Operation & Maintenance Manual: Wheel Loader

Operation & Maintenance VEAM280201
Manual
WHEEL LOADER
-5
SERIAL NUMBERS H50051 AND UP
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects and other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain
lead and lead compounds, chemicals known to the state
of California to cause cancer and reproductive harm.
Wasch hands after handling
© 2006 Komatsu Hanomag GmbH

All Rights Reserved
Printed in Europe 03-06
Introduction
1. Introduction
WA100M-5 – VEAM280201 1-1

1.1. Product publications information Introduction
1.1. Product publications information
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUC-
TION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND
SHOP MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP
MANUALS IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:

Engine and Chassis VZPB192800
OPERATION & MAINTENANCE MANUAL:

Chassis VEAM280200
SHOP MANUAL:
Engine CU3666417-00
Chassis VEBM270100
SAFETY MANUAL: ___________
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIB-
UTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESS-
ING SYSTEM (PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM
KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
1-2 WA100M-5 – VEAM280201

Introduction 1.1. Product publications information
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO ——> Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO ——————>
ATTN.
STREET ADDRESS
ORDRER DATE
TYPE or PRINT CITY. STATE. ZIP CODE

ONLY ———————>
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK PUBLICATION

QTY. PUBLICATION FORM NO. P-PAPER MODEL NUMBER SERIAL NUMBER
DESCRIPTION
➥
M-MICROFICHE
WA100M-5 – VEAM280201 1-3

1.2. Foreword Introduction
1.2. Foreword
The machine must be operated, cleaned, and maintained very
carefully to ensure safe and troublefree operation. If you operate
the machine correctly, these operating instructions will help you to
avoid injuries and damage to property. To ensure this, these oper-
ating instructions take into account all applicable legal regulations
and directives; the operating instructions comprise the following
information:
● Notes on the Operating Instructions
● Notes on Transport
● Notes on Safety Regulations
● Operating Instructions
● Troubleshooting
● Maintenance Instructions
● Technical Data
● Notes on Lubricants and Operating Agents
The operating manual belongs to the machine and is stored in the

lid of the hinged console, on the left of the driver’s cab.
The operating instructions are part of the machine and must

always be available at hand in the machine.
If the operating instructions have been lost or if they have become

unreadable, because they are dirty, you may receive a new copy
from Komatsu or your local Komatsu dealer. If the machine is
resold, the operating instructions, the EU Declaration of Confor-
mity (CE), and the licence are to be handed over to the new
owner.
The owner of the machine has to ensure that
● all persons driving the machine have the legally required min-
imum age and are physically and mentally fit to perform the
tasks they are charged with.
● all persons in charge with operating or maintaining the

machine are appropriately instructed before operation or
maintenance is started. They must have completely read and
understood these operating instructions. In particular, this
applies to the following section "Notes on Safety Regulations"
and the chapter "Safety".
● the machine is correctly operated.
● the machine is not improperly modified.
1-4 WA100M-5 – VEAM280201

Introduction 1.2. Foreword
Please note:
If the owner modifies safety-related parts of the machine, the cer-

tificate of conformity of the manufacturer will lapse and the person
who has performed the modification has to issue a new certifi-
cate. Should you have any questions concerning this point,
please do not hesitate to ask Komatsu.
Our continuous effort to improve the machine’s design may lead

to changes of machine details. However, the introduction of these
improvements does not oblige us to perform them on machines
which have already been delivered and are already in use.
If these improvements result in minor changes, these minor

changes will not be described in the operating instructions.
Should you require new available information about your machine
or have any questions concerning the information given in the
operating instructions, please do not hesitate to contact either
Komatsu or your responsible Komatsu dealer.
These operating instructions may refer to attachments and spe-

cial equipment not available from your local Komatsu dealer.
Should you require attachments or special equipment, ask your
responsible Komatsu dealer.
EU Directives
This machine is labelled with the CE mark indicating that it meets

all basic requirements concerning safety and protection of health
of the EU Machinery Directive 89/392/EEC, its supplements 91/
368 EEC and 93/44 EEC for Europe, and the regulation 95/27/
EEC. In addition, the harmonised European standards EN 292-2
and EN 474/1 of 1994, and EN 474-3 of 1996 were applied for
manufacture of the machine. This fact is documented in the EU
Declaration of Conformity (CE) which is supplied together with the
machine.
This means that in those cases in which the machine is modified

in such a way that safety of the machine is affected, the person
responsible for safety of the machine is the one who has
arranged for the machine to be modified. If you use the machine
for any other purpose than that defined as correct use, you are
the person who has to ensure that safety is maintained. Modifica-
tions of the machine or use of the machine for any other purpose
than that specified as correct use may require a new CE mark
and thus new issuing of an EU Declaration of Conformity.
If a machine is used in other countries than Germany, it may be

possible that special national safety devices and specifications
are missing which may be required for the application in the rele-
vant country. For example, for Komatsu machines, the manufac-
turer has to design the cab roof in such a way that a warning
beacon can be attached to the roof. However, when driving the
machine on roads, this warning beacon must be covered.
Should you have any questions concerning standards and guide-

lines in the respective country the machine is to be used in,
please ask your Komatsu dealer before you start commissioning
the machine.
WA100M-5 – VEAM280201 1-5

1.2. Foreword Introduction
In addition to the operating instructions, you must also adhere to

all legal regulations on public traffic and all applicable regulations
on prevention of accidents.
Notes on later installation of electrical and electronical

devices and components
Electrical or electronical devices and/or components installed

later emit electromagnetic radiation which may influence the
proper function of electronic components and parts of the
machine. This may impair safety of the machine and endanger
persons. For this reason, strictly adhere to the following safety
notes.
If you later install electrical and electronical devices and/or com-

ponents in the machine and connect them to the vehicle electrical
system, you are responsible for any malfunctions of the vehicle
electronics or other components resulting from this installation.
Above all, check that all electrical and electronical components
which you install later comply with the valid version of the EMC
directive 89/336/EEC and that they are labelled with the CE mark.
The following requirements must additionally be met for a later

installation of mobile communication systems.
● Only install devices which have a licence referring to valid

national regulations.
● The device must be stationary.
● Only use portable or mobile devices in the cab, if they are

connected to a stationary external aerial.
● Install the sender in such a way that it is physically separated

from the vehicle electronics.
● When installing the aerial, make sure that it is installed cor-

rectly with a good chassis earth connection between the
aerial and the chassis of the vehicle.
In addition, adhere to all information about installation and con-

nection of cables and maximum power input indicated in the man-
ufacturer’s installation instructions of the machine.
1-6 WA100M-5 – VEAM280201

Introduction 1.3. Safety information
1.3. Safety information

The procedures and precautionary measures concerning opera-
tion and maintenance only apply on the provision that the
machine is used as intended.
Most accidents are caused by disregard of basic safety regula-

tions during operation and maintenance of machines. In order to
avoid accidents and thus damage to persons and property, read
all applicable safety notes and warnings in these operating
instructions and on the machine, before you start operation or
maintenance of the machine and always adhere to these safety
notes and warnings.
The following words are used in this manual and on stickers on

the machine to signify safety instructions and enable them to be
recognized as such at a glance:
DANGER
This word is used for safety messages and safety label
where there is a probability of serious injury if the danger is
not avoided. The safety instruction or sticker contains pre-
cautions which must be observed in order to avoid the dan-
ger. Failure to do so can also result in damage to the
machine.
WARNING
This word is used for safety messages and safety label
where there is a potentially dangerous situation which could
lead to serious injury if the danger is not avoided. The safety
instruction or sticker contains precautions which must be
observed in order to avoid the danger. Failure to do so can
also result in damage to the machine.
CAUTION
This word is used for safety messages and safety label in the
event of danger which could result in minor or partly serious
injuries if the danger is not avoided. It may also relate to dan-
gers which may only result in damage to the machine.
NOTE
This word is used for precautions which have to be taken in
order to avoid situations which could result in shortening the
service lift of the machine.
The safety instructions are listed in the chapter "2. Safety" on

page 2-1 and following.
WA100M-5 – VEAM280201 1-7

1.3. Safety information Introduction
The transport of persons in the work equipment is strictly

forbidden!
We cannot foresee all circumstances which could result in poten-

tial danger during maintenance and operation. The safety instruc-
tions in this manual and on the machine, therefore, do not
necessarily contain all possible safety precautions. If you are
using a procedure or measure not explicitly permitted and recom-
mended in this manual, you must ensure that you and anyone
else can use any such procedure without any danger or damage
to the machine whatsoever. Please contact your local Komatsu
dealer if you have any doubts about the safety of any procedures.
1-8 WA100M-5 – VEAM280201

Introduction 1.4. Introduction
1.4. Introduction
1.4.1. Intended use

This loader is a machine with independent transmission, moving
on wheels. Driving in forward direction, the loader can load or dig
material using its attachments intended for loading operations (i.e.
bucket).
The standard operation cycle of a loader includes filling up and

loading of the bucket, transporting the material and emptying the
bucket.
In combination with the forklift truck attachment the picking up,

transporting and putting down of stacked material is also
considered to be part of the machine’s intended use.
If you use the machine for any other purpose than specified
above, we will not accept any responsibility for safety. All
considerations concerning safety will then be up to the owner or
the operating and maintenance personnel. In any case, neither
you nor any other person are/is authorised to perform work and
functions explicitly prohibited in these operating instructions.
Refer to chapter "3.3.9. Working with the wheel loader" on

page 3-58 for more details.
WA100M-5 – VEAM280201 1-9

1.4. Introduction Introduction
1.4.2. Breaking-in the machine

Before the shipment, each machine was carefully checked and
adjusted. A machine that is to be newly commissioned has to be
treated with utmost care during its first 100 operating hours.
If the machine is used for work involving loads exceeding the

specified maximum load for the running-in period, its performance
may be impaired prematurely and its service life may be short-
ened. A new machine must be run in and maintained very care-
fully and thoroughly.
The following points are particularly important:
● Idle the engine for 5 minutes after starting it up.
● Avoid operation with heavy loads or at high speeds.
● Avoid sudden starts, sudden acceleration, sudden steering

und sudden stops except in cases of emergency.
The precautions given in this manual for operating, maintenance,

and safety procedures are only those that apply when this product
is used for the specified purpose. If the machine is used for a pur-
pose that is not listed in this manual Komatsu cannot bear any
responsibility for safety. All consideration of safety in such opera-
tions is the responsibility of the user.
Operations that are prohibited in this manual must never be car-

ried out under any circumstances.
1-10 WA100M-5 – VEAM280201

Introduction 1.5. Location of plates
1.5. Location of plates
1.5.1. Machine identification plate (PIN)

Position of the identification plate (1) (see enlargement)

Serial no. stamp marking (2)

Machine identification plate (PIN)
1.5.2. Engine name-plate
Engine name-plate with serial no.
WA100M-5 – VEAM280201 1-11

1.5. Location of plates Introduction
1.5.3. Axle serial no. plate

This plate is located on the right of front axle and on the left of
rear axle (1).

1.5.4. Transmission serial no. plate

This plate is located in travel direction front, above the transmis-
sion output (1).
1.5.5. ROPS/FOPS-Cab serial no. plate

This plate is located on the right inside cab on the rear beam (1).
1-12 WA100M-5 – VEAM280201

Introduction 1.5. Location of plates
1.5.6. Seat operator serial no. plate

This plate is located in front of seat, covered by the bellows.
1.5.7. Table to enter serial no. and distributor

Must be filled in before machine is put into service:
Machine serial No.:
Engine serial No.:
Name of Dealer: Phone:
Address: Fax:
Service Personnel for your machine: E-mail
WA100M-5 – VEAM280201 1-13

1.6. Emission Control Warranty Introduction
1.6. Emission Control Warranty
1.6.1. Emission control warranty statement (Applies to Canada only)
1. Products Warranted
Komatsu America International Company, Komatsu Mining Sys-

tems Inc. and Komatsu Utility Cor poration (collectively
"Komatsu") produce and/or market products under brand names
of Komatsu, Dresser, Dressta, Haulpak and Galion. This emission
warranty applies to new engines bearing the Komatsu name
installed in these products and used in Canada in machines
designed for industrial off-highway use. This warranty applies
only to these engines produced on or after January 1, 2000. This
warranty will be administered by Komatsu distribution in Canada.
2. Coverage
Komatsu warrants to the ultimate purchaser and each subse-

quent purchaser that the engine is designed, built and equipped
so as to conform, at the time of sale by Komatsu, with all U.S.
Federal emission regulations applicable at the time of manufac-
ture and that is free from defects in workmanship or material
which would cause it not meet these regulations within five years
or 3,000 hours of operation, whichever occurs first, as measured
from the date of delivery of the engine to the ultimate purchaser.
3. Limitations
Failures, other than those resulting from defects in materials or

workmanship, are not covered by this warranty. Komatsu is not
responsible for failures or damage resulting from what Komatsu
determines to be abuse or neglect, including, but not limited to:
operation without adequate coolant or lubricants; over fueling;
over speeding; lack of maintenance of lubricating, cooling or
intake systems; improper storage, starting, warm-up, run-in or
shutdown practices; unauthorized modifications of the engine.
Komatsu is also not responsible for failures caused by incorrect
fuel or by water, dirt or other contaminants in the fuel. Komatsu is
not responsible for non-engine repairs, "downtime" expense,
related damage, fines, all business costs or other losses resulting
from a warrantable failure.
KOMATSU IS NOT RESPONSIBLE FOR INCIDENTAL OR

