Komatsu WA100M-7 Operation And Maintenance Manual Download Page 225

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5.5 Tools

Maintenance

WA80M-7, WA100M-7 – VENAM03001

5-23

5.5

Tools

5.5.1

List of required tools

Re-order damaged parts from your Komatsu distributor.

No.

Tool name

Part no.

Notes

Tool

42W-98-41100

Standard

Tool

42W-98-41100

Extended

Hose

42U-09-H2670

Grease pump

424-98-H1010

Hose

424-98-H1020

Grease pump hose

Hammer

421-98-H1140

Wrench

42T-09-H0450

Summary of Contents for WA100M-7

Page 1: ...all personnel read it periodically Operation and Maintenance Manual VENAM03001 DANGER Komatsu has had this Operation and Maintenance Manual translated into some other languages used in the European U...

Page 2: ......

Page 3: ...Foreword WA80M 7 WA100M 7 VENAM03001 1 1 1 Foreword...

Page 4: ...his manual and the safety labels affixed to the machine thoroughly and be sure that you understand them fully Keep this manual at the storage location for the Operation and Maintenance Manual given be...

Page 5: ...t modification to the machine by the owner voids the manufacturer s declaration of conformity Our continuous efforts to improve the machine s design may result in minor changes to the machine The intr...

Page 6: ...he follow ing safety instructions are observed If you are installing electrical or electronic equipment and or com ponents in the machine and connect them to the vehicle s electri cal system you are o...

Page 7: ...Indicates an imminently hazardous situation which if not avoided will result in death or serious injury WARNING Indicates a potentially hazardous situation which if not avoided could result in death...

Page 8: ...he right side In addition the type of hazardous condition is dis played inside a triangle and the method of avoiding the hazard ous condition is shown inside a circle Komatsu cannot predict every circ...

Page 9: ...hing Loading 1 3 1 Intended use If you use the machine for any other purpose than those specified above we will not accept any responsibility for its safety Any con siderations regarding safety will t...

Page 10: ...points Let the engine run at idle for 5 minutes after starting Avoid operation with heavy loads or at high engine speeds Avoid sudden starts and stops hard acceleration and sudden steering movements...

Page 11: ...ct identification number PIN Machine serial no plate and its position Position of the serial no plate 1 Serial number stamp 2 The plate is on the right side of the machine s front frame The design of...

Page 12: ...M03001 1 4 3 Axle serial no plate Axle serial no plate 1 Rear axle Left Front axle Right 1 4 4 Transmission serial no plate Transmission serial no plate 1 1 4 5 ROPS FOPS cab serial no plate ROPS FOPS...

Page 13: ...e Under the bellows at the front of the seat or on the rear lower frame arrow mark 1 4 7 Serial number and distributor GJ2K4590 Machine serial number Engine serial number Product identification number...

Page 14: ...provisions of the following EU Directives Explanation of machine category Machinery Directive 2006 42 EC Electro Magnetic Compatibility Directive 2004 108 EC until 19 April 2016 2014 30 EU after 20 A...

Page 15: ...ab serial no plate 1 10 1 4 6 Operator s seat serial no plate 1 11 1 4 7 Serial number and distributor 1 11 1 4 8 Declaration of Conformity 1 12 1 5 Table of contents 1 13 1 6 Dimensions weights and o...

Page 16: ...ation 3 49 3 3 1 Checks before starting 3 49 Visual inspection 3 49 Checks before starting the engine 3 52 Adjustments before starting 3 61 3 3 2 Starting the engine 3 66 Ambient temperature for opera...

Page 17: ...ing the multi purpose bucket 3 93 Bucket level indicator 3 93 3 3 13 Switching off the engine 3 94 3 3 14 Checks after switching off the engine 3 94 3 3 15 Locking 3 95 3 3 16 Handling tyres 3 96 Prec...

Page 18: ...es 4 18 4 6 7 Operator s cab 4 18 5 Maintenance 5 1 5 1 Maintenance guide 5 2 5 1 1 Tipping up the operator s cab 5 3 5 1 2 Tipping down the operator s cab 5 5 5 2 Basic maintenance guidelines 5 10 5...

Page 19: ...Check engine oil level add engine oil WA80M 7 5 43 5 8 6 Maintenance every 50 service hours 5 44 Work equipment lubricating 5 44 Central lubrication system checking replenishing grease 5 46 Check engi...

Page 20: ...Checking for missing fuel spray prevention cap and checking for embrittlement of the rubber 5 74 5 8 13 Maintenance every 8000 service hours 5 75 Clamps of the high pressure line renewing 5 75 Fuel sp...

Page 21: ...Foreword 1 5 Table of contents WA80M 7 WA100M 7 VENAM03001 1 19 Buttons 7 6 Three digit LED display 7 7 8 Index 8 1 8 1 Index 8 2 9 Notes 9 1...

Page 22: ...Dimensions weights and operating data Foreword 1 20 WA80M 7 WA100M 7 VENAM03001 1 6 Dimensions weights and operating data G0070228A e b d a f c F A H B E C D k l m n g h j G0070229A 5144 270 1316 WA80...

Page 23: ...e of bucket mm 4190 4515 e Digging depth mm 90 130 f Max loading height at 45 mm 2910 3185 A Overall length bucket on the ground mm 5640 6000 B Wheelbase mm 2260 2400 C Bucket width mm 1915 2200 D Wid...

Page 24: ...Volume m Hydraulic pressure bar Weight kg Bucket WA80M 7 42U 70 32260 1 0 401 42U 70 32250 1 0 422 42U 70 22120 1 25 336 42U 70 22411 1 3 370 42U 70 32401 0 8 250 597 WA100M 7 42W 7032260 1 05 695 42...

Page 25: ...4 5 Type Part no Payload fork carriage STD kg pair Payload fork carriage with additional CTW kg pair Weight kg Fork carriage WA80M 7 42T 70 22052 2400 215 42U 70 22181 2400 222 42T 70 32301 2400 230 W...

Page 26: ...1 7 Equipment Foreword 1 24 WA80M 7 WA100M 7 VENAM03001...

Page 27: ...1 2 1 2 Safety WARNING Please read and make sure that you fully understand the precautions described in this manual and the safety labels on the machine When operating or servicing the machine always...

Page 28: ...ep them clean at all times When you clean them do not use organic solvents or petrol as this could lead to the label dis solving If the labels are damaged lost or cannot be read properly replace them...

Page 29: ...sembly setup and transport 2 Caution when leaving the operator s seat 09654 C0481 This symbol highlights the danger of unexpected movement of the stopped machine Lower the work equipment to the ground...

Page 30: ...make any holes in it carry out any welding make cuts roll it or put in near a flame 6 Caution when engine is running 09667 A0800 This symbol highlights the risk posed by rotating parts such as a belt...

Page 31: ...machine Keep a safe distance from the vehicle while it is moving 9 Lifting the machine 42W 93 H42010 10 Lifting position mark transport lock 42W 93 42000 11 Warning to stay away from moving parts 0916...

Page 32: ...le 09808 A1681 This symbol highlights the risk of electrocution while handling power cables Read the manual to ensure safe and correct handling 14 Prohibition of short circuit starts 09842 A0481 Do no...

Page 33: ...In such a case seek advice from your Komatsu distributor Always buckle up while moving 18 Caution explosion area 09845 00480 This machine is equipped with a KOMTRAX or if an optional modem is fitted...

