAUTIONS WHEN TRAVELING IN FORWARD OR REVERSE...36

PRECAUTIONS WHEN TRAVELING...37

TRAVELING ON SLOPES...38

PROHIBITED OPERATIONS...39

PRECAUTIONS WHEN OPERATING...39

METHODS OF USING BRAKE...40

OPERATE CAREFULLY ON SNOW...40

PARKING MACHINE...41

TRANSPORTATION...42

LOADING AND UNLOADING...42

SHIPPING...42

BATTERY...43

BATTERY HAZARD PREVENTION...43

STARTING WITH BOOSTER CABLES...44

TOWING...45

WHEN TOWING...45

PRECAUTIONS FOR MAINTENANCE...46

WARNING TAG...46

KEEP WORK PLACE CLEAN AND TIDY...46

APPOINT LEADER WHEN WORKING WITH OTHERS...46

MAINTENANCE WITH ENGINE RUNNING...47

TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...48

INSPECTION AND MAINTENANCE AFTER TURNING E.C.S.S. SWITCH OFF...48

PROPER TOOLS...49

ACCUMULATOR...49

PERSONNEL...49

ATTACHMENTS...49

WORK UNDER THE MACHINE...50

NOISE...50

PRECAUTIONS WHEN USING HAMMER...50

REPAIR WELDING...50

REMOVING BATTERY TERMINAL...50

PRECAUTIONS WITH HIGH-PRESSURE OIL...51

PRECAUTIONS FOR HIGH-PRESSURE FUEL...51

HANDLING HIGH-PRESSURE HOSES...51

WASTE MATERIALS...51

MAINTENANCE OF AIR CONDITIONER...52

COMPRESSED AIR...52

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...52

PRECAUTIONS WITH TIRES...53

HANDLING TIRES...53

PRECAUTIONS WHEN STORING TIRES...53

OPERATION...54

GENERAL VIEW...55

GENERAL VIEW OF MACHINE...55

GENERAL VIEW OF CONTROLS AND GAUGES...56

EXPLANATION OF COMPONENTS...59

MACHINE MONITOR...59

SWITCHES...89

CONTROL LEVERS, PEDALS...102

STEERING TILT LOCK LEVER...107

CAP WITH LOCK...108

SAFETY BAR...110

TOWING PIN...110

GREASE PUMP...111

CAB DOOR OPEN LOCK...111

CAB WINDOW OPEN LOCK CANCEL KNOB...111

BACKUP ALARM...112

FUSE...112

SLOW-BLOW FUSE...114

TAKING OFF POWER...114

CAR RADIO...115

AIR CONDITIONER...121

HANDLING CAB WIPER...126

DUST INDICATOR...126

OPERATION...127

CHECK BEFORE STARTING ENGINE, ADJUST...127

STARTING ENGINE...141

OPERATIONS AND CHECKS AFTER STARTING ENGINE...145

STOPPING ENGINE...147

CHECK AFTER STOPPING ENGINE...147

MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING...147

TURNING...157

OPERATION OF WORK EQUIPMENT...159

WORK POSSIBLE USING WHEEL LOADER...161

PRECAUTIONS FOR OPERATION...167

ADJUSTING WORK EQUIPMENT POSTURE...169

PARKING MACHINE...171

CHECKS AFTER COMPLETION OF OPERATION...173

LOCKING...173

HANDLING THE TIRES...174

TRANSPORTATION...176

TRANSPORTATION PROCEDURE...176

LOADING, UNLOADING WORK WITH TRAILERS...176

LIFTING MACHINE...178

COLD WEATHER OPERATION...181

PRECAUTIONS FOR LOW TEMPERATURE...181

PRECAUTIONS AFTER COMPLETION OF WORK...182

AFTER COLD WEATHER...183

WARMING-UP OPERATION FOR STEERING HYDRAULIC CIRCUIT IN COLD WEATHER...183

LONG-TERM STORAGE...184

BEFORE STORAGE...184

DURING STORAGE...184

AFTER STORAGE...184

TROUBLESHOOTING...185

WHEN MACHINE RUNS OUT OF FUEL...185

TOWING THE MACHINE...186

IF BATTERY IS DISCHARGED...190

OTHER TROUBLE...193

MAINTENANCE...198

GUIDES TO MAINTENANCE...199

OUTLINES OF SERVICE...201

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...201

OUTLINE OF ELECTRIC SYSTEM...203

WEAR PARTS...204

WEAR PARTS LIST...204

USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...205

PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...205

STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...210

TORQUE LIST...210

PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...211

MAINTENANCE SCHEDULE CHART...212

MAINTENANCE SCHEDULE CHART...212

SERVICE PROCEDURE...214

INITIAL 250 HOURS SERVICE...214

INITIAL 1000 HOURS SERVICE...214

WHEN REQUIRED...215

CHECK,CLEAN,OR REPLACE AIR CLEANER ELEMENT...215

CLEAN INSIDE OF COOLING SYSTEM...218

CHECK WATER SEPARATOR...220

CHECK TRANSMISSION OIL LEVEL, ADD OIL...221

CHECK AXLE OIL LEVEL, ADD OIL...222

CLEAN AXLE CASE BREATHER...224

CLEAN CONDENSER OF AIR CONDITIONER...224

CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...225