CONSEQUENTIAL DAMAGES.
This warranty, together with the express commercial warranties,

are the sole warranties of Komatsu. THERE ARE NO OTHER
WARRANTIES, EXPRESS OR IMPLIED, OR OF MERCHANT-
ABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
1-14 WA100M-5 – VEAM280201

Introduction 1.7. Garantie sur le contrôle des émissions
1.7. Garantie sur le contrôle des émissions
1.7.1. Énoncé de garantie sur le contrôle des émissions (applicable au

Canada seulement)
1. Produits garantis:
Komatsu America International Company, Komatsu Mining Sys-

tems Inc. et Komatsu Utility Corporation (collectivement Komatsu)
produisent et/ou font la mise en marché de produits portant les
noms de marque Komatsu, Dresser, Dressta, Haulpak et Galion.
Cette garantie sur le émissions s’applique à tous les nouveaux
moteurs portant le nom Komatsu, installés dans ces produits et
utilisés au Canada dans des machines conçues pour utilisation
industrielle non-routière. Cette garantie s’applique seulement sur
les moteurs produits à partir du 1 er Janvier 2000. Cette garantie
sera administrée par la distribution de Komatsu au Canada.
2. Couverture
Komatsu garantit à l’acheteur ultime et chaque acheteur sub-

séquent que le moteur est conçu, construit et equipé en toute
conformité, au moment de la vente par Komatsu, avec toutes les
Réglementations fédérales américaines sur les émissions appli-
cables au moment de la fabrication et qu’il est exempt de défaults
de construction ou de matériaux qui auraient pour effet de con-
trevenir à ces réglementations en dedans de 5 ans ou 3000 heu-
res d’opération, mesuré à partir de la date de livraison du moteur
au client ultime.
3. Limitations
Les bris, autres que ceux résultant de défaults de matériaux ou

de construction, ne sont pas couverts par cette Garantie.
Komatsu n’est pas responsable pour bris ou dommages résultant
de ce que Komatsu détermine comme étant de l’abus ou négli-
gence, incluant mais ne se limitant pas à: l’operation sans lubrifi-
ants ou agent refroidissants adéquats; la suralimentation
d’essence; la survitesse; le manque d’entretien des systémes de
lubrification, de refroidissement ou d’entree; de pratiques non-
propices d’entreposage, de mise en marche, de réchauffement,
de conditionnement ou d’arrêt; les modifications non autorisées
du moteur. De plus Komatsu n’est pas responsable de bris
causés par de l’essence inadéquate ou de l’eau, des saletés ou
autres contaminants dans léssence. Komatsu nést pas respons-
able des réparations non-reliées au moteur, des dépenses
encourues suite aux temps dárrêts, des dommages relatifs,
amendes, et de tout autre coût d’affaires ou autres pertes résult-
ant d’un bris couvert par la garantie.
KOMATSU N’EST PAS RESPONSABLE DES INCIDENTS OU

DOMMAGES CONSÉQUENTS.
Cette garantie ainsi que les garanties expresses commerciales,

sont les seules garanties Komatsu. IL N’Y A AUCUNE AUTRE
GARANTIE, EXPRESSE OU SOUS-ENTENDUE, MARCHAND-
ABLE OU PROPICE A UNE UTILISATION PARTICULIÈRE.
WA100M-5 – VEAM280201 1-15

1.8. Table of contents Introduction
1.8. Table of contents
1. Introduction .................................................................................................1-1
1.1. Product publications information............................................................................................................... 1-2
1.2. Foreword....................................................................................................................................................... 1-4

EU Directives .................................................................................................................................... 1-5
1.3. Safety information........................................................................................................................................ 1-7
1.4. Introduction .................................................................................................................................................. 1-9

1.4.1. Intended use ..................................................................................................................................... 1-9
1.4.2. Breaking-in the machine ................................................................................................................. 1-10
1.5. Location of plates ...................................................................................................................................... 1-11

1.5.1. Machine identification plate (PIN) ................................................................................................... 1-11
1.5.2. Engine name-plate.......................................................................................................................... 1-11
1.5.3. Axle serial no. plate ........................................................................................................................ 1-12
1.5.4. Transmission serial no. plate .......................................................................................................... 1-12
1.5.5. ROPS/FOPS-Cab serial no. plate................................................................................................... 1-12
1.5.6. Seat operator serial no. plate.......................................................................................................... 1-13
1.5.7. Table to enter serial no. and distributor ......................................................................................... 1-13
1.6. Emission Control Warranty....................................................................................................................... 1-14

1.6.1. Emission control warranty statement (Applies to Canada only) ..................................................... 1-14
1.7. Garantie sur le contrôle des émissions ................................................................................................... 1-15

1.7.1. Énoncé de garantie sur le contrôle des émissions (applicable au Canada seulement) ................. 1-15
1.8. Table of contents ....................................................................................................................................... 1-16
1.9. Dimensions, weights and operating data ................................................................................................ 1-23
1.10.CE-conforming equipment ....................................................................................................................... 1-24

1.10.1. CE-conforming equipment – part 1................................................................................................. 1-24
1.10.2. CE-conforming equipment – part 2................................................................................................. 1-25
1.10.3. Manufacturer-supplied CE-conforming equipment ......................................................................... 1-26
1.11.Loading and securing............................................................................................................................... 1-29
2. Safety ...........................................................................................................2-1
2.1. General safety measures............................................................................................................................. 2-2
2.1.1. Safety instructions ............................................................................................................................ 2-2
2.1.2. Safety devices .................................................................................................................................. 2-2
2.1.3. Emergency exit ................................................................................................................................. 2-2
2.1.4. Clothing and personal protection ...................................................................................................... 2-3
2.1.5. Machine modifications ...................................................................................................................... 2-3
2.1.6. Before you leave the driver’s seat .................................................................................................... 2-3
2.1.7. Mounting and dismounting................................................................................................................ 2-4
1-16 WA100M-5 – VEAM280201

Introduction 1.8. Table of contents
2.1.8. Fire prevention and fire fighting ........................................................................................................ 2-4

2.1.9. Protection against asbestos dust...................................................................................................... 2-5
2.1.10. Protection against injuries................................................................................................................. 2-5
2.1.11. Working at high temperatures........................................................................................................... 2-6
2.1.12. Roll-over protection system (ROPS)................................................................................................. 2-6
2.1.13. Attachment for protection against falling objects (FOPS) ................................................................. 2-6
2.1.14. Attachments...................................................................................................................................... 2-7
2.1.15. Battery .............................................................................................................................................. 2-7
2.2. Safety precautions during operation ......................................................................................................... 2-8

2.2.1. Prior to daily starting up .................................................................................................................... 2-8
Workplace safety .............................................................................................................................. 2-8
In the driver’s cab ............................................................................................................................. 2-8
Indoor operation ............................................................................................................................... 2-9
Gas, dust, and inflammable vapours ................................................................................................ 2-9
Mirrors, windows and lighting ........................................................................................................... 2-9
2.2.2. Machine operation .......................................................................................................................... 2-10
Before you start the engine............................................................................................................. 2-10
Reversing........................................................................................................................................ 2-10
Driving..............................................................................................................................................2-11
Driving on slopes .............................................................................................................................2-11
Emergency Lowering System ......................................................................................................... 2-12
Working close to power lines .......................................................................................................... 2-13
Loading ........................................................................................................................................... 2-14
Good Vision .................................................................................................................................... 2-14
Working on snow ............................................................................................................................ 2-14
Height limitation .............................................................................................................................. 2-15
Brakes ............................................................................................................................................ 2-15
Working on loose soil...................................................................................................................... 2-15
Working with the forklift truck attachment ....................................................................................... 2-15
Parking the machine ....................................................................................................................... 2-17
2.2.3. Transport ........................................................................................................................................ 2-18
Loading and unloading the machine............................................................................................... 2-18
Transport ........................................................................................................................................ 2-18
2.3. Precautions for maintenance.................................................................................................................... 2-19

2.3.1. Personnel ....................................................................................................................................... 2-19
2.3.2. Before carrying out maintenance.................................................................................................... 2-19
2.3.3. During maintenance........................................................................................................................ 2-28
2.3.4. Tyres............................................................................................................................................... 2-32
2.4. Safety labels on the machine.................................................................................................................... 2-34

2.4.1. Positions and order numbers of information labels......................................................................... 2-34
2.4.2. Positions and order numbers of safety labels................................................................................. 2-35
3. Operation ..................................................................................................... 3-1
WA100M-5 – VEAM280201 1-17

3.1. General view ................................................................................................................................................. 3-2

3.1.1. General view of the machine ............................................................................................................ 3-2
3.1.2. Controls and indicators ..................................................................................................................... 3-3
Overall view ...................................................................................................................................... 3-3
Switches, controls and warning lights ............................................................................................... 3-4
3.2. Description of the individual elements ...................................................................................................... 3-5

3.2.1. Instrument panel ............................................................................................................................... 3-5
Warning lights ................................................................................................................................... 3-6
Control lamps.................................................................................................................................... 3-8
Measuring indicators....................................................................................................................... 3-13
3.2.2. Switches ......................................................................................................................................... 3-15
3.2.3. Control levers and pedals ............................................................................................................... 3-23
3.2.4. Articulated steering catch............................................................................................................ 3-28
3.2.5. Traction device ............................................................................................................................... 3-28
3.2.6. Socket (12 V) .................................................................................................................................. 3-29
3.2.7. Door unlocking system ................................................................................................................... 3-29
3.2.8. Alarm horn for reverse driving – option........................................................................................... 3-29
3.2.9. Fuses .............................................................................................................................................. 3-30
3.2.10. Slow-blowing fuses ......................................................................................................................... 3-31
3.2.11. Adjusting the heater and ventilation system ................................................................................... 3-32
3.2.12. Air-conditioning ............................................................................................................................... 3-33
3.3. Operation .................................................................................................................................................... 3-34

3.3.1. Pre-start checks .............................................................................................................................. 3-34
Visual inspection ............................................................................................................................. 3-34
Pre-start checks .............................................................................................................................. 3-36
Adjustments prior to machine start ................................................................................................. 3-41
Adjusting the driver’s seat............................................................................................................... 3-41
3.3.2. Starting the engine.......................................................................................................................... 3-45
Warming up the engine................................................................................................................... 3-46
3.3.3. Driving with the machine................................................................................................................. 3-47
Start-up ........................................................................................................................................... 3-47
Limiting the maximum speed .......................................................................................................... 3-48
3.3.4. Changing the driving direction ........................................................................................................ 3-50
3.3.5. Turning and steering....................................................................................................................... 3-51
3.3.6. Braking............................................................................................................................................ 3-52
3.3.7. Stopping the machine ..................................................................................................................... 3-54
3.3.8. Operating the work equipment........................................................................................................ 3-55
Multifunctional lever ........................................................................................................................ 3-55
Control lever for special equipment ................................................................................................ 3-56
Switching lever of bucket ................................................................................................................ 3-57
3.3.9. Working with the wheel loader........................................................................................................ 3-58
Tyre-appropriate operation ............................................................................................................. 3-58
Switching on the 100 % differential lock (if equipped) .................................................................... 3-58
Loading work .................................................................................................................................. 3-59
Removal work ................................................................................................................................. 3-59
Excavation work.............................................................................................................................. 3-61
1-18 WA100M-5 – VEAM280201

Planing............................................................................................................................................ 3-62
Transporting.................................................................................................................................... 3-63
Unloading ....................................................................................................................................... 3-63
Working with the forklift truck attachment ....................................................................................... 3-64
3.3.10. Precautions for special operations.................................................................................................. 3-66
Permissible water depth ................................................................................................................. 3-66
Working on snow ............................................................................................................................ 3-66
Dumping on steep slopes ............................................................................................................... 3-66
Working in the vicinity of electrical overhead lines ......................................................................... 3-66
Operation on slopes........................................................................................................................ 3-66
Working on loose soil...................................................................................................................... 3-66
If the service brake breaks down .................................................................................................... 3-66
Precautionary measures when driving up or down......................................................................... 3-67
Precautionary measures during machine travel ............................................................................. 3-68
3.3.11. Adjusting the position of the work equipment ................................................................................. 3-69
Selecting a work unit....................................................................................................................... 3-69
Removing the work unit .................................................................................................................. 3-71
Picking up the multi-purpose bucket............................................................................................... 3-72
Removing the multi-purpose bucket ............................................................................................... 3-74
Level indicator for the bucket.......................................................................................................... 3-74
3.3.12. Parking the machine ....................................................................................................................... 3-75
3.3.13. Switching off the engine.................................................................................................................. 3-76
3.3.14. Check after stopping the engine ..................................................................................................... 3-76
3.3.15. Locking ........................................................................................................................................... 3-76
3.3.16. Tyre handling .................................................................................................................................. 3-77
Precautionary measures when handling tyres................................................................................ 3-77
Tyre pressure.................................................................................................................................. 3-77
3.4. Transporting the machine......................................................................................................................... 3-79