Page 34: ...g instructions for information about correct and safe handling 21 Caution shared line with high pressure 6271 81 2980 Do not open the high pressure fuel system when the engine is running Engine operat...

Page 35: ...s manual let the person in charge explain the matter to you If abnormalities are found If you detect any abnormality in the machine during operation or maintenance noise vibration smell incorrect gaug...

Page 36: ...rgency Safety features Be sure that all guards and covers are in their proper position Ensure that guards and covers are repaired immediately if they are damaged Understand the method of use of safety...

Page 37: ...ine 1 Lower the work equipment to the ground 2 Switch off the engine 3 Push the multi function lever forward to position S The remaining hydraulic pressure is released by doing this 4 Engage the work...

Page 38: ...chine always ensure that the work equipment is locked and cannot move Prevention of burns Hot coolant To prevent burns from hot water or steam spurting out when checking or draining the coolant wait f...

Page 39: ...ation and prevent access by unauthorised persons After adding fuel or oil wipe up any spilled fuel or oil When carrying out grinding or welding work on the chas sis move any flammable materials to a s...

Page 40: ...e oil to spurt out leading to fire dam age or serious injury Explosion caused by lighting equipment When checking fuel oil battery electrolyte window washer fluid or coolant always use lighting with a...

Page 41: ...when operating the machine FOPS Attachment for protection against falling objects The FOPS is integrated into the cab If working on sites where there is a risk of falling boulders or other objects wor...

Page 42: ...ce of the soil in the working area and deter mine the optimum and safest procedure When carrying out operations near combustible materials such as thatched roofs dry leaves or dry grass there is a haz...

Page 43: ...ectric cables inform the local power company about the work to be performed and ask them to take the necessary action Even approaching high voltage cables may cause an electric shock that possibly res...

Page 44: ...d adjusted as specified in the applicable regulations If the visibility cannot be sufficiently assured position a sig nalman if necessary Operators should pay careful attention to the signs and follow...

Page 45: ...on or serious property damage It might also become impossible to switch off the engine Signals and signs from the signalman Set up signs to warn of slopes and soft ground If the visibility is not good...

Page 46: ...o minimise dust build up when cleaning Never use compressed air for cleaning In case of danger from asbestos dust in the air always oper ate the machine from a downwind position All workers must use a...

Page 47: ...he window glass to ensure a good view Before getting on the machine check again that there is no one in the surrounding area and that there are no obstacles blocking the machine When starting the engi...

Page 48: ...e work equipment control system Check for any abnormality in the sound of the machine vibra tion heat smell and check the gauges Check that there is no leakage of oil or fuel If any abnormality is fou...

Page 49: ...and avoid sudden steering If the engine fails while you are driving you can still steer the machine More force is however necessary for this In case of engine failure immediately drive to the side of...

Page 50: ...s or embankments In case of an emergency quickly lower the bucket to the ground to stabilise the machine Do not turn or traverse on slopes Only execute these manoeuvres on level ground If it is necess...

Page 51: ...equipped with a pressure accumulator so that the work unit can be lowered by means of the multi function lever when the diesel engine is off NOTICE The work equipment cannot be lowered if it is locked...

Page 52: ...ip of the slope the load will decrease suddenly In this case the machine s ground speed may increase suddenly Therefore drive especially slow and care ful in such places Perform loading work with the...

Page 53: ...aced beside the road are buried in the snow and cannot be seen There is a hazard of the machine tipping over or hitting cov ered objects so work carefully When travelling on snow covered roads always...

Page 54: ...ions of the responsible superior it is necessary to transport several stacked palettes be sure to verify that the stacking devices of all palettes are free of defects The overall height of the palette...

Page 55: ...e machine from rolling away When parking the machine on public roads ensure that it does not obstruct traffic Put up signal lamps and required warning signs to ensure that passing traffic can clearly...

Page 56: ...e contains sulphuric acid When handling batteries always wear protective goggles If battery acid gets into your eyes it may cause blindness If acid gets into your eyes flush them immediately with larg...

Page 57: ...i nals by accidentally touching them with metal objects e g tools Always disconnect the negative terminal ground side first when removing the battery when installing the battery con nect the positive...

Page 58: ...ing service or maintenance This could lead to accidents that can cause serious injuries Always attach the warning tag to the work equipment control lever or on the multi function lever to alert others...

Page 59: ...parts if any defect is found even when they have not reached the time specified interval Hydraulic hoses have to be replaced every 2 years In order to ensure safe assembly and operation of the machine...

Page 60: ...perform this work in pairs after defining unmistakable signals One person has to remain on the operator s seat to immediately shut down the engine when necessary Only operate the operat ing level afte...

Page 61: ...A80M 7 WA100M 7 VENAM03001 2 35 Securing the articulated steering 1 Park the machine in a straight line 2 On the left side Loosen the spring pin and remove bolt 1 3 On the right side Insert the bolt 2...

Page 62: ...use a supporting prop 1 which is to be positioned below the boom 2 Park the machine on level solid ground 3 Apply the parking brake 4 Place wheel chocks in front of the wheels to prevent the machine...

Page 63: ...orkers must always maintain contact with each other When working near the fan fan belt or other rotating parts there is a risk of being caught in the device Ensure that you do not go too close to them...

Page 64: ...chock Never work under a machine that has not been sufficiently secured Keeping the machine clean Always keep the machine clean and tidy Oils grease and tools or parts laying around are dangerous beca...

Page 65: ...water Dispose of meeting environmental standards If the machine is equipped with a fuel strainer in the tank filler port it may not be removed when adding fuel Coolant The machine is equipped with an...

Page 66: ...tial slipping hazard and is flam mable Replace hoses every 2 years at the latest Handling high pressure oil Always keep in mind that the hydraulic circuits are under high pressure Do not add or remove...

Page 67: ...t or use a cutting torch Do not hit or roll the accumulator Do not subject it to any impact Before the maintenance technician extracts the pressure accumulator the hydraulic system has to be depressur...

Page 68: ...riv ers lakes or seas Obey applicable laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters and batteries Maintaining the air conditioner If refrigerant from...

Page 69: ...e tyre pressure is too low the tyres may heat up and burst If the tyre pressure is too high there is also danger that the tyre may burst If a tyre heats up considerably inflammable gases are pro duced...

Page 70: ...ected room that can not be accessed by unauthorised persons Place the tyres on an even surface and incline them 60 to 70 2 against a solid stopper and secure them with wheel chocks 1 so that they cann...

Page 71: ...Operation WA80M 7 WA100M 7 VENAM03001 3 1 3 Operation...

Page 72: ...3 1 General view Operation 3 2 WA80M 7 WA100M 7 VENAM03001 3 1 General view 3 1 1 General view of the machine 1 2 3 4 5 7 8 9 10 11 12 13 14 6...

Page 73: ...0M 7 VENAM03001 3 3 1 Bucket 2 Tipping lever 3 Front wheel 4 Bucket cylinder 5 Front work lights 6 ROPS cab 7 Warning beacon 8 Rear wheel 9 Turn signals 10 Headlights 11 Boom 12 Lift cylinder 13 Rear...

Page 74: ...3 1 General view Operation 3 4 WA80M 7 WA100M 7 VENAM03001 3 1 2 Controls General view G0010060 1 2 3 4 5 6 9 10 11 12 13 14 8 7 15 16 WA80M 7 WA100M 7 G0080301 9...

