Komatsu WA400-5L Wheel Loader Operation and Maintenance Manual CEAM009602

Description

• Model List:
  • WA400-5L Wheel Loader

• 1. INTRODUCTION
• 1.1. FOREWORD
• 1.2. SAFETY INFORMATION
• 1.3. APPROVED AND NONAPPROVED USES
• 1.3.1. NONAPPROVED
• 1.4. PRODUCT IDENTIFICATION
• 1.4.1. MACHINE SERIAL NUMBER
• 1.4.2. ENGINE SERIAL NUMBER AND EMISSION LABEL
• 1.4.3. SERVICE METER LOCATION
• 1.5. SERIAL NUMBERS AND DEALER INFORMATION
• 1.6. CONTENTS
• 2. SAFETY
• 2.1. GENERAL SAFETY RULES AND PRECAUTIONS
• 2.1.1. GENERAL SAFETY RULES
• 2.1.2. SAFETY FEATURES
• 2.1.3. PERSONAL PROTECTIVE EQUIPMENT
• 2.1.4. UNAUTHORIZED MODIFICATIONS
• 2.1.5. LEAVING OPERATORS COMPARTMENT
• 2.1.6. MOUNTING AND DISMOUNTING
• 2.1.7. FIRE PREVENTION FOR FUEL AND OIL
• 2.1.8. DUST HAZARD PRECAUTIONS
• 2.1.9. CRUSH OR PINCH POINT DANGERS
• 2.1.10. FIRE EXTINGUISHER AND FIRST AID KIT
• 2.1.11. INSIDE OPERATORS COMPARTMENT
• 2.1.12. PRECAUTIONS WHEN USING ROPS
• 2.1.13. PRECAUTIONS FOR ATTACHMENTS
• 2.2. STARTING YOUR WORK OPERATIONS
• 2.2.1. WORK SITE HAZARDS
• 2.2.2. AVOIDING DANGEROUS SITUATIONS
• 2.2.3. WORKING CLEARANCES
• 2.3. RULES FOR ROAD TRAVEL
• 2.3.1. TRAVELING IN REVERSE
• 2.3.2. TRAVELING ON ICY OR SNOWCOVERED SURFACES
• 2.3.3. WORKING ON LOOSE OR UNSTABLE GROUND
• 2.3.4. TRAVEL ON SLOPES
• 2.3.5. PARKING THE MACHINE
• 2.4. PRECAUTIONS DURING MAINTENANCE OPERATIONS
• 2.4.1. WARNING TAGS
• 2.4.2. EQUIPMENT STORAGE
• 2.4.3. WORKING UNDER THE MACHINE
• 2.4.4. USING DROP LAMPS
• 2.4.5. KEEPING THE MACHINE CLEAN
• 2.4.6. RUNNING THE MACHINE DURING MAINTENANCE
• 2.4.7. RULES FOR REFUELING THE MACHINE
• 2.4.8. COOLING SYSTEM PRECAUTIONS
• 2.4.9. BATTERY PRECAUTIONS
• 2.4.10. STARTING THE MACHINE
• 2.4.11. HIGH PRESSURE HOSES
• 2.4.12. HIGH TEMPERATURES AREAS
• 2.4.13. DISPOSAL OF WASTE MATERIALS
• 2.4.14. INFLATING TIRES
• 2.4.15. ACCUMULATOR
• 2.4.16. CRITICAL PARTS
• 2.4.17. VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED
• 2.5. SAFETY AND WARNING DECALS
• 2.5.1. LOCATION OF THE SAFETY DECALS
• 2.5.2. LOCATION OF SAFETY LABELS
• 3. OPERATION
• 3.1. GENERAL VIEW OF MACHINE
• 3.1.1. OUTSIDE VIEW OF THE MACHINE
• 3.1.2. INSIDE VIEW OF THE CAB
• 3.2. DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS
• 3.2.1. INSTRUMENT BEZEL
• 3.2.2. SWITCH PANELS
• 3.3. DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM
• 3.3.1. INSTRUMENT BEZEL
• 3.4. MACHINE ELECTRONIC MONITORING DISPLAY
• 3.4.1. MONITOR MODE SELECTOR SWITCHES
• 3.4.2. MONITOR DISPLAY INFORMATION
• 3.4.3. EMERGENCY STOP WARNING SYSTEM