3.4.1. Securing the articulated steering .................................................................................................... 3-79
3.4.2. Lifting the machine.......................................................................................................................... 3-80
3.4.3. Driving the machine onto loading area of transport vehicle............................................................ 3-81
3.4.4. Securing the machine during the transport..................................................................................... 3-82
3.4.5. After transport ................................................................................................................................. 3-82
3.5. Cold weather operation ............................................................................................................................. 3-83

3.5.1. Before the cold season ................................................................................................................... 3-83
3.5.2. Precautions after completion of work.............................................................................................. 3-84
3.5.3. After the cold season ...................................................................................................................... 3-84
3.6. Long-term storage ..................................................................................................................................... 3-85

3.6.1. Before storage ................................................................................................................................ 3-85
3.6.2. During storage ................................................................................................................................ 3-85
3.6.3. After storage ................................................................................................................................... 3-86
4. Troubleshooting ......................................................................................... 4-1
WA100M-5 – VEAM280201 1-19

4.1. Towing the machine..................................................................................................................................... 4-2
4.2. Starting the engine with a booster cable ................................................................................................... 4-6
4.3. For insufficient braking effect..................................................................................................................... 4-8

4.3.1. Checking the service brake .............................................................................................................. 4-8
4.3.2. Checking the parking brake function ................................................................................................ 4-8
4.4. Emergency steering properties .................................................................................................................. 4-9
4.5. Emergency lowering .................................................................................................................................... 4-9
4.6. Other troubles ............................................................................................................................................ 4-10

4.6.1. Electrical system............................................................................................................................. 4-10
4.6.2. Engine............................................................................................................................................. 4-11
4.6.3. Hydraulic system ............................................................................................................................ 4-14
4.6.4. Brakes............................................................................................................................................. 4-16
4.6.5. Steering .......................................................................................................................................... 4-16
4.6.6. Axles ............................................................................................................................................... 4-17
4.6.7. Driver’s cab ..................................................................................................................................... 4-17
5. Maintenance ................................................................................................5-1
5.1. Maintenance guide....................................................................................................................................... 5-2
5.1.1. Guidelines......................................................................................................................................... 5-2
5.2. Maintenance basics ................................................................................................................................... 5-12

5.2.1. Oil, fuel and coolant specifications ................................................................................................. 5-12
Oil ................................................................................................................................................... 5-12
Fuel................................................................................................................................................. 5-13
Coolant ........................................................................................................................................... 5-14
Grease ............................................................................................................................................ 5-14
Storing oil and fuel .......................................................................................................................... 5-15
Filters .............................................................................................................................................. 5-15
Biodegradable hydraulic oil and lubricants ..................................................................................... 5-15
5.2.2. Specifications of the electrical system ............................................................................................ 5-16
5.2.3. Wearing parts list ............................................................................................................................ 5-17
5.3. Lubricants, fuels and filling capacities .................................................................................................... 5-18

5.3.1. Lubrication chart ............................................................................................................................. 5-19
5.4. Tools and standard tightening torques (bolts, nuts).............................................................................. 5-20

5.4.1. Introduction of recommended tools ................................................................................................ 5-20
5.4.2. Torque list ....................................................................................................................................... 5-21
5.5. Periodical replacement of safety-critical parts ....................................................................................... 5-23
5.6. Maintenance schedule chart ..................................................................................................................... 5-24
5.7. Service procedure...................................................................................................................................... 5-26

5.7.1. Pre-start checklist ........................................................................................................................... 5-26
Cooling system – checking the coolant level, topping up coolant................................................... 5-26
1-20 WA100M-5 – VEAM280201

Cleaning the radiator segments...................................................................................................... 5-27

V-Belt, checking the condition......................................................................................................... 5-27
Engine, checking the oil level, topping up oil .................................................................................. 5-28
Checking the fuel level – refuelling ................................................................................................. 5-30
Water separator at the fuel filter – Draining water and dirt sediments ............................................ 5-31
Checking the controls ..................................................................................................................... 5-31
Checking the electrical connections ............................................................................................... 5-32
Heater/air conditioning – checking rate of air flow .......................................................................... 5-32
Miscellaneous tests before starting work........................................................................................ 5-33
5.7.2. Maintenance upon demand ............................................................................................................ 5-33
Checking the air-conditioning system ............................................................................................. 5-33
Checking the window washing-fluid level, adding fluid ................................................................... 5-35
Re-charging a built-in battery.......................................................................................................... 5-36
5.7.3. Maintenance after the first 50 operating hours ............................................................................... 5-37
Hydraulic system, replacing the filter insert .................................................................................... 5-37
Checking and tightening the wheel nuts ......................................................................................... 5-38
5.7.4. Maintenance after the first 250 operating hours ............................................................................. 5-39
Front and rear axle – oil change ..................................................................................................... 5-39
Transfer box gearing – changing oil ............................................................................................... 5-40
Checking and adjusting the valve clearance ................................................................................. 5-40
5.7.5. Maintenance every 10 operating hours .......................................................................................... 5-41
Lubrication, articulated steering...................................................................................................... 5-41
5.7.6. Maintenance every 50 operating hours .......................................................................................... 5-42
Checking the service brake and oil level, refilling oil ...................................................................... 5-42
Battery – checking the acid level .................................................................................................... 5-42
Lubrication, work unit...................................................................................................................... 5-43
5.7.7. Maintenance every 250 operating hours ........................................................................................ 5-44
Service brake – Checking the brake pads ...................................................................................... 5-44
V-Belt, generator – checking and adjusting the tension.................................................................. 5-44
Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert............ 5-46
Lubrication, steering cylinder .......................................................................................................... 5-49
Lubrication, self-aligning bearings of rear axle ............................................................................... 5-50
Checking and tightening the wheel nuts ......................................................................................... 5-51
5.7.8. Maintenance every 500 operating hours ........................................................................................ 5-52
Hand pump - Checking the oil level ................................................................................................ 5-52
Service brake - Checking the brake pads and brake discs, checking the oil level ......................... 5-52
Engine – changing oil ..................................................................................................................... 5-54
Replacing the oil filter cartridge ...................................................................................................... 5-55
Changing the fuel filter element ...................................................................................................... 5-56
Bleeding the fuel system................................................................................................................. 5-57
Bleeding the low pressure side:...................................................................................................... 5-57
Bleeding the high pressure side: .................................................................................................... 5-57
Air filter, replacing the filter insert, replacing the safety filter........................................................... 5-58
Heater/air conditioning – cleaning/replacing filter fleece ................................................................ 5-59
Cleaning the condenser of air conditioning..................................................................................... 5-60
Multi-functional lever accumulator - checking gas pressure ......................................................... 5-60
E.C.S.S.-pressure accumulator (Option) - checking gas pressure ................................................ 5-60
Front and rear axle – checking the oil level .................................................................................... 5-61
WA100M-5 – VEAM280201 1-21

Transfer box gearing – checking the oil level.................................................................................. 5-62

5.7.9. Maintenance every 1000 operating hours ...................................................................................... 5-63
V-Belt, generator – checking and adjusting the tension.................................................................. 5-63
Service Brake - Checking and adjusting oil .................................................................................... 5-63
Checking and adjusting system pressures ..................................................................................... 5-63
Have the system pressures checked and adjusted at an authorised Komatsu garage. ................. 5-63
Hydraulics – Exchanging the venting filters .................................................................................... 5-64
Hydraulic system, replacing the filter insert .................................................................................... 5-65
Front and rear axle – oil change ..................................................................................................... 5-66
Transfer box gearing – changing oil................................................................................................ 5-67
Cooling system – exchanging coolant and cleaning the system .................................................... 5-68
Checking and adjusting the valve clearance ................................................................................. 5-70
Hydraulic system, oil change .......................................................................................................... 5-71
Ventilating the hydraulic oil tank ..................................................................................................... 5-72
Checking the fuel pump .................................................................................................................. 5-73
Checking the fuel and coolant tubes, replacing the tubes (if required) ........................................... 5-73
Checking the water pump ............................................................................................................... 5-73
Lubrication, universal joint .............................................................................................................. 5-74
6. Technical data .............................................................................................6-1

6.1. Technical data .............................................................................................................................................. 6-2
6.2. Noise emission levels.................................................................................................................................. 6-3
6.3. Vibration levels............................................................................................................................................. 6-3
6.4. Limit values for slopes ................................................................................................................................ 6-5
7. Special equipment and attachments.........................................................7-1

7.1. E.C.S.S. ......................................................................................................................................................... 7-2
7.1.1. Structure and functioning principle of the E.C.S.S............................................................................ 7-2
7.1.2. Precautionary measures for switching on the E.C.S.S. .................................................................... 7-2
7.1.3. Operating the E.C.S.S. ..................................................................................................................... 7-3
Switching ON the E.C.S.S. ............................................................................................................... 7-3
Switching OFF the E.C.S.S. ............................................................................................................. 7-3
7.1.4. Precautions when handling the accumulator .................................................................................... 7-4
8. Index.............................................................................................................8-1
9. Notes ............................................................................................................9-1
1-22 WA100M-5 – VEAM280201

Introduction 1.9. Dimensions, weights and operating data
1.9. Dimensions, weights and operating data
Dimensions, weights and operating data

Bucket capacity to ISO 7546 1.2 m³ 42.38 cu ft
Material density 1.8 t/m³ 3.033 pound/cubic yard
Static tipping load, straight 5530 kg 12,191.4 pound
Static tipping load, 40° angle 4680 kg 10,317.5 pound
Working load without CTW 2900 kg 6,393.3 pound
Working load with CTW 3100 kg 6,834.3 pound
Breakout force, hydraulic 66.1 kN 66.1 kN
Lifting capacity, hydraulic, on ground 66.1 kN 66.1 kN
Operating weight 6760 kg 14,903.1 pound
Turning radius over bucket 4570 mm 15’ 0" ft. in.
L Bucket length in transport position 5715 mm 18’ 9" ft. in. with teeth 19’
A Bucket length during planing 5775 mm 18’ 11" ft. in. with teeth 19’ 5"
T1 Width with bucket 2200 mm 7’ 2" ft. in.
T2 Width without bucket (above wheels) 2090 mm 6’ 8" ft. in.
G Height, including ROPS 2850 mm 9’ 3" ft. in.
D Track 1635 mm 5’ 4" ft. in. 405/70 R20 SPT9
B Width over tyres 2400 mm 7’ 9" ft. in. tyres
H Distance articulated steer. - front axle 1200 mm 3’ 9" ft. in.
Ground clearance, axle /transfer gear 380 mm 1’ 2" ft. in.
E
ground clearance, cardan shaft 510 mm 1’ 7" ft. in.
F Center of gravity, height above axle center - mm - ft. in. CTW = additional
I Center of gravity, distance to front axle - mm - ft. in. counterweight
WA100M-5 – VEAM280201 1-23

1.10. CE-conforming equipment Introduction
1.10. CE-conforming equipment
1.10.1. CE-conforming equipment – part 1
CE-conforming equipment
1 2 3 4 –
Volume Hydr. pressure Weight

Type Part No.
cu ft (m³) bar lb (kg)
42W-70-22000 42.38 (1.2) --- 844.36 (383)
42W-70-22010 42.38 (1.2) --- 899.47 (408)
42W-70-22050
--- --- 670.19 (304)
Bucket WA100M-5 (Fork carrier)
42W-70-22071 37.08 (1.05) 250
42W-70-22080 56.50 (1.6) --- 1,016.32 (461)
42W-70-22110 63.56 (1.8) --- 1,093.48 (496)
1-24 WA100M-5 – VEAM280201

Introduction 1.10. CE-conforming equipment
1.10.2. CE-conforming equipment – part 2
CE-conforming equipment
1 2 3 4 –
Work load of fork Work load of fork

Weight
Type Part No. carrier STD carrier with CTW
lb (kg)
lb (kg) / pair lb (kg) / pair
Fork carrier WA100M-5 42W-70-22050 4409 (2000) 4850 (2200) 670.2 (304)
WA100M-5 – VEAM280201 1-25

1.10.3. Manufacturer-supplied CE-conforming equipment

The responsibility for observing valid regulations in the case of
wheel loaders with "interchangeable equipment" (e.g. bucket or
fork-lift) which was not supplied from works lies with the customer
which was subsequently fitted to the machine.
The guidelines for CE Conformity and road-traffic registration are

deemed to have been fulfilled when the manufacturer of the
equipment confirms fulfilment of the document 42T-93-21070.
The certification must be sent to the customer and the wheel

loader manufacturer. The CE conformity declaration for a specific
wheel loader is only legally valid once this has taken place.
The dimensions X1, X2, Y1 and Y2 must be provided by the

manufacturer of the equipment for approval for use on public
roads.
The dimension Sh (smallest tyre radius) must be added to the

dimension D2.
The figure G (in kg) represents the maximum load (equipment

and operating load) which may act upon this point.
1-26 WA100M-5 – VEAM280201

Introduction 1.10. CE-conforming equipment
WA100M-5 – VEAM280201 1-27

Manufacturer-supplied CE-conforming equipment
WA100M-5 ft. in. mm

A1 Distance: bucket pivoting point - front axle, horizontal
A1 5’ 8" 1770
A2 Distance: bucket pivoting point - front axle, vertical
A2 3’ 9" 1200
B1 Distance: driver's eye - front axle, horizontal
Sh 1’ 8" 545
B2 Distance: driver's eye - front axle, vertical
B1 6’ 4" 1946
D1 Distance front axle- lower edge of headlights, horizontal
B2 6’ 4" 1951
D2 Distance front axle- lower edge of headlights, vertical
C1 4’ 8" 1456
Weight of the equipment and carrying load without C2 5’ 2" 1578
G
additional counterweight
D1 1’ 1" 325
H1 Distance: bucket pivoting point - bucket upper edge, vertical
(carrying position) D2 3’ 3" 1028
H2 Distance: bucket pivoting point - vision line, vertical G 8’ 4" 2550