Page 75: ...rake 4 Steering column adjustment lever 5 Monitor 6 Turn signal lever 7 Headlight switch 8 Horn 9 Work equipment lock lever 10 Multi function lever 11 Special equipment control lever 12 Starting switc...

Page 76: ...3 1 General view Operation 3 6 WA80M 7 WA100M 7 VENAM03001 3 1 3 Machine monitor G0010011E 1 2 3 4 5 6 7 8 10 9 15 14 13 11 12 17 18 20 19 16...

Page 77: ...e caution lamp 6 High beam pilot lamp 7 Direction selector switch pilot lamps 8 Turn signal pilot lamp 9 Seat belt caution lamp 10 E C S S pilot lamp 11 Rear window defroster pilot lamp 12 Trailer tur...

Page 78: ...3 1 General view Operation 3 8 WA80M 7 WA100M 7 VENAM03001 3 1 4 Switches G0070417 G0010061 1 2 3 7 8 9 15 14 16 4 12 6 10 11 18 19 17 25 23 28 21 20 24 26 27 30 29 31 5 13 G0010005 22...

Page 79: ...h option 10 Turn indicator lever 11 Windshield wiper and washer switch 12 Horn button 13 Fan reversal switch 14 Switch for quick coupler 15 Sweeper switch 16 Back up light switch 17 Blower switch 18 T...

Page 80: ...itor The machine monitor consists of All elements needed for the efficient operation of the machine are explained below Pilot lamps This group includes the pilot lamps for high beam glow plugs turn in...

Page 81: ...001 3 11 Gauges This group includes the fuel gauge the service meter the coolant temperature gauge and the speedometer Caution lamps This group includes caution lamps for battery charge circuit park i...

Page 82: ...2 5 4 1 1 Warning symbol display Water separator caution lamp Air cleaner caution lamp Differential lock caution lamp Engine stop caution lamp Engine controller error code caution lamp 2 Battery char...

Page 83: ...his lamp lights up if the air cleaner becomes clogged when the engine is running If this is the case clean or replace the air cleaner cartridge For details see Air cleaner renewing renewing safety fil...

Page 84: ...he alternator generates a voltage to charge the battery The lamp goes out If the battery charge circuit caution lamp does not go out when the engine is running there is a malfunction For details see O...

Page 85: ...to the B ON position At the same time the acoustic warning signal sounds With the engine running After starting the engine the engine oil pressure builds up and the lamp goes out If the lamp does not...

Page 86: ...2 pilot lamp 3 Intake air pre heater pilot lamp 4 High beam pilot lamp 5 Direction selector switch pilot lamps 6 Turn signal pilot lamp 7 E C S S pilot lamp 8 Rear window defroster pilot lamp 9 Traile...

Page 87: ...Pressing and releasing button 2 on the multi function lever once causes the machine to return to speed range 1 and lamp 1 goes out 3 Intake air pre heater pilot lamp This lamp lights up when the star...

Page 88: ...tch in R position If the direction selector switch is in the neutral position N both pilot lamps are unlit 6 Turn signal pilot lamp This lamp flashes when the turn signal is engaged REMARK If the turn...

Page 89: ...turn signal is acti vated If the turn indicator circuit is interrupted the lamp flashes more quickly 10 Pilot lamp in the E C S S switch Option This lamp in the switch is lit when the E C S S is acti...

Page 90: ...ound light is green if enough fuel is available The background light is red when the fuel level is low Refill fuel NOTICE The symbol for the fill level indicator flashes if there is no contact with th...

Page 91: ...kground light is green if the coolant temperature is nor mal The background light is red if the coolant temperature is too high The acoustic warning signal sounds NOTICE The symbol for the coolant tem...

Page 92: ...scriptions of the individual elements Operation 3 22 WA80M 7 WA100M 7 VENAM03001 3 2 2 Switches G0070417 G0010061 1 2 3 7 8 9 15 14 16 4 12 6 10 11 18 19 17 25 23 28 21 20 24 26 27 30 29 31 5 13 G0010...

Page 93: ...tch option 10 Turn indicator lever 11 Windshield wiper and washer switch 12 Horn button 13 Fan reversal switch 14 Switch for quick coupler 15 Sweeper switch 16 Switch for quick coupler Back up light s...

Page 94: ...eadlights the side clear ance lights the tail lights and the search lights on and off 3 Rear window wiper and washer switch Use this switch to turn the rear window wiper and washer on and off The swit...

Page 95: ...on You can read out the errors in the engine controller using this but ton For details see Reading error code 3 112 6 Save button This button can be used to save the programmed type and dimen sion of...

Page 96: ...on and off 10 Turn signal lever Use the turn signal lever to turn the turn signal on and off 11 Windshield wiper and washer switch Use this switch to turn the windshield wiper and washer on and off Th...

Page 97: ...he switch causes the fan to rotate in the usual direc tion 14 Electrical quick coupler button Use this button to unlock the quick coupler Pull the button s lock A in the direction of the arrow to unlo...

Page 98: ...light must be switched off on public roads 17 Blower switch Use this rotary switch to control the airflow in several levels 18 Temperature switch Use this rotary switch to control the power of the he...

Page 99: ...operating in speed range 2 Pressing and releasing button 2 again causes the machine to return to speed range 1 and indicator 1 goes out 22 Switch 3rd control circuit option WA100M 7 WARNING If the wor...

Page 100: ...tive If the machine is travelling at a speed higher than 5 km h the E C S S is activated automatically and the E C S S pilot lamp on the machine monitor lights up If the machine is travelling slower t...

Page 101: ...e switch in this position the engine starts NOTICE Starting the engine is possible only when the direction selector switch is in the neutral position N 27 Cigarette lighter This is used to light cigar...

Page 102: ...re being replaced Never switch off the main switch while the engine is running This can lead to damage to electrical systems If the battery switch is switched off the power supply to all electrical sy...

Page 103: ...TICE Only use this switch in emergencies This switch is used if the starting switch is off but the engine does not stop 1 Lift the cover The switch is located beneath the cover 2 Pull on the switch in...

Page 104: ...3 2 3 Control levers and pedals 1 Steering column adjustment 2 Parking brake 3 Brake pedal 4 Accelerator pedal 5 Multi function lever 6 Accessory control lever 3rd control circuit and electrical quick...

Page 105: ...the parking brake is released NOTICE The machine will not start with the parking brake engaged If the direction selector switch is brought into the forward F or reverse R position with the parking bra...

Page 106: ...on The multi function lever locks in this position The floating position is used for levelling drawing off In this switching position the work equipment lowers under its own weight and moves freely du...

Page 107: ...cial equipment control lever to positions 1 2 or 3 with no additional equipment attached This would cause the work equipment to operate against overpressure and heat the oil unnecessarily possibly dam...

Page 108: ...80M 7 WA100M 7 VENAM03001 7 Work equipment lock lever The work equipment lock lever secures the work equipment against unintended use Use this lock lever to lock the work equipment before driving on r...

Page 109: ...ing Lock the articulated steering before lifting the machine and prior to repair and maintenance work 1 Park the machine in a straight line 2 On the left side Loosen the spring pin and remove bolt 1 3...

Page 110: ...with the attachment regulations Before using a trailer obtain instruction from your Komatsu dealer You can tow a trailer using the Rockinger Varioblock trailer tow hitch An electric connection with 13...