CLEAN RADIATOR FINS AND COOLER FINS...225

CHECK ELECTRICAL INTAKE AIR HEATER...228

REPLACE BOLT ON CUTTING EDGE...228

REPLACE BUCKET TEETH...229

CHECK AIR CONDITIONER...230

REPLACE SLOW-BLOW FUSE...230

SELECTION AND INSPECTION OF TIRES...231

CHECK BEFORE STARTING...233

EVERY 50 HOURS SERVICE...233

DRAIN WATER, SEDIMENT FROM FUEL TANK...233

EVERY 100 HOURS SERVICE...233

LUBRICATE REAR AXLE PIVOT PIN...233

CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...234

CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...234

EVERY 250 HOURS SERVICE...235

CHECK BATTERY ELECTROLYTE LEVEL...235

CHECK PARKING BRAKE...237

CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...237

CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN...238

CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...238

LUBRICATING...239

EVERY 500 HOURS SERVICE...240

CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...240

REPLACE FUEL FILTER CARTRIDGE...241

EVERY 1000 HOURS SERVICE...242

CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER...242

CLEAN TRANSMISSION CASE BREATHER...243

LUBRICATING...243

CHECK TIGHTENING PARTS OF TURBOCHARGER...244

CHECK PLAY OF TURBOCHARGER ROTOR...244

CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT...244

REPLACE CORROSION RESISTOR CARTRIDGE...244

EVERY 2000 HOURS SERVICE...244

CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...244

REPLACE HYDRAULIC TANK BREATHER ELEMENT...246

CHANGE AXLE OIL...247

REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER...247

CLEAN PPC CIRCUIT STRAINER...248

CLEAN ENGINE BREATHER ELEMENT...248

CHECK ALTERNATOR, STARTING MOTOR...248

CHECK ENGINE VALVE CLEARANCE, ADJUST...248

CLEAN AND CHECK TURBOCHARGER...249

CHECK INJECTOR...249

CHECK ACCUMULATOR GAS PRESSURE...249

CHECK VIBRATION DAMPER...249

CHECK BRAKE DISC WEAR...249

EVERY 4000 HOURS SERVICE...250

LUBRICATING...250

CHECK WATER PUMP...251

CHECK AIR CONDITIONER COMPRESSOR, ADJUST...251

REPLACE INJECTOR ASSEMBLY...251

CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP,HARDENING OF RUBBER...252

CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP,HARDENING OF RUBBER...252

EVERY 8000 HOURS SERVICE...252

REPLACE HIGH-PRESSURE PIPING CLAMP...252

REPLACE FUEL SPRAY PREVENTION CAP...252

SPECIFICATIONS...253

SPECIFICATIONS...254

ATTACHMENTS, OPTIONS...255

SELECTING BUCKET AND TIRES...256

HANDLING LOAD METER...257

GENERAL LOCATIONS...257

LOAD METER FUNCTIONS...259

HANDLING LOAD METER DISPLAY...262

METHOD OF SETTING TIME ON CLOCK...277

PRINTER OUTPUT...279

HANDLING TORQUE CONVERTER LOCK-UP...282

GENERAL LOCATIONS...282

METHOD OF OPERATION...283

WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED...284

HANDLING AUTO-GREASING SYSTEM...285

METHOD OF OPERATING AUTO-GREASING SYSTEM...285

PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM...291

TROUBLESHOOTING...291

HANDLING JOYSTICK STEERING SYSTEM...292

EXPLANATION OF COMPONENTS...292

STRUCTURE AND FUNCTION OF JOYSTICK STEERING...294

GETTING IN OR OUT OF OPERATOR'S CAB...296

ADJUSTMENT OF JOYSTICK CONSOLE...296

OPERATION METHOD OF JOYSTICK STEERING SYSTEM...297

HANDLING EPC WORK EQUIPMENT LEVER...300

OPERATIONAL FEATURES...300

SWITCHES...300

SEMI AUTO DIGGING OPERATIONS...301

METHOD OF REMOTE POSITIONER...303

HANDLING MULTI-FUNCTION LEVER...305

EXPLANATION OF COMPONENTS...305

USING FNR SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE...308

INDEX...310

SEBM028006 - Wheel Loader WA400-5 Shop Manual...314

COVER...314

CONTENTS...315

01 GENERAL...341

GENERAL ASSEMBLY DRAWING...342

SPECIFICATIONS...343

WEIGHT TABLE...347

LIST OF LUBRICANT AND COOLANT...349

10 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...351

COOLING SYSTEM...352

ENGINE MOUNT, TRANSMISSION MOUNT...353

POWER TRAIN...354

POWER TRAIN SYSTEM DIAGRAM...355

DRIVE SHAFT (PROPELLER SHAFT)...358

TORQUE CONVERTER,TRANSMISSION PIPING...359