(carrying position) H1 2’ 9" 909
J Distance road level - lower edge of bucket in carrying posi- H2 4’ 8" 1465
tion (to be considered during driving on public roads)
J 0’ 9" 270
Sh Distance: road level - front axle
X1 6’ 8" 2085
a Tip-in angle
X2 3’ 1" 935
b1 Bucket connection dimension boom width, interior Y1 7’ 1" 2165
c Bucket connection dimension between d1 and d2, vertical Y2 3’ 4" 1035
d1 Bucket connection dimension bolts for boom a 52° 52°
d2 Bucket connection dimension bolt for tip-in rod b1 3’ 1" 960
e Bucket connection dimension d1- d2 horizontally displaced c 1’ 3" 423

d1 0’ 1" 40
h Distance lower edge of bucket - drill hole of boom bolt
d2 0’ 1" 40
e 0’ 3" 98
h 0’ 8" 230
Tyre 455/70 R20 SPT9
42W-70-22000
Bucket
42.38 cu ft (1.2 m3)
1-28 WA100M-5 – VEAM280201

Introduction 1.11. Loading and securing
1.11. Loading and securing

Observe all safety instructions carefully in order to prevent acci-
dents with severe injury. See "3.4. Transporting the machine" on
page 3-79.
DANGER
● Always secure articulated joint if maintenance or repair
work is to be carried out or if the machine is going to be
lifted or transported.
● An articulated joint may jack-knife unexpectedly if not

secured. Danger of injury if joint jack-knifes.
WA100M-5 – VEAM280201 1-29

1.11. Loading and securing Introduction
1. Set the machine to straight driving.
2. On the left: Loosen the spring bolt and remove the bolt (1).
3. On the right: Insert the bolt (2) and secure by means of the
spring bolt.
NOTE
Due to safety reasons and to avoid consequential damages,
it is prohibited to attach other points (such as axles, cardan
shafts, articulated joint, bucket teeth) than those specified
for lifting and securing. It is also prohibited to attach ropes
etc. to the driver’s cabin.
1-30 WA100M-5 – VEAM280201

Safety
2. Safety
DANGER
Failure to adhere to these safety instructions can lead to
accidents with serious injuries!
Read and adhere to all safety instructions.
This chapter also contains safety instructions for special equip-

ment and attachments.
WA100M-5 – VEAM280201 2-1

2.1. General safety measures Safety
2.1. General safety measures
2.1.1. Safety instructions

● Do not operate or service the machine unless you have been
trained and are authorised to do so.
● Always adhere to all instructions, measures, and safety

instructions when operating or servicing the machine.
● When working together with other persons, agree beforehand

on all hand signals that you want to use to avoid accidents
due to misunderstandings.
2.1.2. Safety devices

● Check that all safety devices and covers of the machine are
correctly installed.
● Ensure that damaged safety devices and covers are repaired

before you start the machine.
● Use all safety devices as prescribed, e.g. the safety lever for
the work hydraulic system and the safety belt.
● Do not remove any of the safety devices. Safety devices

must be kept in perfect condition.
2.1.3. Emergency exit

In an emergency situation, you can use the window on the right-
hand side of the driver's cab (2) (seen from the driving direction)
as an emergency exit.
2-2 WA100M-5 – VEAM280201

Safety 2.1. General safety measures
2.1.4. Clothing and personal protection

● Do not wear loose-fitting clothing, jewellery, or open long hair.
There is danger that you get caught by control elements or
moving parts leading to serious injuries.
● Immediately replace clothing stained with highly inflammable

substances.
● When operating and servicing the machine, wear the appro-

priate protective equipment, e.g. safety helmet, safety gog-
gles, safety shoes, dust protection mask, and safety gloves.
● Always wear safety goggles, safety helmet, and protective

clothing, if it is likely that chippings or splinters will be pro-
duced while operating the machine (e.g. when removing or
driving in bolts or cleaning with compressed air).
● Ensure that no unauthorised person is within the danger

zone.
2.1.5. Machine modifications

● Komatsu will not be liable for modifications performed without
prior expressed consent by the manufacturer.
● Komatsu will not be liable for any injuries or damage resulting

from unapproved modifications.
2.1.6. Before you leave the driver’s seat

1. Lower the work unit onto the ground
2. Press slowly the multi-function lever to the front into position

'S'. The remaining hydraulics pressure will be reduced.
3. Switch off the engine.
4. Remove the ignition key before you leave the driver's seat.
Store the ignition key in a safe place.
5. Close the cabin door.
WA100M-5 – VEAM280201 2-3

2.1.7. Mounting and dismounting

● Do not jump on or off the machine. Do not mount on or dis-
mount from a moving machine.
● Always use the handle bars and tread steps for mounting or
dismounting the machine. Do not hold onto the control levers
while mounting and dismounting.
● To ensure safe hold, hold the handle bar with one hand and
stand on the tread steps with both feet. Optionally, stand on
the tread steps with one foot and hold the handle bars with
both hands.
2.1.8. Fire prevention and fire fighting

● Fuel, oil, and antifreezing compound are highly inflammable
and could cause a fire.
● Do not approach inflammable material with naked light.
● Prior to refuelling, switch off the engine and stop smoking.
● Refuelling and refilling of oil are to be performed in sufficiently

ventilated places.
● Store oil and fuel in special places appropriate for this pur-
pose. Ensure that unauthorised persons do not have access
to these places.
● Tightly close all cover caps.
● Check the fuel system, the lubrication system, and the

hydraulic system for leaks. Have leaks repaired. Remove any
excess oil, fuel, or other inflammable substances.
● Carefully and completely remove wooden chippings, leaves,

paper, and other highly inflammable materials that may have
collected in the engine compartment, since they could cause
a fire.
● Do not operate the machine in the vicinity of naked light.
2-4 WA100M-5 – VEAM280201

Fire extinguisher and first-aid kit
● A fire extinguisher can be stored in the compartment under

the driver's seat. Two appropriate fastening points are already
attached to the back of the compartment.
● A fully operational fire extinguisher must be available at hand.
● If, in the course of certain operations, there is danger of fire,

fire extinguishers must be at hand. Familiarise with the use of
the fire extinguishers.
● Inform yourself on measures to be taken in the event of a fire.
● The first-aid kit can be stored in the compartment under the

driver's seat next to the fire extinguisher.
● Make sure that you know all telephone numbers of the per-
sons that you need to contact in an emergency.
2.1.9. Protection against asbestos dust

Asbestos dust is a health hazard if breathed in. This machine is
free of any parts containing asbestos.
When handling material that may contain asbestos fibres, strictly

adhere to all legal instructions and regulations. Furthermore,
adhere to the following protective measures for your own protec-
tion:
● Work, if possible, with a following wind.
● While working, wear an approved dust protection mask.
● After work, clean the machine with water to minimise forma-

tion of dust. Do not use compressed air for cleaning.
2.1.10. Protection against injuries

Do not insert any part of your body in the operating range of mov-
ing parts, such as work unit and cylinder, or machine and work
unit. Never stand in a hazardous area. Distances vary when the
work unit or steering are operated, this may lead to serious inju-
ries.
WA100M-5 – VEAM280201 2-5

2.1.11. Working at high temperatures

● Directly after operating the machine, the engine coolant, the
engine oil, and the hydraulic oil are extremely hot and under
pressure. Do not try to unscrew caps, drain water or oil, or
replace filters directly after operating the machine, since this
may lead to severe burns due to hot fluids or hot machine
parts. Wait until the temperature has fallen. Strictly adhere to
the described procedures when performing the required mea-
sures.
● Lower the work equipment.
● Switch off the engine and wait for the radiator to cool down
before you unscrew the radiator cap. Slowly turn the radiator
cap until it reaches the first catch to let the pressure escape.
Then, proceed turning the cap further and remove it. If you do
not let the pressure escape, boiling water may spurt out when
you remove the radiator cap.
● Switch off the engine. Allow the hydraulic oil to cool down
before you unscrew the cap of the hydraulic tank to drain the
hydraulic oil. Slowly turn the cap of the hydraulic tank to let
the pressure escape from the tank. If you do not let the pres-
sure escape, oil may spurt out when you remove the cap of
the hydraulic tank.
2.1.12. Roll-over protection system (ROPS)

● The roll-over protection system (ROPS) protects the operator
and absorbs load and impact energy, if the machine should
roll over.
● The ROPS is a fixed component of the cab. The machine

must not be operated without this roll-over protection system.
● The ROPS meets the regulations of all member states of the

EU. If, however, the ROPS is modified, damaged, or repaired
without permission, its stability is impaired. In this case, the
ROPS must be replaced, since its correct function can no
longer be guaranteed.
● The ROPS can only provide maximum protection, if the driver

wears the safety belt correctly. For this reason, the safety belt
is to be worn when the machine is in operation.
2.1.13. Attachment for protection against falling objects (FOPS)
NOTE
FOPS is a fixed component of the cab.
When you work on a site where there is danger of falling rocks or

other objects, the machines must be equipped with a FOPS. If the
FOPS is modified without permission or damaged, its stability is
impaired. In this case, the FOPS must be replaced, since its cor-
rect function can no longer be guaranteed.
2-6 WA100M-5 – VEAM280201

2.1.14. Attachments
● Prior to assembly and operation of an additional attachment,
read the attachment's manual and strictly adhere to the
instructions on assembly and operation.
● Do not use attachments that have not been approved of by

Komatsu or the responsible Komatsu dealer. If you use
attachments which have not been approved of, safety, correct
operation, and service life of the machine may be impaired.
● Komatsu are not liable for injuries, accidents, and damage

resulting from the use of attachments that have not been
approved.
2.1.15. Battery
The batteries are filled with sulphuric acid (battery acid).
● Always wear safety goggles when handling batteries.

● Contact of battery acid with eyes can cause blindness. If acid
should get into your eyes, immediately rinse your eyes with
ample water and call for medical help. Rinse your eyes with
water until a doctor arrives or you are able to visit an
ophthalmologist or go to a hospital.
● Sulphuric acid that gets into contact with skin or clothing may
cause acid burns. Immediately rinse the area that has come
into contact with the acid with ample water.
● When working in the area of the battery, your hands may
unintentionally get in touch with acid. For this reason, do not
touch your eyes while working in the area of the battery.
Always wash your hands after work.
● Batteries produce detonating gas. Detonating gas is
extremely explosive and may be ignited even by the
smallest spark.
● Do not disconnect the battery while the engine is still running.
● Prior to start of work on batteries, set the start switch to '0'.
Set the main switch of the battery (if installed) to 'Off'.
● Avoid any short-circuits via the poles or the pole terminals of
the battery due to unintentional touching with metal objects,
such as tools.
● When removing or inserting the battery, note which of the
poles is the positive (+) and which is the negative (-) one.
Always disconnect the mass cable first and reconnect it last.
● Tightly fasten the pole terminals. Loose pole terminals may
produce sparks and thus cause explosions. Ensure that the
cover of the positive pole (+) is always mounted.
● Tighten the cover caps.
● When repairing the electrical system or performing electric
welding, disconnect the negative (-) pole terminal from the
battery to interrupt the electric circuit.
WA100M-5 – VEAM280201 2-7

2.2. Safety precautions during operation Safety
2.2. Safety precautions during operation
2.2.1. Prior to daily starting up
Workplace safety
● Before you start operation, check the working area for

dangerous working conditions.
● Inspect the surface of the soil in the working area and

determine the optimum and safest procedure.
● Determine the required safety measures against dangers on

public roads in co-operation with the owners, users, and
responsible authorities.
● On sites where there are underground water pipes, gas

pipes, or conduits for high voltage cables, contact the
responsible supply company to determine the lines' positions.
Ensure that these facilities will not be damaged.
● When working with water or crossing sand banks, first check

the subsoil and depth and flow rate of the water. Ensure that
the permitted water depth will not be exceeded.
In the driver's cab
● Do not leave any tools or spare parts lying around in the cab.
These may actuate, damage, or block control levers, pedals,
or switches. Store these parts in the tool box.
● Keep the cab floor, the control elements, the tread steps, and
the handrails free of oil, grease, and excessive dirt.
● Immediately repair any damage. Tighten loose screw

connections.
● Check the safety belt, the belt buckle, and the fastening
elements for damage and wear. Replace worn or damaged
parts.
2-8 WA100M-5 – VEAM280201