Page 111: ...Operation 3 2 Descriptions of the individual elements WA80M 7 WA100M 7 VENAM03001 3 41 Automatic hitch G00100501 G00100500...

Page 112: ...g light to the power outlet Use the power outlet to connect a reading light 3 2 8 Door unlocking The cab doors are equipped with detents that engage when the door is fully opened to prevent the door f...

Page 113: ...efore replac ing fuses only switch the battery main switch off once the green pilot lamp on the relay box has gone out Remove the key to the battery main switch Fuses with improper ratings may cause c...

Page 114: ...3 2 Descriptions of the individual elements Operation 3 44 WA80M 7 WA100M 7 VENAM03001 Fuse allocation G0010012...

Page 115: ...2 5 10 A Monitor F2 6 20 A Working lamps F2 7 10 A Left side clearance lamp license plate lighting attachment clearance lamp F2 8 10 A Right side clearance lamp F3 1 10 A High beam F3 2 10 A Low beam...

Page 116: ...use 250 A 5 Battery relay 120 A 6 Engine controller fuse 30 A 7 Engine controller fuse 5 A 8 Pilot lamp controller 1 A450 option Immobiliser 2 K56 1 Relay headlight 3 K56 2 Relay high beam 4 K67 Turn...

Page 117: ...and at the side windows Adjusting the heating system NOTICE The heating capacity depends on the coolant temperature of the engine Full heating capacity is only achieved when the engine has warmed up...

Page 118: ...n starting the machine and turning on the air conditioner Turning on the air conditioner 1 Turn the fan switch 1 to position 4 2 Turn the temperature control switch 2 to cold 3 Activate the air condit...

Page 119: ...ork equipment and the hydraulic system Also check for loose cables and accumulations of dirt Repair any defects and remove accumulations of dirt Before starting to work Perform the following tasks dai...

Page 120: ...ls Check the handrails for damages and loose screws Repair damages and retighten loose screws 8 Check gauges and indicators Check all gauges and indicators for damages and loose screws Replace defecti...

Page 121: ...S Check for loose or damaged screws Have any screws retightened or replaced by a Komatsu distributor Always retighten loose screws to the specified torque Always replace damaged screws with original p...

Page 122: ...t with the hot engine Wait until the engine has cooled down before adding coolant 1 Open the bonnet 2 Check that the coolant level in the expansion tank is between the FULL and LOW marks Add coolant i...

Page 123: ...tion is only allowed to be operated at idling speed 5 Press the accelerator pedal fully down for 30 s The engine is running at its max speed 6 Release the accelerator pedal The engine is running at id...

Page 124: ...leaning of the radiator fins 1 Unscrew the four screws 1 and remove the radiator guard 2 Unscrew both screws 2 to flip out the fan grille approx 45 and clean the radiator fins 3 Reinstall the fan gril...

Page 125: ...pull out again after a moment The oil level must be between the H and L marks on the dip stick 3 If the oil level is below the L mark add engine oil through the oil filler neck 2 See chapter Fuel lubr...

Page 126: ...ntly large oil tray 1 Place the tray underneath the drain screw arrow 2 Remove the cap 1 of the drain valve 3 Screw a drain hose 2 onto the drain valve This opens the drain valve 4 Drain excessive oil...

Page 127: ...el may ignite Immediately remove any spilled fuel 1 Turn the starting switch to the B ON position 2 Check the fuel level at the fuel gauge 3 Turn the starting switch to the A OFF position 4 Add fuel a...

Page 128: ...until pure fuel flows out 4 Retighten the valve 1 again by turning clockwise ATTENTION Do not over tighten the valve as this might damage the thread NOTICE It is recommended to fill the filter with fu...

Page 129: ...ter pilot lamp 5 is lit if the intake air pre heater is active NOTICE Contact your Komatsu distributor if one of the pilot lamps does not light up Do not use only the gauges and indicators for the che...

Page 130: ...ficient the filter cloth in the heater air con ditioner may be clogged and should be cleaned or replaced If the cooling performance of the air conditioner is too low check whether the condenser is dir...

Page 131: ...e operator s seat can be adjusted with spring support with levers 3 and 4 Use lever 3 to adjust the front section of the seat and lever 4 for the rear section Height adjustment Equally adjust the fron...

Page 132: ...To adjust the backrest apply a light load to it and pull and hold lever 5 Take load off the backrest to tilt it forward Press the backrest to the rear to tilt it backward Release lever 5 when the bac...

Page 133: ...eased 3 Adjusting the height The seat hight can be set to several different positions Raise the seat to the desired height until you can hear it click ing into place If the seat is raised above the up...

Page 134: ...ring wheel when sitting comfortably while at the same time having a good view of the work equipment Hold the steering wheel in this position 3 Lock the steering column in this position by applying the...

Page 135: ...belt so that it is not twisted and fits snugly The machine is equipped with a seat belt that retracts automati cally Automatically retracting seat belts offer full freedom of movement when pulled slo...

Page 136: ...entilation 3 Turn the starting switch to the B ON position The fuel level and coolant temperature LCDs as well as all caution and pilot lamp LED light up for 2 seconds and the acousting warning signal...

Page 137: ...olant temperature is below 20 C the engine speed is automatically brought up to 1100 rpm to warm up the engine As soon as the coolant temperature reaches 30 C the warm up is ended automatically engine...

Page 138: ...tioning of all hydraulic cylinders with the multi function lever Verify the proper functioning of the steering To warm up the hydraulic oil repeatedly tip the multi func tion lever for the work equipm...

Page 139: ...ure that there are no persons in the area sur rounding the machine and sound the horn 1 Start the engine as described in chapter Starting the engine 3 66 2 Raise the work equipment to the carrying pos...

Page 140: ...1 Stop the machine 2 Initially set the speed regulator to the lowest speed To do so turn the speed regulator 1 all the way to the left stop 0 posi tion 3 Depress the accelerator pedal The machine stay...

Page 141: ...ound the horn 1 Start the engine as described in chapter Starting the engine 3 66 2 Apply the parking brake The parking brake caution lamp lights up 3 Depress the brake pedal 4 Release the parking bra...

Page 142: ...ed should not exceed 15 km h Use the direction selector switch to switch between forward and reverse The machine may still be coasting when the direction is reversed Driving in reverse The back up lig...

Page 143: ...machine may fall over or slip when operated too close to steep slopes ridges or embankments The limit values are listed in chapter Limit values for slopes 6 6 Do not turn or traverse on slopes Only ex...

Page 144: ...arking brake lever 4 Release the lock button The parking brake pilot lamp goes out Braking with the service brake If the deceleration by releasing the accelerator pedal is insuffi cient use the servic...

Page 145: ...wnhill for extended periods of time the ser vice brake may overheat and become damaged Keep the engine running when driving downhill Use the brake in addition when necessary Accident hazard through no...

Page 146: ...und WARNING Inadvertently operating the multi function lever or moving the work equipment may cause accidents Engage the work equipment lock lever before leaving the operator s cab 5 Engage the work e...

Page 147: ...this position The floating position is used for levelling drawing off In this switching position the work equipment lowers under its own weight and moves freely due to external force S Lower This swit...

Page 148: ...ched the desired digging angle 3 3 10 Working with the wheel loader Saving the tyres When digging in piles of soil or blasted rock the tyres may become cut by slipping This reduces the service life of...