• 3.4.4. CAUTION ALERT WARNING SYSTEM
• 3.4.5. INSPECTION AND MAINTENANCE ALERT WARNING SYSTEM
• 3.4.6. MODE ALERT LAMPS
• 3.4.7. GAUGE DISPLAY
• 3.4.8. MACHINE MONITOR
• 3.5. MACHINE SWITCHES AND CONTROLS
• 3.5.1. SWITCH LOCATION
• 3.6. SOUND SYSTEM
• 3.6.1. DIGITAL ESPERIA RADIO COMPONENTS
• 3.6.2. BLAUPUNKT CALAIS RADIO COMPONENTS
• 3.6.3. AIR CONDITIONER CONTROL PANEL
• 3.6.4. CONTROL LEVERS, PEDALS
• 3.7. SECURITY AND LOCKS
• 3.7.1. IGNITION KEY LOCKED AREAS
• 3.7.2. PADLOCKED AREAS
• 3.8. SAFETY FEATURES
• 3.8.1. PASSIVE SAFETY FEATURES
• 3.8.2. ACTIVE SAFETY FEATURES
• 3.9. MACHINE FEATURES
• 3.9.1. CAB DOORS
• 3.9.2. ELECTRICAL
• 3.9.3. MACHINE CAB AND CHASSIS
• 3.10. PRECAUTIONS BEFORE STARTING WORK OPERATIONS
• 3.10.1. PREOPERATIONAL CHECKS
• 3.10.2. STARTUP PROCEDURES
• 3.11. OPERATIONS AND CHECKS AFTER STARTING ENGINE
• 3.11.1. BREAKING IN THE MACHINE
• 3.12. TRAVELING, STOPPING AND PARKING THE MACHINE
• 3.12.1. TRAVELING
• 3.12.2. STOPPING AND PARKING THE MACHINE
• 3.13. EMERGENCY STEERING
• 3.13.1. USING THE EMERGENCY STEERING
• 3.14. STARTING YOUR WORK OPERATIONS
• 3.14.1. WORK EQUIPMENT
• 3.14.2. SCOOPING A LOAD OR CUTTING A GRADE
• 3.14.3. LEVELING OPERATIONS
• 3.14.4. PUSHING OPERATION
• 3.14.5. LOAD AND CARRY OPERATIONS
• 3.14.6. LOADING OPERATIONS
• 3.15. PRECAUTIONS DURING OPERATION
• 3.15.1. PERMISSIBLE WATER DEPTH
• 3.15.2. IF WHEEL BRAKE DOES NOT WORK
• 3.15.3. PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES
• 3.15.4. PRECAUTIONS WHEN DRIVING THE MACHINE
• 3.15.5. PRECAUTIONS REGARDING BRAKE FUNCTION
• 3.16. WORK EQUIPMENT AND MACHINE POSTURE
• 3.16.1. ADJUSTING BUCKET
• 3.17. TRANSPORTING THE MACHINE
• 3.17.1. LOADING AND SECURING THE MACHINE
• 3.18. LIFTING THE MACHINE
• 3.18.1. LIFTING LOCATIONS AND PROCEDURES
• 3.18.2. USING WIRE ROPE
• 3.19. TOWING THE MACHINE
• 3.20. COLD WEATHER OPERATION
• 3.20.1. FUEL AND LUBRICANTS
• 3.20.2. COOLANT
• 3.20.3. PRECAUTIONS AFTER COMPLETION OF WORK
• 3.20.4. AFTER COLD WEATHER
• 3.20.5. WARMING UP THE STEERING
• 4. MAINTENANCE
• 4.1. GUIDES TO MAINTENANCE
• 4.1.1. CHECK SERVICE METER
• 4.1.2. KOMATSU GENUINE REPLACEMENT PARTS
• 4.1.3. KOMATSU GENUINE OILS
• 4.1.4. ALWAYS USE CLEAN WASHER FLUID
• 4.1.5. ALWAYS USE CLEAN OIL AND GREASE
• 4.1.6. CHECKING FOR FOREIGN MATERIALS IN DRAINED OIL AND ON FILTERS
• 4.1.7. FUEL STRAINER
• 4.1.8. WELDING INSTRUCTIONS
• 4.1.9. DO NOT DROP THINGS INSIDE THE MACHINE
• 4.1.10. DUSTY WORKSITES
• 4.1.11. AVOID MIXING OIL
• 4.1.12. LOCKING INSPECTION COVERS
• 4.1.13. BLEEDING AIR FROM HYDRAULIC CIRCUIT