Safety 2.2. Safety precautions during operation
Indoor operation
Do not operate machines in-door unless these areas are

sufficiently ventilated (e.g. workshops).
CAUTION
Danger of intoxication!
Gas, dust, and inflammable vapours
Do not operate combustion engines in an environment that may

contain inflammable gases or vapours. These gases, dusts, or
vapours may ignite or be sucked in by the suction system, thus
causing a rise in engine speed or an exceeding of the engine's
maximum rpm. This may lead to a fire, an explosion, and major
damage to property. It may also happen that the engine cannot be
switched off anymore. Also refer to section "Indoor operation" on
page 2-9.
Mirrors, windows and lighting
● Clean the windows and the headlights to ensure maximum

sight.
● Adjust the rear-view mirror in such a way that you have an

excellent view of the rear from the driver's seat. Keep the
mirrors clean.
● Ensure that the complete lighting system operates properly

and that it is correctly adjusted.
● Immediately replace broken window panes by new ones.
WA100M-5 – VEAM280201 2-9

2.2.2. Machine operation
Before you start the engine
● Walk around the machine to check whether persons or

objects are in the way before you get on the machine.
● Do not start the engine, if a warning sign has been attached

to the control lever or another point.
● Sound the horn just before you start the engine.
● Start and operate the machine only from the driver's seat.
● Apart from the operator, no other person is permitted in the

driver's cab or the vicinity of the machine.
1
● If the machine is provided with a reversing warning system,
you must ensure that it operates correctly.
● Before you start the machine, check that the articulated steer-
ing is unlocked (Left side: position '1') and that the locking bar
is attached to the frame by means of bolts and spring bolts.
● Always wear the safety belt when operating the machine.
Reversing
These rules must be observed for all machines, i.e. also for those
machines equipped with a reversing warning system:
● Check that there is nobody near the machine or in the way.
● Before you start reversing, sound the horn to warn persons

within or near the operating area.
● When working in potentially dangerous areas or areas with

obstructed view, ask another person to regulate and super-
vise traffic.
2-10 WA100M-5 – VEAM280201

Driving
● During driving, the bucket is in its transport position. Make

sure to heed the transport position indicator for this purpose.
● When driving on uneven ground, drive slowly and avoid sud-

den steering movements.
● You can continue to steer the machine even if the engine cuts
out during a journey. This will require more force however.
● If the engine cuts out, move over straight to the side of the
road, switch on the hazard warning lights and secure the
machine.
Driving on slopes
● Keep sufficient distance to ridges and steep slopes. There is

danger of the machine tipping over or sliding down on steep
slopes, embankments, or hill flanks (approx. 200 to 300 mm).
The limiting values are defined in chapter "6.4. Limit values
for slopes" on page 6-5.
● To keep the centre of gravity as low as possible when driving

on slopes, embankments, and hill flanks, you must set the
bucket to a position just above the ground. In an emergency,
quickly lower the bucket to the ground to stabilise the
machine.
● Do not turn on a slope or drive across a slope. Turn or cross

the section only level ground.
● When driving on slopes, avoid driving on grass, fallen leaves,

or steel plates. Driving sideways on these surfaces may result
in the machine sliding. Drive very slowly and carefully.
● When driving down a slope, use the braking power of the

engine and drive slowly.
● If the engine stops while you are driving on a slope,

immediately apply the service brake to stop the machine.
Then apply the parking brake. Lower the work unit.
● When driving on a hill with a load, drive
❍ uphill: in forward direction
❍ downhill: in reverse direction
WA100M-5 – VEAM280201 2-11

Emergency Lowering System
The machine is provided with a pressure accumulator for the work

hydraulic system. If the engine is not running, you can lower the
work unit with the multi-function lever.
NOTE
If you have secured the work hydraulic system with the lock-
ing lever of the work hydraulic system, you cannot lower the
work unit.
1. Make sure that nobody is standing below the work unit.
2. Press slowly the multi-function lever into position ‘’P’’. The

work unit is lowered.
2-12 WA100M-5 – VEAM280201

Working close to power lines
● A voltage overspill may occur, if you or the machine get too

close to power lines. For this reason, always heed the
required safety distance between the machine and the power
lines.
Nominal Voltage Safety Distance
up to 1.000 V 3.280 ft 1m
over 1 kV up to 110 kV 9.842 ft 3m

with unknown nominal voltage 16.404 ft 5m
● The safety distances given here reflect the German safety

standards. You can find the safety distances applying to your
country in the relevant national regulations.
● Before you start work, obtain information about line voltages

from your supply company.
● When estimating the distance, take into account all possible

movements of the machine, the work unit, and the line. An
uneven surface may result in the machine swaying, or wind
may move the lines, etc.
● Should the work unit come into contact with a power line,
proceed as follows:
1. Do not leave the driver's cab. The driver's cab is a "Faraday

cage" protecting you from electric shock.
2. Warn other persons and tell them to stay far away from both
the power line and your machine.
3. Try to move the machine out of the range of influence of the

power line by moving it away from the line, moving away the
work unit, etc.
4. Have the power in the line switched off.
WA100M-5 – VEAM280201 2-13

Loading
● Proceed as follows to fill embankments, to backfill ditches, or

to deposit earth over the edge of a hill:
1. First, dump a heap of earth in front of the hill.
2. Fill the bucket with earth again and drive the machine into
the heap of earth. Dump the bucket contents behind the first
heap of earth.
● The load is relieved very suddenly when the heap of earth is

pushed over the edge of the hill or when the machine reaches
the edge of the hill. If this happens, the driving speed may
suddenly increase. For this reason, drive particularly slowly
and carefully at these points.
● If possible, perform all load operations with a following wind to

protect yourself against dust and impaired vision.
● Avoid sudden starts, turns, or stops when the bucket is full.
Good Vision
● When working in dark areas, switch on the working lights of

the machine and provide additional lighting for the working
area.
● If vision is impaired, e.g. due to mist, snow, or rain, interrupt

work and wait until vision has improved to such an extent that
safe work is ensured again.
Working on snow
● When working on snow or ice-covered surfaces, there is dan-

ger of the machine starting to skid even at a very flat angle.
For this reason, drive slowly and avoid sudden starts, turns,
or stops.
● Very often snow hides the edges of roads and other objects.
For this reason, proceed very carefully when removing snow.
● When driving on hill flanks covered with snow do not brake

abruptly to stop the machine. To stop the machine, lower the
bucket onto the ground.
● The load may vary considerably, depending on the structure

of the snow. For this reason, reduce the load and pay atten-
tion that the machine does not start to skid.
2-14 WA100M-5 – VEAM280201

Height limitation
When working in areas with height limitations, e.g. in tunnels,

beneath bridges or power transmission lines, or in garages, pay
attention that the work unit does not touch or damage these facili-
ties.
Brakes
● Use the brake pedal only for braking, do not use the brake
pedal as a foot rest.
● When you are driving downhill you can use the braking force
of the engine by reducing the speed (rpm) of the engine. If
required, you can additionally press down the braking pedal
for braking.
Working on loose soil
● Do not drive the machine too close to edges of hills, over-

hangs, and deep ditches.
● If the soil starts to sag at these locations, the machine may tip
over, fall down, or roll over, thus injuring you severely.
● Take into account that the soil is wet and soft after heavy rain-
fall, or very loose after blasting.
Working with the forklift truck attachment
● Check daily, before starting operation, the fork tines of the

machine for visual damages (e.g. fissures, cracks, abrasion).
Also the protective device for unintentional removing or

shifting of the fork tines may have no faults. Never operate
with a damaged forklift truck attachment.
● Before inserting the forklift truck attachment into the quick-

change unit, check whether it is appropriately locked in.
● Make sure that the distance between the individual fork tines
is sufficient.
● Never exceed the maximum permitted loading capacity of the

forklift truck attachment.
19.685 in
It depends on the condition of the ground on which the work is (500 mm)
to be performed and the stroke height. The values specified in
chapter "1.10. CE-conforming equipment" on page 1-24 refer
19.685 in
to the most unfavourable stroke position with the boom in (500 mm)
horizontal position.
The centre of gravity of the load lies 19.685 inch (500 mm)
75_156
from the fork back and the fork tines (see drawing).
WA100M-5 – VEAM280201 2-15

● Transports palettes only individually.
If you are instructed by the responsible colleague to transport

more than one box palette, which are also piled up, you must
make sure in any case that the locations under which the
forklift truck attachment is gripping for transporting are in
perfect condition.
The overall height of the palette pile must not exceed 6.56 ft
(2 m).
Make sure that the fork tines are adapted to the length of the
load. Move the fork tines so far under the load that the load
comes to a rest at the fork back.
● Make sure that the fork tines are adapted to the length of the
load. Move the fork tines so far under the load that the load
comes to a rest at the fork back.
● If you are transporting a load which is impairing your sight on

the route, you must drive the machine into a direction in which
you have free sight. If it cannot be avoided, drive backwards.
If this is not possible, ask a colleague to assist you by clearing
your way and indicating to you any obstacle.
In this case, drive very slowly and extremely careful.
● During transporting, lower the boom to its transport position.
Both red arrows of the transport position marking (see

adjacent figure) on the bucket cylinder must be next to each
other.
Incline the load slightly to the back during the transport.
● Always drive slowly when you are transporting loads (speed

range 1).
● If you are driving on slopes or hills, transport the load always

in such a way that it is pointing to uphil.
● The boom performs a semicircular movement during the

lifting.
Lift the boom to the desired transporting height only shortly

before approaching the deposit surface. This prevents that
the load is damaged during the lifting.
● Lower the forklift truck attachment completely to the ground

before quitting the driver's cab.
2-16 WA100M-5 – VEAM280201

Parking the machine
● If possible, park the machine on an even surface.
If you have to park the machine on a slope, you must park the
machine with the work unit pointing down the slope.
Lower the work unit (1) until it firmly touches the ground, or let
the cutting edge of the bucket sink deeply into the soil.
Block the wheels with wheel chocks (2) to ensure that the
machine cannot roll 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 see the machine.
● Adhere to all regulations on parking vehicles and securing

building sites.
● Before you leave the machine, completely lower the work unit
onto the ground.
Secure the control lever of the work hydraulic system against

accidental operation.
Switch off the motor.
Lock all points that can be locked and store the key in a safe
place.
WA100M-5 – VEAM280201 2-17

2.2.3. Transport
Loading and unloading the machine
Loading and unloading is potentially dangerous. For this reason,

proceed with extreme care.
● Load and unload the machine only on solid and level ground.
Keep a safety distance to the edge of the road.
3
● Block the wheels of the transport vehicle (1) and place
support blocks (2) under both ramps before driving the
machine onto the transport vehicle.
● Only use ramps (3) with appropriate carrying capacities and 4 1
widths. The ramps must be long enough to ensure that the
maximum loading gradient (4) of 15° is not exceeded. 5 2
● Ensure that the ramps are positioned and fastened safely and
that both sides have the same height. Set the distance
between the ramps to the distance between the wheel tracks
(5).
● Ensure that the surfaces of the ramps are clean and free of
grease, oil, ice, and loose material. Remove any dirt adhering
to the wheels.
● When loading and unloading the machine, keep the engine
speed low and drive slowly.
● Do not carry out steering movements on the ramps. If
required, drive off the ramps again, correct alignment of the
machine, and drive up again.
● After loading, i.e. when the machine is on the transport
vehicle, apply the parking brake.
● Block the wheels of the machine with wheel chocks.
● Set the steering wheel of the machine to straight driving.
● Secure the articulated steering with the locking bolt
(Right side: 1).
● Secure the machine on the transport vehicle by means of

appropriate fastening equipment. Only use the attachment
points on the machine for lifting and securing. For safety rea-
sons, do not use any other points for fastening (e.g. axle, car-
dan shaft, articulated steering, bucket teeth, or strapping
around the cab).
Transport
● When moving the machine on a transport vehicle, adhere to

all applicable motor vehicle traffic regulations.
● Determine the transport route, taking into account the width,

length, height, and weight of the load and, if necessary, have
this approved by the responsible authorities.
2-18 WA100M-5 – VEAM280201

Safety 2.3. Precautions for maintenance
2.3. Precautions for maintenance
2.3.1. Personnel
Do not service or repair the machine unless you are an appropri-
ately qualified technician or have been appropriately instructed by
a qualified technician.
2.3.2. Before carrying out maintenance
Warning sign
While the machine is being serviced, the engine must not be

started and the control elements must not be actuated without
prior agreement, since this could cause accidents with serious
injury.
Always attach the warning sign to the control lever for the work
hydraulic system to warn other persons that work is being
performed on the machine. If required, put up additional warning
signs around the machine.
You may purchase these warning signs from your Komatsu

dealer.
Tools
Only use tools which are suitable for the task you want to carry
out. If you use damaged or makeshift tools or tools which are of
inferior quality, injuries may occur.
WA100M-5 – VEAM280201 2-19

2.3. Precautions for maintenance Safety
Safety-related parts
The quality of these parts is subject to normal wear and tear. For
this reason, replace safety-related parts by new ones at regular
intervals, regardless of whether they are defective or not.
Safety-related parts are:
● Fuel system:
❍ fuel hose,
❍ overflow hose,
❍ tank cap
● Hydraulic system:
❍ all hydraulic hoses
Immediately replace defective parts, even if the interval for

replacement has not elapsed.
Replace hydraulic hoses every 6 years.
Prior to start of inspection and maintenance
Prior to start of inspection and maintenance operations, park the

machine on solid, even ground. Lower the work unit.
If your machine is provided with E.C.S.S., you must switch off the
E.C.S.S..
Switch off the engine and safeguard the machine.
If the engine has to be running during maintenance, e.g. for

pressure checks of the hydraulic system, proceed with particular
care. Carry out such measures with two persons with whom you
have arranged clear hand signs beforehand.
One person must be seated on the driver's seat to ensure that the
engine can be immediately switched off, if required. This person
must always ask the second person before actuating the control
levers.
The person performing the maintenance measures must take

care not to touch or get caught by moving parts.
Securing the articulated steering
Before starting maintenance, secure the articulated steering

against accidental movement using the locking bar on the right
side (position 'A').
2-20 WA100M-5 – VEAM280201