Page 149: ...ton 2 on the multi function lever The differential lock may only be switched on when the machine is stopped When the differential lock is engaged pilot lamp 1 on the instru ment panel is lit If only o...

Page 150: ...lways drive the machine into the material in a straight line Observe the instructions in section Saving the tyres 3 78 when digging Proceed as follows when digging 1 Drive the machine into the stockpi...

Page 151: ...causing tyre slip and increased tyre wear Always keep the load at the centre of the bucket An uneven load distribution may impair the machine s balance 6 Raise the boom while entering the material to...

Page 152: ...the machine with the service brake while keeping the accelerator pedal depressed 3 Slightly tilt the bucket downwards 4 While driving forward move the multi function lever for the boom slightly toward...

Page 153: ...ging After filling in the holes you may level the ground ATTENTION Danger of accidents Carelessly driving in reverse may cause severe accidents Check that there are no persons behind the machine befor...

Page 154: ...erating with a raised load may result in the load falling from the bucket and causing accidents Turn slowly and decelerate cautiously with a raised load ATTENTION Driving into a stockpile or a pile of...

Page 155: ...The rear counterweight should not touch the ground Working with the forklift attachment Working with a forklift attachment on a wheel loader is different both from working with a bucket and working wi...

Page 156: ...load so the load con tacts the back of the forklift attachment 3 Slightly tilt the forklift attachment to prevent the load from slip ping off 4 Lower the boom to the carrying position 5 Raise the loa...

Page 157: ...tions in section Working on snow 2 27 Dumping on steep slopes Follow the instructions in section While loading 2 26 Working near high voltage cables Follow the instructions in section Working near hig...

Page 158: ...Operation 3 49 Fasten any manual tools before starting to drive The required tyre pressure the ground speed and the type of tyre vary depending on the road conditions Contact your Komatsu distributor...

Page 159: ...control lever to position 1 while pressing and holding button 4 3 Slightly raise the boom by setting the multi function lever to position H 4 Slightly tilt the quick coupler forward Push the multi fun...

Page 160: ...equipment contact the quick coupler 7 Lock the quick coupler by setting the special equipment con trol lever to position 2 The locking bolts b must be visible WARNING If the work equipment is not loc...

Page 161: ...hydraulic lines of the multi purpose bucket to quick couplers 5 and 6 12 Start the engine Now the multi purpose bucket can be operated with the spe cial equipment control lever WARNING If the work equ...

Page 162: ...ial equipment control lever to position 1 while pressing and holding button 4 3 Use the multi function lever to set the quick coupler to the dump position A until the quick coupler disengages from the...

Page 163: ...ment control lever to position 1 while pressing and holding button 4 7 Use the multi function lever to set the quick coupler to posi tion A until the quick coupler disengages from the mounting hooks o...

Page 164: ...thout load at a medium speed for 5 minutes before switching it off so that the engine can cool down 3 Lower the working equipment 4 Turn the starting switch to the A OFF position to stop the engine 5...

Page 165: ...Operation 3 3 Operation WA80M 7 WA100M 7 VENAM03001 3 95 3 3 15 Locking Lock at the following locations NOTICE The ignition key fits all locks 1 2 3 1 Engine bonnet 2 Cab door 3 Battery box...

Page 166: ...re the tyre pressure does not drop below 2 bar If the tyre inflation pressure is too low there will be overload if it is too high it will cause tyre cuts and shock burst As a general principle for vis...

Page 167: ...1465 11 20 3 44 2 5 36 DUNLOP 405 70 R20 SPT9 tread 1441 1406 13 20 2 5 36 2 5 36 DUNLOP 365 70 R18 SPT9 tread 1520 1485 11 18 3 75 54 3 44 MICHELIN 375 75 R20 XZSL tread 1450 1415 11 20 2 4 35 2 29...

Page 168: ...by the tyre manufacturer or an authorised representative Increase the tyre pressure if the deflection ratio is too great WA100M 7 BARUM 405 70 24 NB38 tread 1745 13 24 3 44 2 75 40 DUNLOP 405 70 R20 S...

Page 169: ...machine Keep a sufficient distance from the road shoulder Use ramps of ample width length thickness and strength Install the ramps with an inclination of less than 15 When using an embankment compact...

Page 170: ...the centre of the tyres If the ramp sags noticeably reinforce it with blocks or similar 3 Determine the direction of the ramp then slowly load the machine 4 Load the machine correctly in the specified...

Page 171: ...he trans porter for possible damage before and after loading particu larly when transporting frequently 6 Put wheel chocks in front of and behind the wheels Secure the machine with chains or wire rope...

Page 172: ...ight The ramp s angle of inclination must not exceed 15 Set the distance between the ramps to match the centre of the tyres If the ramp sags noticeably reinforce it with blocks or similar 3 Remove the...

Page 173: ...ulated steering before lifting the machine Engage the work equipment lock lever Danger of injury Objects placed on the machine may drop when the machine is lifted Remove all loose objects from the mac...

Page 174: ...n in the diagram above The slings ropes chains or similar may only be used at a max imum angle of 10 see illustration above and must not touch any part of the machine aside from the attachment points...

Page 175: ...read locker Torque 400 Nm Deformation wear damage and excessive corrosion The lifting eyes must turn easily and be oriented as shown in the illustration The lifting point of the traverse must lie over...

Page 176: ...antifreeze should contact your eyes or skin wash it off with a large amount of fresh water and see a doctor at once When changing the coolant or when handling coolant con taining antifreeze that has...

Page 177: ...machine on solid dry ground If this is impossible park the machine on wooden boards The boards prevent the wheels from freezing to the ground so the machine will be able to move the next morning Open...

Page 178: ...overed in storage Lock all control levers with the lock levers To prevent corrosion fill the cooling system with original Komatsu Supercoolant AF NAC Check that the mixing ratio is 30 at least 3 6 2 D...

Page 179: ...roceed as follows before using a machine after long term stor age Wipe the grease from the hydraulic piston rods Refill oil and grease at all lubrication points When a machine is stored for a long per...

Page 180: ...the machine itself KOMTRAX may be installed and removed by your Komatsu distributor Prevent cables and wires from snagging Do not damage or pull cables by force Short circuits or disconnected wires m...

Page 181: ...pped with KOMTRAX WA80M 7 WA100M 7 VENAM03001 3 111 side the wireless communication service area The KOMTRAX communications terminal does not need inspec tion or maintenance Consult your Komatsu distr...

Page 182: ...work Check the indicator and proceed as follows NOTICE Contact your Komatsu distributor to arrange a repair 1 Stop the engine if an error code appears 2 Turn the starting switch to the B ON position 3...

Page 183: ...nitor area Press the START key and the error code is displayed 5 Contact your Komatsu distributor and tell them what the error code is 3 8 1 Adjusting the monitor The two keys are for setting the tyre...

Page 184: ...3 8 Reading error code Operation 3 114 WA80M 7 WA100M 7 VENAM03001...

Page 185: ...Troubleshooting WA80M 7 WA100M 7 VENAM03001 4 1 4 Troubleshooting...

Page 186: ...d may not exceed 2 km h Before you are permitted to tow a machine that is equipped with a hydrostatic drive you have to establish a short circuit connec tion between the high pressure side and the low...