• 4.1.14. PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES
• 4.1.15. CHECKS AFTER INSPECTION AND MAINTENANCE
• 4.2. SYSTEMS TROUBLESHOOTING CHARTS
• 4.2.1. ELECTRICAL SYSTEM
• 4.2.2. CHASSIS
• 4.2.3. ENGINE
• 4.3. OUTLINES OF SERVICE
• 4.3.1. HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC
• 4.3.2. PERFORMING KOWA (Komatsu Oil Wear Analysis)
• 4.3.3. KOWA ANALYSIS ITEMS
• 4.3.4. OUTLINE OF ELECTRIC SYSTEM
• 4.4. WEAR PARTS LIST
• 4.5. FUEL, COOLANT AND LUBRICANTS
• 4.5.1. PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS
• 4.6. STANDARD TIGHTENING TORQUES FOR FASTENERS AND HOSES
• 4.6.1. TORQUE LIST
• 4.7. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS
• 4.8. MAINTENANCE SCHEDULE CHART
• 4.9. GENERAL MAINTENANCE AND INSPECTION
• 4.9.1. INITIAL 250 HOURS SERVICE
• 4.9.2. WHEN REQUIRED
• 4.9.3. EVERY 50 HOURS SERVICE
• 4.9.4. EVERY 100 HOURS SERVICE
• 4.9.5. EVERY 250 HOURS SERVICE
• 4.9.6. EVERY 500 HOURS SERVICE
• 4.9.7. EVERY 1000 HOURS SERVICE
• 4.9.8. EVERY 2000 HOURS SERVICE
• 4.9.9. EVERY 4000 HOURS SERVICE
• 4.9.10. EVERY 8000 HOURS SERVICE
• 4.10. GENERAL MAINTENANCE AND INSPECTION
• 4.10.1. INITIAL 250 HOURS SERVICE
• 4.10.2. WHEN REQUIRED
• 4.11. EVERY SPECIFIC HOURS SERVICE
• 4.11.1. EVERY 50 HOURS OF SERVICE
• 4.11.2. EVERY 100 HOURS SERVICE
• 4.11.3. EVERY 250 HOURS OF SERVICE
• 4.11.4. EVERY 500 HOURS SERVICE
• 4.11.5. EVERY 1000 HOURS SERVICE
• 4.11.6. EVERY 2000 HOURS SERVICE
• 4.11.7. EVERY 4000 HOURS SERVICE
• 4.11.8. EVERY 8000 HOURS SERVICE
• 4.12. LONGTERM STORAGE
• 4.12.1. BEFORE STORAGE
• 4.12.2. DURING STORAGE
• 4.13. TROUBLESHOOTING EMERGENCY PROBLEMS
• 4.13.1. WHEN MACHINE RUNS OUT OF FUEL
• 4.14. TOWING THE MACHINE
• 4.14.1. WHEN ENGINE CAN BE USED
• 4.14.2. WHEN ENGINE CANNOT BE USED
• 4.14.3. RELEASING THE PARKING BRAKE
• 4.14.4. EMERGENCY TRAVEL OPERATION
• 5. SPECIFICATIONS
• 5.1. SPECIFICATIONS
• 5.1.1. MACHINE DIMENSIONS AND WEIGHTS
• 5.2. MACHINE SYSTEMS SPECIFICATIONS
• 5.2.1. ENGINE
• 6. OPTIONS, ATTACHMENTS
• 6.1. MONITOR WITH LOAD METER
• 6.1.1. LOAD METER
• 6.1.2. SWITCHES
• 6.1.3. LOAD METER FUNCTIONS
• 6.1.4. USING LOAD METER DISPLAY
• 6.1.5. PRINTER OUTPUT
• 6.2. TORQUE CONVERTER LOCKUP
• 6.2.1. GENERAL LOCATIONS
• 6.2.2. WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED
• 6.3. WASTE HANDLER ENGINE COOLING FAN CONTROL SYSTEM
• 6.3.1. FAN SYSTEM OPERATION
• 6.4. HANDLING JOYSTICK STEERING SYSTEM
• 6.4.1. EXPLANATION OF COMPONENTS
• 6.4.2. STRUCTURE AND FUNCTION OF JOYSTICK STEERING
• 6.5. SELECTING BUCKET AND TIRES