Supporting the boom
When work needs to be conducted under a raised boom then the

boom must be supported against the danger of suddenly falling.
NOTE
Use only the prescribed supporting prop to support the work
unit. Never use other objects as supports.
1. Park the machine on a piece of level, solid ground.
2. Put the parking brake on.
3. Place the wheel chock in front of the wheels to prevent the

machine from rolling away.
4. Raise the boom to the desired height.
5. Switch the engine off.
WARNING
Danger of injury caused by boom! It is only permitted to step
into the area below the boom if the boom is supported.
6. Position the supporting prop underneath the boom.
7. With the engine switched off, lower the boom slowly until it
rests safely on the supporting prop.
8. Set the drive direction selector to "N" and move the working
hydraulic's catch lever to position "1".
WA100M-5 – VEAM280201 2-21

Tipping up the driver's cab
1. Park the machine on solid, level ground.
2. Lower the work unit to the ground and switch off the engine.
3. Close the cab door.
4. Use the locking bolt to secure the articulated steering (cross-

reference "Securing the articulated steering", Page 2-24).
NOTE
The machine has to be positioned straight and the articu-
lated steering has to be secured with the locking bolt! If the
driver's cab is tipped up while the machine is bent, the front
frame can cause damage to the windscreen!
5. Open the bonnet.
6. On both sides, remove the safety pins (1) and the fastening
screws (2) for the cab.
1
2
7. Take the hand pump lever out of its holder on the radiator (2)
and insert it into the receptacle of the pump (3).
2-22 WA100M-5 – VEAM280201

8. Set the lever at the pump to "pump up" and pump the cab
upward until it reaches the limit stop.
9. Move the safety rod on the right side upward until it reaches
the pin at the cab floor.
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 floor.
11. Take the lever out of the pump.
WA100M-5 – VEAM280201 2-23

Tipping down the driver's cab
1. Insert the lever into the pump. Set the lever at the pump to
"pump up" and pump the cab upward until it reaches the limit
stop.
2. Fold down the safety rod on the right side and fasten it in this
position (arrow).
3. Set the lever to "pump down" and pump the cab downward
until the cylinder is entirely retracted (the resistance at the
lever increases markedly).
4. Remove the lever from the pump and fasten it to the radiator.
2-24 WA100M-5 – VEAM280201

5. Screw in the fastening screws (2) for the cab (1 left, 1 right),
tighten them and secure them with the safety pins (1).
Torque = 50 kpm (500 Nm).
6. Close the bonnet.

2 1
1
Tipping up the driver's cab (option with electric actuator)

NOTE
5. Open the bonnet.
1
2
7. Press the "On" (3) and "Lift" (4) buttons simultaneously, until
the cab reaches the upper limit stop.
3
4
G0090003
WA100M-5 – VEAM280201 2-25

8. The top final position has been reached if the slipping clutch
of the electric actuator (6) is activated, with a clearly audible
sound.
9. Move the safety rod (7) on the right side upward until it
7 7
reaches the cylinder linkage.
10. Press the "On" (3) and "Lower" (5) buttons simultaneously,
until the safety rod is secure against the cab floor.
3
5
G0090003
Tipping down the driver's cab (option with electric actuator)
the cab reaches the upper limit stop. Remove the safety rod.
3
4
G0090003
position (arrow).
2-26 WA100M-5 – VEAM280201


until the cab reaches the lower limit stop. The "Retracted"
position has been reached if the slipping clutch of the electric
actuator (6) is activated, with a clearly audible sound.
3 G0090003
2 1
1
WA100M-5 – VEAM280201 2-27

2.3.3. During maintenance
Attachments
Attachments removed from the machine must be put down in a

safe location in such a way that they cannot tip over.
CAUTION
Caution - risk of injury!
Working under the machine
● Always lower all movable work units onto the ground or set
them to their lowest positions before you start to perform
maintenance or repair measures under the machine.
● Block the wheels of the machine using wheel chocks.
● Do not work under a machine that is not appropriately sup-

ported.
Keeping the machine clean
● Always keep the machine clean and tidy.
● Oil, grease, and tools lying around involve danger, since they
may cause slipping or tripping over.
● Do not clean sensors, plugs, and the interior of the driver's

cab with water or steam. If water seeps into the electric sys-
tem, there is danger of uncontrolled and unintentional move-
ment of the machine which may cause accidents.
Specific measures
Always wear appropriate safety clothes and safety goggles when

you perform grinding, welding, use a sledge hammer or carry out
similar work.
2-28 WA100M-5 – VEAM280201

Refuelling and topping up of oil
● Spilled fuel or oil involves danger of slipping and fire. For this
reason, immediately remove any spilled liquid.
● Always refuel and top up oil in a place that is sufficiently

ventilated.
● After refuelling and topping up, close the filling openings with
cover caps.
● Do not use fuel for rinsing or cleaning of components.
● Ensure that neither oil nor fuel can seep into the soil or water.
Dispose of used substances according to the relevant
environmental regulations.
● If the machine is provided with a fuel sieve in the tank

opening, do not remove this fuel sieve before you start
refuelling.
Coolant
● The machine is provided with an aluminium cooling system.

Apply only coolants in the prescribed mixing ration.
● Caution, antifreeze is highly inflammable.
● To check the coolant level, first switch off the engine and wait
for the cooling system to cool down. Then, check the coolant
level in the expansion tank.
● Slowly unscrew the cap to let the pressure escape.
● If required, top up water in the expansion tank.
WA100M-5 – VEAM280201 2-29

Use of lighting
Always use explosion-proof lighting when checking fuel, oil,

coolant, or battery acid.
High-pressure hoses
● Neither bend high-pressure hoses nor hit them with hard

objects. Do not use piping or hoses with fissures, cracks, or
bends, since they may burst during operation.
● Immediately replace any loose or damaged fuel or oil hoses.

Leaking fuel or oil involves danger of fire and slipping.
● Replace all hoses every six years at the latest.
Handling high-pressure oil
● Always take into account that the hydraulic lines are

subjected to high pressure.
● Do not top up oil, drain oil, or perform maintenance or

inspection measures unless the work unit is completely
lowered and the system is depressurised.
● If oil comes out under high pressure, this involves danger of

an oil jet penetrating the skin or getting into the eyes. For this
reason, always wear safety goggles and thick safety gloves,
and use a piece of cardboard or wood when checking for oil
leaks.
● If you have been hit by an oil jet, immediately go and see a

doctor and explain what has happened.
2-30 WA100M-5 – VEAM280201

Handling of pressure accumulators
WARNING
Danger of injury! Pressure accumulator is filled with highly
pressurised nitrogen.
Do not open or damage the pressure accumulator.
● Immediately inform your Komatsu dealer, if you detect

malfunctions or defects of pressure accumulators.
● Filling the pressure accumulator with gas or topping up gas in

the pressure accumulator is strictly limited to persons
authorised to handle highly pressurised gas.
● Do not hit against the pressure accumulator.
● Keep naked light and sources of heat away from pressure

accumulator.
● Do not drill holes into the pressure accumulator.
● Do not weld parts to the pressure accumulator.
● The service technicians must depressurise the hydraulic

system before they can remove the pressure accumulator.
● The service technician must let the gas escape before they
can disassemble the pressure accumulator.
Fan and belts
● Always keep sufficient distance from rotating parts and pay

attention that nothing gets within the operating range of
rotating parts.
● There is danger that parts getting caught by the fan or the belt
are cut off or hurled away.
● Do not wear loose clothing, neckerchiefs or the like, or open,

long hair that might get caught.
Waste material
● Do not pour used oil into the sewage system, rivers, etc.
● Collect used oil of the machine in appropriate containers. Do

not let oil flow out onto the ground.
● Adhere to all applicable laws and regulations when disposing

of harmful substances, such as oil, fuel, coolant, solvents, fil-
ters, batteries, etc.
WA100M-5 – VEAM280201 2-31

2.3.4. Tyres
Handling of tyres
(See "3.3.16. Tyre handling" on page 3-77)
Tyres may burst and the resulting blast wave or parts whirling
around may cause severe injury or damage. Make sure that the
applicable procedures for servicing and replacing of wheels or
tyres are fully understood and that only correct procedures are
used.
To ensure safety and reduce wear and tear, always adhere to the
following instructions:
● Inflate tyres up to the defined pressure. If the 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. A burning tyre may burst very easily, thus spreading
fire over a large area.
● Check the tyre pressure when the tyres are still cold. Do not
let off pressure, when the pressure in a warm tyre has
increased.
● Do not light a fire and do not carry out welding near the tyre.
● Keep the working area free of pointed or sharp objects that

may damage the tyre.
● Avoid any overload.
The values for the tyre pressure and for the permitted speed cor-
respond to the manufacturer specifications and refer to standard
operations. If you want to perform special operations, contact the
responsible Komatsu dealer or the tyre manufacturer.
2-32 WA100M-5 – VEAM280201

Storing tyres
● Basically, tyres must be stored in a protected room that

cannot be accessed by unauthorised persons.
● Place the tyres on an even surface and incline them 60° to

70° (2) against a solid stopper. Secure the tyres with wheel
chocks (1) so that they cannot roll away, tip over, or slip.
● If, however, a tyre tips over despite this safety measure, do

not try to stop it, but get out of the way as quickly as possible,
since tyres for construction machines are very heavy and
may cause serious injuries.
WA100M-5 – VEAM280201 2-33

2.4. Safety labels on the machine Safety
2.4. Safety labels on the machine

All safety labels must be kept clean all times. Missing or damaged
safety labels must be replaced.
2.4.1. Positions and order numbers of information labels
2
4 4
4
5,8 3b 7b 1,5 5 6 3a 7a 5,
1 2 3a
(42W-93-21A40)
3b
4
5
(42W-93-21A30)
6
7a 7b
42T-93-21B70
42T-93-21B80
G00100162_USA
)
2-34 WA100M-5 – VEAM280201

Safety 2.4. Safety labels on the machine
2.4.2. Positions and order numbers of safety labels
2 a,b, c, d, e 4
J
C C F, 7 A
11 14,17
12
D 10 G,H,I 5 6 B B 1,3 D 11
e OF F ON
START
(42T-93-21C20)
e
(42U-93-11D60)
A B C D F G I J
(42U-93-11D80)
(09842-A0481)
(09667-A0880) (421-93H1380) (421-93-H1370) (421-93-H1360) (421-93-H1300) (421-93-H1660) (421-93-H1310)
1 2 3 4 5 6
p
(09963-03000)
42U-93-11B40
42U-93-11B60
(42U-93-11B40) (42U-93-11B50) (42U-93-11B60) (42U-93-11D40)
(42U-93-11D20)
7 10 11 12 14 17
(42U-93-11C10)
(42U-93-11B70)
42U-93-11B90
(42U-93-11B90) (42U-93-11C20)
(42U-93-11D50)
G0065160_1-USA
(42U-93-11B80)
WA100M-5 – VEAM280201 2-35

2.4. Safety labels on the machine Safety
2-36 WA100M-5 – VEAM280201

Operation
3. Operation
WA100M-5 – VEAM280201 3-1

3.1. General view Operation
3.1. General view
3.1.1. General view of the machine
1 Tipping lever 5 Lift cylinder

2 Bucket cylinder 6 Front wheel
3 Indicator lamp, Headlamp 7 Boom
4 Rear wheel 8 Bucket
3-2 WA100M-5 – VEAM280201

Operation 3.1. General view
3.1.2. Controls and indicators
Overall view
1 Instrument panel 9 Driving direction switch

2 Horn button 10 Multifunctional lever
3 Light switch 11 Control lever for special equipment
4 Direction indicator lever 12 Accelerator pedal
5 Inch-Brake pedal 13 Socket (12 V)
6 Speed range 2 14 Variable shift control switch – option
7 Parking brake 15 Car radio – option
8 Steering column adjustment 16 Safety lever for work hydraulic
17 Differential lock 100%
WA100M-5 – VEAM280201 3-3

3.1. General view Operation
Switches, controls and warning lights
29 33 27 25 20 32 22 24 21 18 23 19 44
34 40 31 30
41
G0065034A
39 42 43 45
37 28
36 26
35 38
18 Brake fluid reservoir warning light 32 High beam control lamp