Page 187: ...ction selector switch to N 2 Tip up the operator s cab For details see Tipping up the operator s cab 5 3 3 Remove the protective caps from the valves NOTICE Observe the types of the valves Version A o...

Page 188: ...it is level with the top of the lock nut 4 Retighten the lock nut 2 Perform this task on both valves Version B Hold the valve 1 with a wrench Loosen the lock nut 2 and screw out the threaded pin 3 cou...

Page 189: ...screw out the threaded pin 3 counter clockwise by means of an Allen key all the way Retighten the lock nut 2 Perform this task on both valves Version B Hold the valve 1 with a wrench Loosen the lock...

Page 190: ...e towing machine Always use two machines to tow a machine with defective brakes Connect the three machines with appropriate towing devices If you intend to tow a machine with defective brakes or the m...

Page 191: ...e block of the defective machine spark formation occurs here Therefore perform the connection at a spot that is as far away as possible from the battery Be careful when disconnecting the cable from th...

Page 192: ...he booster cable B to the frame of the defective vehicle 5 Let the engine run at high speed Starting the engine ATTENTION Ensure that the cable terminals are securely fastened to the bat tery terminal...

Page 193: ...matsu workshop 4 3 2 Checking the parking brake 1 Start the engine align the machine forward and drive the machine up a 25 slope with an empty bucket 2 Stop the machine with the service brake and hold...

Page 194: ...t running the work equipment can still be lowered with the multi function lever emergency lowering If the hose break safety device is installed the machine is equipped with a pressure accumulator so t...

Page 195: ...disconnections and cables Alternator is not functioning Check the function of the alternator replace defective alternator Drive belts of the alternator are not tensioned properly Tension drive belt Al...

Page 196: ...filter car tridge Lines or hoses of the engine lubrica tion damaged Check lines and hoses visual inspection discharge of oil Replace defective lines and hoses Line or hose connections of the engine l...

Page 197: ...eck the contacts or replace the temperature sensor Coolant temperature gauge The coolant temperature gauge does not show a temperature with the engine warm in operation Coolant temperature gauge is no...

Page 198: ...oises Valve clearance too large Adjust the valve clearance The engine will not start or switches off during operation Fuel filter or fuel prefilter blocked Clean the fuel prefilter or replace the fuel...

Page 199: ...ydrostatic engine Forward reverse valve is defective Check the forward reverse valve Replace the defective forward reverse valve Switch relay is not functioning Check the function of the switch relay...

Page 200: ...ic system WORK EQUIPMENT Fault Cause Remedy Lifting power too low Hydraulic pump is defective Directional valve DBV is defective Cylinder is defective leaks inside Repair the hydraulic pump Check and...

Page 201: ...level in the brake oil con tainer too low Add brake oil Check brake system for damages and leakages visual inspection discharge of brake oil PARKING BRAKE Fault Cause Remedy Brake without effect Tole...

Page 202: ...distributor These tasks should be performed by the distributor 4 6 7 Operator s cab If errors or causes of errors occur that are not listed here have the repair performed by your Komatsu distributor...

Page 203: ...Maintenance WA80M 7 WA100M 7 VENAM03001 5 1 5 Maintenance...

Page 204: ...g main tenance Always position the machine as specified for maintenance and repairs Unless explicitly specified otherwise the machine must be posi tioned as follows Lower the work equipment to the gro...

Page 205: ...ing 2 35 NOTICE The machine has to be positioned as for driving in a straight line and the articulated steering has to be secured with the locking bolt If the operator s cab is tipped up while the mac...

Page 206: ...ld out the safety rod on the right side over the retaining pin 10 Set the lever at the pump to pump down and pump the cab downward until the safety rod is secure against the right side of the cab floo...

Page 207: ...mp up and pump the cab upward until it reaches the limit stop 2 Fold in the safety rod on the right side and secure it in the folded position arrow 3 Set the lever to pump down and pump the cab downwa...

Page 208: ...Choose oils and grease with proper viscosities specified for ambient temperature Always use clean washer fluid Use ethanol based window washer fluid and ensure it is not con taminated by dirt Always u...

Page 209: ...nuts or tools into the machine If such objects are dropped into the machine they will dam age the machine and cause malfunctions leading to machine failure If you drop anything inside the machine alw...

Page 210: ...After repairing or replacing parts or lines of the hydraulic circuit it is necessary to bleed the air from the circuit Precautions when installing hydraulic hoses When removing parts with sealing rin...

Page 211: ...and become caught in the lever linkage Is there any leakage of water or oil Have all the bolts been tightened Checks with the engine running If a maintenance task must be carried out with the engine...

Page 212: ...mperature range specified in the Operation and Maintenance Manual Even if the oil is not contaminated it needs to be changed after the specified interval Oil in a machine corresponds to the blood in a...

Page 213: ...ation during storage or when refilling Always use the fuel specified in the Operation and Mainte nance Manual If the fuel is used at temperatures lower than the specified temperature particularly at t...

Page 214: ...ater such as a river water or well water hard water contains large amounts of minerals calcium magnesium etc This accelerates the formation of scale inside the engine or the radiator Once present scal...

Page 215: ...iffness or screeching Always wipe off all of the old grease that is pushed out when greasing Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease woul...

Page 216: ...with Komatsu machines is permitted For infor mation on products cleared for use and best suited for your appli cation please contact your Komatsu distributor 5 2 2 Outlines of the electrical system I...

Page 217: ...theses need to be replaced at the same time Order numbers for the parts See the Parts Book Komatsu Item Part no Part name Quantity Replacement interval Hydraulic oil filter Filter insert O ring O ring...

Page 218: ...5 4 Fuel lubricants and coolants quantities Maintenance 5 16 WA80M 7 WA100M 7 VENAM03001 5 4 Fuel lubricants and coolants quantities 5 4 1 Lubrication table...

Page 219: ...g of the symbol Symbol Meaning of the symbol Read the Operation and Maintenance Manual Lubricating Changing engine oil Checking engine oil level Change hydraulic oil Checking hydraulic oil level Chang...

Page 220: ...5 4 Fuel lubricants and coolants quantities Maintenance 5 18 WA80M 7 WA100M 7 VENAM03001...

Page 221: ...ng of the symbol Symbol Meaning of the symbol Read the Operation and Maintenance Manual Lubricating Changing engine oil Checking engine oil level Change hydraulic oil Checking hydraulic oil level Chan...

Page 222: ...ILLUBE D LS 80W 90 ESSO TORQUE FLUID 62 SHELL SPIRAX S4 TXM GO 80 API GL4 API GL4 API GL4 API GL 5 API GL4 API GL4 SAE 80 SAE 80 SAE 80 SAE 80W 90 SAE 10W 30 SAE 10W 30 1 Hydraulic system Steering Hyd...

Page 223: ...ication litres Refill amount Specification litres Refill amount Engine oil pan 11 5 11 11 5 11 Transmission 1 3 1 3 Hydraulic system 50 50 Front and rear axles per axle Planetary gear 2 0 7 2 1 3 Diff...

Page 224: ...Maintenance 5 22 WA80M 7 WA100M 7 VENAM03001 5 4 2 Recommended brands recommended quality for products other than Komatsu genuine oil Please contact your Komatsu distributor when using commer cially a...

Page 225: ...equired tools Re order damaged parts from your Komatsu distributor No Tool name Part no Notes 1 Tool 42W 98 41100 Standard 1 Tool 42W 98 41100 Extended 2 Hose 42U 09 H2670 3 Grease pump 424 98 H1010 4...