19 Air filter warning light 33 Warning light: Water separator
20 Parking brake control lamp 34 Fuel gauge
21 Charging current warning light 35 Wiper and washer system switch (rear window)
22 Direction indicator switch control lamp 36 Wiper and washer system switch (windscreen)
23 Engine oil pressure warning light 37 Hazard warning lights switch and control lamp
24 Flasher signal control lamp 38 E.C.S.S. switch with control lamp – option
25 Intake air pre-heater control lamp 39 Warning beacon switch with control lamp – option
26 Heated rear window control lamp 40 Meter display pilot lamp
27 E.C.S.S. control lampt – option 41 Air conditioning switch with control lamp– option
28 Working lights switch and control lamp 42 Control lamp in the switch of the 3rd control circuit
- Optional
29 Switch and control lamp differential lock 43 Control lamp in Sprayer switch
100% - Optional
30 Coolant temperature indicator 44 Control lamp: Speed range 2
31 Operating hour meter 45 Switch with fan reversal control lamp
3-4 WA100M-5 – VEAM280201

Operation 3.2. Description of the individual elements
3.2. Description of the individual elements
3.2.1. Instrument panel
A C
A A A A C C C C A
B
A A
The instrument panel can be divided in
A Control lamps
B Measuring indicators
C Warning lights
In the following sections of this chapter, all elements required for

an efficient machine operation are explained in detail.
Control lamps
This group comprises the control lamps for parking brake, high
beam, low beam, heated rear windscreen, air preheater, direction
indicator, driving direction switch, E.C.S.S. (option) and control
lamps for the high-speed gear (option).
Measuring indicators
This group comprises the fuel gauge, the operating hour meter
and the temperature indicator of the coolant.
Warning lights
This group comprises the warning lights for charging current, air
filter, engine oil-pressure and brake fluid supply.
WA100M-5 – VEAM280201 3-5

3.2. Description of the individual elements Operation
Warning lights
6 3 4 1 5 2
1 Brake fluid warning light

2 Air filter warning light
3 Parking brake control lamp
4 Charging current warning light
5 Engine oil-pressure warning light
6 Warning light: water separator
1. Brake fluid warning light
If the brake fluid supply is too low, the brake fluid warning light
lights up in red.
In this case you must immediately stop the machine and switch
off the engine. Proceed as described in chapter Troubleshooting:
"4.6. Other troubles" on page 4-10“.
75_006
2. Air filter warning light
If the air filter is polluted, the air filter warning light lights up in red.
In this case, you must clean or exchange the air filter. Proceed as
described in chapter Maintenance: "Air filter, removing and re-
installing the filter insert, checking and cleaning the filter insert" on
page 5-46.
75_013
3-6 WA100M-5 – VEAM280201

3. Parking brake control lamp
The parking brake control lamp lights up in red if you set the start
switch to the 'I' operating position while the parking brake is
applied.
In addition, the acoustic warner sounds if you set the driving

direction switch to forward or reverse driving with the parking 75_005
brake applied.
4. Charging current warning light
● Before you start up the engine:

The charging current warning light must light up if you set the
start switch to the 'I' operating position.
● With the engine running:

As soon as the engine runs, the generator starts to generate
current and to charge the battery. At the same time, the
charging current warning light will go out. A fault is present, if 75_011
the charging current warning light does not go out while the
engine is running.
In the latter case, proceed as described in chapter "4.6. Other

troubles" on page 4-10
5. Engine oil-pressure warning light
● Before you start up the engine:

The engine oil-pressure warning light must light up if you set
the start switch to the 'I' operating position. At the same time,
the acoustic warner will sound.
● With the engine running:

After starting the engine, the lubricating pressure builds up
75_012
and the lamp goes out. If the engine oil-pressure warning light
does not go out with the engine running or if it suddenly lights
up during operation, while the acoustic warner sounds at the
same time, a fault has occurred in the oil-pressure system.
In both cases, you must immediately stop the machine and switch
off the engine. Proceed as described in the chapter "4.6. Other
troubles" on page 4-10
6. Warning light: Water separator
The warning light of the water separator lights up in red when too
much water has collected in the water separator at the fuel filer.
If this is the case, you have to drain the water from the water sep-
arator.
Proceed as described in the chapter Maintenance "Water separa-

tor at the fuel filter – Draining water and dirt sediments" on
page 5-31.
WA100M-5 – VEAM280201 3-7

Control lamps
6 4 11 2 3
15 14
G0065034A
8 12 13 16
1 7
10
1 Control lamp in hazard warning lights switch

2 Driving direction switch indicators
3 Direction indicator control lamp
4 Air preheater control lamp
5 Heated rear windscreen indicator
6 E.C.S.S. control lamp (only activated for installed E.C.S.S.) – option
7 Control lamp in working lights switch
8 Control lamp in the warning beacon switch – option
9 Control lamp in the air conditioning switch – option
10 Control lamp in E.C.S.S. switch – option
11 High beam control lamp
12 Control lamp in the switch of the 3rd control circuit - Optional
13 Control lamp in Sprayer switch - Optional
14 Control lamp: Speed range 2
15 Control lamp: Differential lock 100%
16 Control lamp: Fan reversal
3-8 WA100M-5 – VEAM280201

1. Control lamp in hazard warning lights switch
The control lamp flashes when the hazard warning lights are
switched on.
2. Driving direction switch indicators
The indicators of the driving direction switch indicate which driving

direction you have selected:
● left arrow lights up:

Machine drives backwards GK100836
(driving direction switch in 'R' position)
● right arrow lights up:

Machine drives forward
(driving direction switch in 'F' position)
If the driving direction switch is set to the 'N' neutral position, both
control lamps will go out.
3. Direction indicator control lamp
The direction indicator control lamp flashes if you have switched

on the right or left direction indicators or the hazard flashers.
If the direction indicator control lamp flashes in very short

intervE.C.S.S., a fault has occurred in the direction indicator
GK100837
system. In this case, proceed as described in chapter "4.6. Other
troubles" on page 4-10.
4. Air preheater control lamp
The control lamp lights up, if you set the start switch to the 'I'
operating position and if the air preheater is running.
You can start the engine, after the control lamp has gone out.
GK100838
In the event of temperatures below 32°F (0°C), the pilot lamp
again lights up after the start, for 30 s.
5. Heated rear windscreen indicator
The control lamp of the heated rear windscreen lights up, if you
have switched on the heated rear windscreen.
GK100839
WA100M-5 – VEAM280201 3-9

6. E.C.S.S. control lamp (only activated for installed

E.C.S.S. electronics) – option
The E.C.S.S. control lamp on the instrument panel is only active if

the E.C.S.S. is installed.
It lights up, when the E.C.S.S. is switched on and when the

machine drives faster than 3.10 mph (5 km/h).
7. Control lamp in working lights switch
The control lamp illuminates when the working lights are switched
on.
GK100816
8. Control lamp in the warning beacon switch – option
The warning beacon switch with control lamp is only installed in

machines which are provided with a warning beacon.
The control lamp in the switch lights up in green when the warning
beacon is switched on. GK100846
9. Control lamp in the air conditioning switch – option
The air conditioning switch with control lamp is only installed on

machines which have been fitted with air conditioning.
The control lamp shines blue when the air conditioning is

switched on. GK100845
10. Control lamp in E.C.S.S. switch – option
The E.C.S.S. switch with control lamp is only installed in

machines equipped with E.C.S.S..
The control lamp in the switch flashes green when the E.C.S.S.
are switched on.
11. High beam control lamp
The high beam control lamp illuminates when the high beam
lights are switched on.
The control lamp also illuminates when you press the headlamp
flasher. GK100840
3-10 WA100M-5 – VEAM280201

12. Control lamp in the switch of the 3rd control circuit -

Optional
This control lamp goes on when you switch on the sprayer (water
supply) while using a sweeper.
As long as the control lamp is lit, the sprayer is on.
If you press the switch again, the sprayer (water supply) is

switched off and the control lamp goes out.
13. Control lamp in Sprayer switch - Optional

14. Control lamp: Speed range 2
This control lamp goes on if you press the button (1) on the multi-
function lever once and release it.
As long as the control lamp is on, the machine is operating in

speed range 2.
If you press and release the button (1) again, the machine
switches back to speed range 1 and the control lamp goes out.
15. Control lamp: Differential lock 100%
This control lamp goes on if you press the button (2) on the multi-
function lever and keep it pressed.
As long as you keep the button pressed, the control lamp remains
lit and the differentials in the axles are locked 100%.
If you release the button (2), the differentials are unlocked and the
control lamp goes out.
WA100M-5 – VEAM280201 3-11

16. Control lamp: Fan reversal
This control lamp goes on if you press the fan reversal switch and
keep it pressed.
As long as the control lamp is on, the fan wheel rotates in the
opposite direction.
Once you release the switch, the fan wheel rotates in the normal
direction and the control light goes out.
GK043111
3-12 WA100M-5 – VEAM280201

Measuring indicators
1 Fuel level indicator

2 Operating hour meter
3 Coolant temperature indicator
1. Fuel level indicator
If you set the start switch to the 'I' operating position, the fuel
gauge indicates the available fuel supply.
F = The tank is full

E = The tank is in the critical range
The background lights up in green if enough fuel is available.
The background lights up in red if the fuel is almost used up. Refill
the fuel.
If only the two bars at the right of the fuel display are lit, there is
no electrical contact between the fuel display and the tank level
sensor.
2. Operating hour meter
The operating hour meter indicates the total hours of operation. It

only counts the hours with the engine running, no matter whether
the machine is actually driving or not. If the operating hour meter
is ON, the icon on top of the operating hour meter is flashing.
WA100M-5 – VEAM280201 3-13

3. Coolant temperature indicator
If you set the start switch to position 'I', the temperature display
shows the temperature of the coolant.
● The background lights up in green if the coolant temperature

is normal.
● The background lights up red when the coolant temperature

is too high. The acoustic warning signal sounds.
Eliminate the malfunction as described in Chapter "4.6. Other GK100849A

troubles" on page 4-10.
● If only the two bars on the right of the temperature display are
lit, there is no electrical contact with the temperature sensor.
3-14 WA100M-5 – VEAM280201

3.2.2. Switches
12 11 17
3
18
10
9
G0065031A
4 6 5
19 20 21 22
15
Aside the battery
8
16
13
WA100M-5 – VEAM280201 3-15

1 Switch and control lamp of hazard flashers 11 Heated rear windscreen switch
2 Switch of front windscreen wiper and washer 12 Working lights switch and control lamp
3 Switch of rear windscreen wiper and washer 13 Variable shift control switch – option
4 Direction indicator lever 15 Switch for inside lighting
5 Horn button 16 Battery main switch – option
6 Light switch 17 E.C.S.S. switch with control lamp– option
7 Driving direction switch 18 Air conditioning switch with control lamp– option
8 Start switch
19 Warning beacon switch with control lamp – option
20 Control lamp in the switch of the 3rd control circuit

9 Fan rotary switch, for ventilation and heating
- Optional
10 Heating temperature switch 21 Control lamp in Sprayer switch - Optional
22 Switch with fan reversal control lamp
1. Hazard flasher switch (with control lamp)
This switch is used to switch on/off the hazard flasher.
NOTE
You may switch on the hazard flasher only in an emergency
situation.
If you switch on the hazard flasher, all direction indicators of the

machine will start to flash. At the same time, the control lamp of
the hazard flasher switch and the direction indicator control lamp
start to flash.
2. Switch of front windscreen wiper and washer
This switch is used to switch on/off the front windscreen wiper and
washer.
The switch has two switching stages:
● Switching stage '1' locks in permanently and is used to switch

on/off the windscreen wiper.
● If you hold the switch pressed in switching stage '2', the wind-
screen washer is only operated for the time you keep the
switch pressed.
3-16 WA100M-5 – VEAM280201

3. Switch of rear windscreen wiper and washer
This switch is used to switch on/off the rear windscreen wiper and
washer.
The switch has two switching stages:
● Switching stage '1' locks in permanently and is used to switch

on/off the windscreen wiper.
● If you hold the switch pressed in switching stage '2', the wind-
screen washer is only operated for the time you keep the
switch pressed.
4. Direction indicator lever
The direction indicator lever is used to switch on/off the direction

indicators.
Indicate right turn = Press direction indicator lever to the front (1)
Indicate left turn = Draw direction indicator lever to the back (2)
After you have passed the bend, the direction indicator lever auto-
matically returns to its home position and the direction indicator
will be switched off.
5. Horn button
The horn sounds when you press the horn button.
6. Light switch
The light switch is used to switch on/off the main headlights, the
side lamps and the taillights.
● Switching off the lights

Switch in '0' position
● Switching on the parking light

Turn the light switch to the front until it reaches position '1'.
The side lamps and the taillights light up.
WA100M-5 – VEAM280201 3-17

● Switching on the low beam

Continue to turn the light switch until it reaches position '2'. All
lights which were already switched on in position '1' (parking
light) remain lit. In addition, the low beam is switched on. The
low beam control lamp lights up.
● How to flash one’s lights (high beam)

In order to flash your lights, you need to draw the lever briefly
in the direction of the steering wheel. The high beam is only
switched on as long as you draw the lever. The high beam
control lamp will also light up for that time.
● Switching on the high beam

In order to switch on the high beam you must press the lever
completely down. In this position the lever locks in and the
high beam control lamp lights up.
7. Driving direction switch
You can change the driving direction of the machine with the
driving direction switch..
Position F = Forward driving