Page 226: ...ffi cult to determine the extent of wear or deterioration during peri odic maintenance Hence it is required to replace these parts regardless of their condition after a certain period of usage This is...

Page 227: ...er the first 500 service hours 5 42 Front and rear axle change oil 5 42 Transfer case change oil 5 42 5 8 5 Maintenance every 10 service hours 5 43 Articulated steering lubricating 5 43 Check coolant...

Page 228: ...eeding 5 64 5 8 10 Maintenance every 1500 service hours 5 65 Front and rear axle change oil 5 65 Transfer case change oil 5 67 5 8 11 Maintenance every 2000 service hours 5 68 Valve clearance checking...

Page 229: ...or clean radiator fins V belt check condition Check engine oil level add engine oil Check the fuel level add fuel Additional water separator optional Water separator draining water and dirt accumulati...

Page 230: ...verheat and fail If the cooling performance of the air conditioner is too low check whether the condenser is dirty Clean a dirty condenser with cold water If the water pressure is too high the fins ma...

Page 231: ...is correct as shown in the dia gram on the right the condition is normal When the air condi tioner is switched on you will see a few bubbles After this the liquid takes on a translucent milky white co...

Page 232: ...acid from your skin and eyes with large amounts of water and consult a doctor Gases that form in the battery may explode Do not bring open fire or sparks near the battery Do not smoke Before charging...

Page 233: ...VENAM03001 5 31 Air grille cleaning Clean the air grilles from both sides if they are dirty NOTICE Do not use a high pressure cleaner to clean the air grilles Radiator fins cleaning Clean the radiato...

Page 234: ...e and cooling properties and can be used continuously for two years or 4000 hours Komatsu recommends using a amine free engine coolant AF NAC If you use a different coolant this can lead to serious pr...

Page 235: ...olant which has been drained in the course of repairing the radiator alternatively have this work done by a specialist company Coolant is toxic Do not let it flow away in drainage channels and do not...

Page 236: ...CE Fill the cooling system slowly Otherwise the enclosed air may not be able to escape fully After filling wait for three more minutes and top off fluid if required 1 Slowly fill the cooling system wi...

Page 237: ...lant expansion tank clean the inside of the coolant expansion tank and fill it with amine free coolant until the midpoint between FULL and LOW Air cleaner checking cleaning WARNING When using compress...

Page 238: ...this case the filter insert and the safety filter need to be replaced Removing the filter insert WARNING While the engine is running moving parts in the engine compart ment may cause severe injuries D...

Page 239: ...ir ATTENTION Flying dust particles may cause injury to the eyes Wear safety goggles when cleaning the filter inserts with pressur ised air Hazardous dusts may cause lung irritation Wear a dust mask wh...

Page 240: ...r is cleaned Checking the filter insert Always check the filter insert before installing Check filter inserts for damaged seals NOTICE Also check any new filter inserts before installing Installing th...

Page 241: ...cleaning 5 35 2 Install the filter insert Changing the safety filter NOTICE Do not clean the safety filter Renew it after the filter insert has been renewed six times Keep the working area clean Do n...

Page 242: ...e Hydraulic system renewing filter insert renew ing venting filters 5 62 Wheel nuts checking and retightening WARNING Loose wheel nuts may cause severe accidents Periodically check and retighten the w...

Page 243: ...ine that is not properly parked and secured may cause severe accidents Park the machine on solid level ground Secure the machine before beginning maintenance work 1 For maintenance work park the machi...

Page 244: ...100M 7 VENAM03001 5 8 4 Maintenance after the first 500 service hours Carry out the following maintenance only after the first 500 ser vice hours Front and rear axle change oil For details see Front a...

Page 245: ...e guide 5 2 2 Clean the grease nipples indicated by the arrows Articulated steering 2 points 3 Use a grease pump to press a sufficient amount of grease into the grease nipples 4 Remove any excess old...

Page 246: ...severe accidents Park the machine on solid level ground Secure the machine before beginning maintenance work 1 For maintenance work park the machine as described in chapter Maintenance guide 5 2 2 Cl...

Page 247: ...5 8 Maintenance procedure Maintenance Maintenance every 50 service hours WA80M 7 WA100M 7 VENAM03001 5 45 G0070247C G0070248 1 2 5 5 6 3 4...

Page 248: ...Permitted lubricants Grease of NLGI class 2 with EP additives compatible with plas tics NBR elastomers copper and copper alloys and a max flow pressure of 700 mbar Fill the lubricant container to abov...

Page 249: ...intenance procedure Maintenance Maintenance every 50 service hours WA80M 7 WA100M 7 VENAM03001 5 47 Check engine oil level add engine oil WA100M 7 For details see Check engine oil level add engine oil...

Page 250: ...ake pads WARNING Danger of accidents If the brake oil level is too low the service brake might fail ATTENTION Danger of accidents Using commercially available brake fluid may reduce the performance of...

Page 251: ...ents Park the machine on solid level ground Secure the machine before beginning maintenance work 1 For maintenance work park the machine as described in chapter 5 1 Maintenance guide 5 2 2 Clean the i...

Page 252: ...e severe accidents Park the machine on solid level ground Secure the machine before beginning maintenance work 1 For maintenance work park the machine as described in chapter Maintenance guide 5 2 2 C...

Page 253: ...ried out every 10 50 100 and 250 service hours Manual pump check oil level 1 The oil level in the hand pump is checked with the cab tipped down 2 Remove the screw plug 1 3 The oil level should be at t...

Page 254: ...id may reduce the performance of the brake system Only fill with the specified oil Do not use brake fluid Keep extremely clean All repairs of the brake system have to be performed by a Komatsu worksho...

Page 255: ...may cause severe accidents Park the machine on solid level ground Secure the machine before beginning maintenance work NOTICE Change the oil only with the engine off and at operating temper ature 1 Fo...

Page 256: ...tly Then tighten the filter cartridge as specified by the filter manufacturer 5 After renewing the filter cartridge fill clean engine oil through the oil filler neck 3 until the oil level reaches the...

Page 257: ...the cab 4 screws 2 Remove the filter cloth 2 from the heater 3 3 Clean the filter cloth in warm water 30 40 C added with a mild detergent Caution Do not rub or wring the filter cloth 4 Dry the filter...

Page 258: ...he water pressure is too high the fins may warp Keep a suffi cient distance when cleaning with a high pressure washing machine Pressure accumulator for multi function lever checking gas pressure Have...

Page 259: ...ne lower the work equipment and apply the parking brake 2 Remove the screw plug 1 from the check bore 3 Check the oil level The oil level should be at the lower edge of the check bore 4 If the oil lev...

Page 260: ...enance on a machine that is not properly parked and secured may cause severe accidents Park the machine on solid level ground Secure the machine before beginning maintenance work 1 For maintenance wor...

Page 261: ...h to unscrew the fuel filter 1 anticlock wise 5 Unscrew the sensor 3 and the drain valve 7 with o rings 4 and 6 from the fuel filter 6 Screw the sensor 3 and the drain valve 7 with new o rings 4 and 6...

Page 262: ...n the engine compartment may cause severe injuries Do not work in the engine compartment while the engine is running An automatic tensioning device is installed so there is no need to set the tension...

Page 263: ...reduce the performance of the brake system Only fill with the specified oil Do not use brake fluid Keep extremely clean All repairs of the brake system have to be performed by a Komatsu workshop For m...

Page 264: ...a below the boom if the boom is supported 4 Position the supporting prop underneath the boom 5 With the engine switched off lower the boom slowly until it rests safely on the supporting prop 6 Clean t...

Page 265: ...ew the two fuel filters 1 anti clockwise 5 Unscrew the sensor 3 and the drain valve 7 with o rings 4 and 6 from the fuel filter 6 Screw the sensor 3 and the drain valve 7 with new o rings 4 and 6 to t...

Page 266: ...g gles and rubber gloves when working on the injection pump In the event of being hit by a high pressure fuel jet immediately con sult a doctor For maintenance work park and secure the machine as desc...

Page 267: ...achine before beginning maintenance work Epicyclic gearing 1 Start the engine raise the work equipment and move the machine until the screw plug 1 of the epicyclic gearing on the wheel to be checked i...

Page 268: ...lugs of the drain holes 2 and the two screw plugs of the filling and check bores 1 Drain the oil 3 Clean the screw plugs and install an intact seal 4 Insert the screw plugs 2 and tighten firmly 5 Fill...

Page 269: ...not properly parked and secured may cause severe accidents Park the machine on solid level ground Secure the machine before beginning maintenance work Provide a sufficiently large drain tray 1 For mai...

Page 270: ...e checking and setting Have the valve clearance checked and adjusted by a Komatsu distributor Water pump checking Check the water pump to see if water is coming out of it and if you discover anything...

Page 271: ...y spurt out and cause scalding Wear rubber gloves and hold the oil drain tray underneath the drain in a way that prevents the oil from making contact with your body Provide a sufficiently large drain...

Page 272: ...edge of the sight glass 4 11 Start the engine 12 Repeatedly raise and lower the work equipment while tilting and dumping the bucket 13 Lower the bucket to the ground and set it to the scraping posi t...

Page 273: ...ine without the filter element The filter element cannot be cleaned If the filter element is cleaned or serviced the filter capacity will be reduced As a result the turbocharger and the aftercooler wi...

Page 274: ...blow by gas condensing However this is not a problem as long as the coolant level is normal 4 Coat both O rings 6 with engine oil and attach them to the top and bottom of the new filter element You c...

Page 275: ...replaced if required at a Komatsu workshop Water pump checking Have the water pump checked in a Komatsu workshop Checking the clamp of the high pressure line is firmly seated and checking for embritt...

Page 276: ...injection lines as well as at both ends of the high pressure lines prevent any fuel which emerges or sprays out from coming into contact with hot parts of the engine and causing a fire Perform a visua...

Page 277: ...rm all maintenance tasks scheduled to be carried out every 10 50 100 250 500 1000 and 2000 service hours Clamps of the high pressure line renewing Please contact your Komatsu workshop to have the pipi...

Page 278: ...5 8 Maintenance procedure Maintenance every 8000 service hours Maintenance 5 76 WA80M 7 WA100M 7 VENAM03001...

Page 279: ...Technical data WA80M 7 WA100M 7 VENAM03001 6 1 6 Technical data...

Page 280: ...0 30 km h Max tractive force 20 km h 30 km h 4197 daN 3998 daN Min turn radius Outer edge of bucket 4290 mm Outer edge of tyre 3875 mm Bucket standard 1 0 m Power Engine Type Komatsu SAA4D95LE 6 Engin...

Page 281: ...ith ISO 11201 the greatest value for the standard deviation of the average measured A rated acoustic pressure level at the operator s seat is A dB Acoustic power level generated by the machine measure...

Page 282: ...ocedures that are defined in the standards ISO 2631 1 and ISO 5349 Operating conditions Wheel loader V shape loading Guide to reduce vibration levels on machine The following guides can help an operat...

Page 283: ...low down when it is necessary to go over rough terrain Make the curve radius of travelling path as large as pos sible Travel at low speed when travelling around sharp curves 7 Minimise vibrations for...

Page 284: ...hine at rest can stand on a slope without tipping over You must not work with the machine at these angles as the motor transmission hydraulic system or axles will not be sup plied with sufficient oil...

Page 285: ...Special equipment attachments WA80M 7 WA100M 7 VENAM03001 7 1 7 Special equipment attachments...

Page 286: ...cumulator and the solenoid valve When the E C S S is activated the solenoid valve opens and the circuit at the piston head of the lift cylinder is connected to the pressure accumulator 7 1 2 Precautio...

Page 287: ...ivated automatically and the E C S S pilot lamp on the machine monitor lights up If the machine is travelling at a speed lower than 5 km h the E C S S system is deactivated and the pilot lamp on the m...

Page 288: ...ition indicator shows the status of the bucket NOTICE When the quick coupler is dismounted the clamp at the piston rod C and indicator rod D have to be dismounted as well Else the cylinder seal could...

Page 289: ...n 6 minutes NOTICE To adjust lubrication times under greater loads please contact your Komatsu distributor 7 3 2 Operating the central lubrication system Position of the lubrication pump Left under th...

Page 290: ...removed and remounted afterwards LED display Buttons G0070304 1 2 3 4 5 6 1 Three digit LED display Values and operational condition 2 Intermission sequence 3 Pump operation 4 Monitoring the system f...

Page 291: ...ng which the pump is pumping Input and display value in minutes c COUNTER CO CONTACT Caution Do not use This mode triggers a malfunction C Cycle O OFF P Pressure Display of the start of the menu Monit...

Page 292: ...7 3 Central lubrication system Special equipment attachments 7 8 WA80M 7 WA100M 7 VENAM03001...

Page 293: ...Index WA80M 7 WA100M 7 VENAM03001 8 1 8 Index...

Page 294: ...3 49 checks 3 94 cigarette lighter 3 31 cleaning cooling system 5 32 control lever additional functions 3 78 control levers special equipment 3 37 controls 3 4 caution lamps 3 12 control levers 3 34...

Page 295: ...artridge 5 54 engine oil change 5 53 front axle checking oil level 5 57 oil change 5 65 fuel and coolant hoses 5 73 fuel filter changing filter cartridge 5 63 fuel prefilter changing filter cartridge...

Page 296: ...n 2 21 parking the machine 2 29 ROPS 2 15 safety labels 1 6 signal words 1 5 tyres 2 43 safety instructions asbestos 2 20 leaving the machine 2 11 loading 2 26 pressure accumulator 2 41 safety clothin...

Page 297: ...17 turning 3 73 tyre pressure chart 3 97 tyres 2 43 3 96 U using the machine carrying 3 84 forklift attachment 3 85 levelling 3 83 loading 3 80 near high voltage cables 2 17 on snow 2 27 saving the t...

Page 298: ...8 1 Index Index 8 6 WA80M 7 WA100M 7 VENAM03001...

Page 299: ...Notes WA80M 7 WA100M 7 VENAM03001 9 1 9 Notes...

Page 300: ...Notes 9 2 WA80M 7 WA100M 7 VENAM03001...

Page 301: ...Notes WA80M 7 WA100M 7 VENAM03001 9 3...

Page 302: ...Notes 9 4 WA80M 7 WA100M 7 VENAM03001...

Page 303: ...Notes WA80M 7 WA100M 7 VENAM03001 9 5...

Page 304: ...Notes 9 6 WA80M 7 WA100M 7 VENAM03001...

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