Position N = Neutral position
Position R = Reverse driving
NOTE
You can only start the engine if the driving direction switch is
switched to the neutral position 'N'.
8. Start switch
You can start and switch off the engine with the start switch. 0
● '0': Stop position I
In this position, the engine is switched off, permitting you to P
remove the ignition key. All functional circuits are interrupted II
in the stop position.
● 'I': Operating position
The control lamps light up in the operating position 'I' and the
75_209
air preheater is in operation. All functional circuits are
activated. The ignition key remains in this position with the
engine running.
● 'II': Start position
In start position 'II', the engine starts.
NOTE
You may only start the engine, if the driving direction switch
is set to the neutral position 'N'.
3-18 WA100M-5 – VEAM280201

9. Fan rotary switch for ventilation and heating
This rotary switch permits to regulate the fan step by step.
Position 1 = Fan off

Position 2 = Low air flow
Position 3 = Medium air flow
Position 4 = High air flow
10. Temperature rotary switch
The temperature rotary switch permits to adjust continuously the

capacity of the heating system from 'cold' (heating OFF) to 'warm'.
11. Heated rear windscreen switch
This rotary switch is used to switch on/off the heated rear wind-
screen.
12. Working lights switch (with control lamp)
CAUTION
The front working lights may blind oncoming traffic! Before
driving on public roads, turn off the working lights.
This switch is used to switch on/off the working lights.
WA100M-5 – VEAM280201 3-19

13. Variable shift control switch – option
This variable shift control switch allows a stepless determination

of the maximum speed in all speed range positions.
Turn the dial to the right to increase the setting; turn it to the left to
decrease the setting. The conditions for use may differ according
to the condition of the road surface.
14. G0070163.eps
15.
15. Switch for inside lighting
The inside lighting has three different switch settings:
Switch setting 1 = Steady light

Switch setting 0 = Off
Switch setting 2 = Steady light
NOTE
You can also switch on the inside lighting, if the start switch
is in stop position '0'. For this reason, switch off the inside
lighting before you leave the driver’s cab.
16. Battery main switch – option
NOTE 1
Do not operate the battery main switch with the engine
running!
The battery main switch (1) disconnects the power supply of the
machine’s electrical system. The switch is situated next to the
battery in the rear section of the machine.
If the machine is to be taken out of service for a longer time, you

must switch off the battery main switch and remove the ignition
key.
17. E.C.S.S. switch (with control lamp) – option
The E.C.S.S. switch is only installed in machines which are

provided with E.C.S.S..
If you switch on the E.C.S.S. with this switch, the green control
lamp lights up in this switch.
● If the machine drives faster than 3.10 mph (5 km/h), the
E.C.S.S. is automatically activated and the E.C.S.S. control
lamp lights up on the instrument panel.
● If the machine drives slower than 3.10 mph (5 km/h), the
E.C.S.S. is switched off and the control lamp on the instru-
ment panel goes out. However, the control lamp in the
E.C.S.S. switch remains lit in green.
3-20 WA100M-5 – VEAM280201

18. Air conditioning switch (with control lamp) – option
The air conditioning switch with control lamp is only installed on

machines which have been fitted with air conditioning.
● If you turn the air conditioning and the blowers on with this
switch, the control lamp shines blue and the air conditioning is
in operation.
● If the blowers are switched off, the blue control lamp in the
switch goes out and the air conditioning is no longer in opera-
tion.
19. Warning beacon switch (with control lamp) – option
The warning beacon switch is only installed in machines which

are provided with a warning beacon.
If you switch on the warning beacon, the green control lamp in the
switch lights up.
G0065034A
20. Control lamp in the switch of the 3rd control circuit -

Optional
This control lamp goes on when you press and hold the switch to
unlock the quick-change unit.
As long as the control lamp is lit, the quick-change unit is not

locked.
If you release the switch, the quick-change unit locks and the con-
trol lamp goes out.
21. Control lamp in Sprayer switch - Optional

WA100M-5 – VEAM280201 3-21

22. Switch with fan reversal pilot lamp
If you press the fan reversal switch and hold it pressed, the fan
wheel rotates in the opposite direction. The control lamp is on.
Once you release the fan reversal switch, the fan wheel rotates in
the normal direction and the control light goes out.
G0065034A
3-22 WA100M-5 – VEAM280201

3.2.3. Control levers and pedals
1 Brake pedal
2 Parking brake
3 Steering column adjustment
4 Accelerator pedal
5 Multifunctional lever
6 Control lever for special equipment
7 Safety lever for the work hydraulic system
8 Switching lever for bucket (without fig.)
WA100M-5 – VEAM280201 3-23

1. Brake pedal
WARNING
● If you are driving downhill, let the engine run and use the
braking effect of the engine. If required, brake
additionally using the brake pedal.
● Danger of accidents due to unintentional braking!
● Do not use the brake pedal as a foot rest.
The brake is operated via a combined brake/inch pedal. The inch-

ing exerts an additional braking effect on the hydrostatic drive
system.
2. Parking brake
As soon as you pull the parking brake lever from its normal posi-
tion, the braking action comes into effect. If the start switch is set
to the 'I' operating position, the parking brake warning light lights
up in the instrument panel. The machine will drive again, if you re-
loosen the parking brake.
NOTE
You cannot start the machine with the parking brake being
applied. If you set the driving direction switch to the 'F' posi-
tion (forward driving) or 'R' (reversing) with the parking brake
still being applied, the alarm buzzer will sound.
3. Steering column adjustment
The lever (2) for adjusting the steering column (1) position permits
to incline the steering column smoothly in two directions (front or
back). The adjustment range is 4.921 inch (125 mm).
Proceed as described in chapter "Adjusting the steering column"

on page 3-43
3-24 WA100M-5 – VEAM280201

4. Accelerator pedal
The accelerator pedal regulates the speed (r.p.m.) and perfor-

mance of the engine.
5. Multifunctional lever for the work hydraulic system
The work unit is operated with the multifunctional lever. The multi-
functional lever has 6 positions which control the work unit as fol-
lows:
SW Float
â The multifunctional lever is locked in
this position. The floating position is
provided for planing operations
(removing subsoil). In this switch posi-
tion, the work unit is lowered by its
own weight, and can be freely oper-
ated by external parties.
ç
S Lower The boom is lowered in this position.
If the engine is switched off, you can
lower the boom in this position.
0 Hold
å The boom is held in position.
ã
H Raise The boom is raised in position.
ä
E Tilt IIn this position, the bucket is tilted.
à
A Dump In this position, the bucket is dumped.
WA100M-5 – VEAM280201 3-25

6. Control lever for special equipment
The control lever for special equipment has three switch settings
whose functions depend on the type of the used special equip-
ment.
● If the standard bucket, the light-weight material bucket or the

forklift truck attachment is attached to the quick-change unit,
the control lever for special equipment provides the following
functions:
Position 1 = Locking pins for work unit are drawn in

Position 0 = Neutral position (locking pins are drawn in; you
can pick up the work unit in this position)
Position 2 = Locking pins for work unit are extended
● If the multi-purpose bucket is attached to the quick-change

unit, the control lever has the functional assignment
described above. If the switching lever for the bucket is in 2
position ‘1’, the multi-purpose bucket is active. You can then
operate the multi-purpose bucket via the control lever for spe-
cial equipment.
It then has the following functions: 1
Position 1 = Close multi-purpose bucket

Position 0 = Neutral position 75_160
Position 2 = Open multi-purpose bucket
● If you use attachments requiring a steady oil flow (e.g. brush,

snow remover), the control lever has the following functions:
Position 1 = Work unit turns backwards

Position 0 = Neutral position
Position 2 = Work unit turns forward
Position 3 = Work unit turns forward in permanent opera-
tion (locks in
● For permanent operation, you must set the control lever to

position ‘3’. The control lever locks in this position.
NOTE
Without connected special equipment, you must not set the
control lever for special equipment to switch settings ‘1’, ‘2’
or ‘3’. If you do not heed this note, the work hydraulic system
will operate in order to counteract overpressure thus unnec-
essarily heating up the oil.
3-26 WA100M-5 – VEAM280201

7. Safety lever for the work hydraulic system
The safety lever for the work hydraulic system protects the work
hydraulic system against unintentional activation. Before driving
on streets or beginning maintenance operations, it is required to
block the work hydraulic system with this safety lever
Position 1 = working hydraulics locked

Position 2 = working hydraulics released
8. Switching lever of bucket
If you have the multi-purpose bucket attached to the machine, 2

you can use this switching lever to change the function assign-
ment of the control lever for special equipment (see "6. Control
lever for special equipment" on page 3-26).
1
Position 1 = the control lever for special equipment oper-
ates the multi-purpose bucket.
75_160
ates the quick-change unit.
WA100M-5 – VEAM280201 3-27

3.2.4. Articulated steering catch

The articulated steering catch is used to join rigidly the front and
rear part of the machine, thus preventing the articulated steering
from bending. You must block the articulated steering before the 1
machine is hoisted or before repairs or maintenance operations
are being performed.
spring bolt.
3.2.5. Traction device

You can use the traction device (hitch) to tow off, e.g., another
machine or trailer.
You must also fix the machine at the tie bolt during transport.
Always secure the bolt of the traction device, which is fixed to a
chain, with the spring bolt.
3-28 WA100M-5 – VEAM280201

3.2.6. Socket (12 V)
CAUTION
● Danger of accidents!
Electrical devices may interfere with the on-board
electronics.
● For this reason, connect only the working lamp to the

socket.
You may connect a working lamp to the socket.
3.2.7. Door unlocking system

The cab door and window have a lock that engages when you
open the door or window entirely (1) and that prevents the door or
1
window from closing when the vehicle is moving. To close the 2
door (2) or the window (3) again, you have to pull back the
respective release mechanism.
3.2.8. Alarm horn for reverse driving – option

The horn sounds if you have set the driving direction switch to the
reverse/backwards position.
WA100M-5 – VEAM280201 3-29

3.2.9. Fuses
CAUTION
● Parts of the electrical system may be damaged, if you
replace fuses with the ignition switched on!
● Turn the start switch to switching position '0' (OFF),
before starting to replace fuses.
● Fuses with wrong amperages may cause fires due to
electrical faults or may immediately blow again!
● Only replace defective fuses with fuses of the same rat-
ing.
The fuses protect the electrical system. Replace defective, cor-

roded, or loose fuses.
When the driver's cab is tipped up, the box can be found in the
engine compartment on the right.
Fuse assignment
3-30 WA100M-5 – VEAM280201

3.2.10. Slow-blowing fuses

If the power supply fails, a main fuse or relay might be blown.
Check the electrical system and replace defect fuses or relays.
When the driver's cab is tipped up, the box can be found in the
engine compartment on the right.
1 Relay, starter motor 92 Ω

2 Fuse, battery 100 A
3 Relay, air preheater for engine 12 Ω
4 Fuse, air preheater for engine 250 A
5 Relay, battery 32 Ω
WA100M-5 – VEAM280201 3-31

3.2.11. Adjusting the heater and ventilation system

Adjusting the ventilation system
When the ventilation system is operated, air is blown into the

driver's cab. If the cabin is closed, a light overpressure is built up,
preventing dust from outside to settle down in the cab. To
increase the volume of filtered fresh air, you can open the ventila-
tion grid a little.
The air is distributed by means of air outlet nozzles.

● You may open or close the nozzles individually.
● The exhaust direction can be varied using the diffusing disks.
● You can direct the air ventilation nozzles (1) onto the front
windshield and the air ventilation nozzles (2) onto the side
windows.
G0065014c
Adjusting the heating system
NOTE
The heating capacity depends on the coolant temperature of
the engine. Full heating capacity is only realised, if the
engine is completely warmed up.
2
1
1 Blower rotary switch
2 Temperature rotary switch
You can realise maximum heating inside the cabin, if you open all
air ventilation nozzles, set the temperature rotary switch to maxi-
mum heating power while switching on the fan with its highest
level.
You may realise a comfortable temperature, if you open all air
ventilation nozzles, set the temperature rotary switch to a comfort-
able temperature and set the fan to an appropriately low air
throughput.
To cool down the temperature inside the cabin, open all air venti-
lation nozzles, set the temperature rotary switch to position 'Cold'
and set the fan to its highest level.
To prevent premature tiredness due to lack of oxygen, it is recom-
mended to open the door a little from time to time and to lock it in
this position. Optionally, you may leave open the ventilation grid
above the side window.
3-32 WA100M-5 – VEAM280201

3.2.12. Air-conditioning
NOTE
Only operate the air-conditioning with the engine running.
Run the air-conditioning for at least 10 minutes every month
irrespective of season. This prevents the compressor shaft
seal from drying out.
Do not let the air conditioning system run at idle speed for long
periods, as this would empty the battery.
The windows and doors of the operator’s cab must be closed

when operating the air conditioning.
We recommend ventilating the operator’s cab thoroughly first

when starting the machine and switching on the air conditioning if
the machine has been standing in bright sunshine for any length
of time.
G0065014b.eps
Switching on the air-conditioning
1. Open all air circulation nozzles (see arrows).
2. Turn the rotary switch (1) of the fan to position '4'.
3. Set the temperature control lever (2) to 'cold'.
4. Press the switch for the air conditioning. The air conditioning
system is now switched on and the control lamp in the switch
2
shines blue. The greatest cooling effect is achieved with this
1
setting, particularly if the engine is running at high revs. As
soon as the required temperature has been reached, turn the
blowers down by one stage and carry out any further adjust-
ment of the temperature using the temperature control. The
lowest blower setting can be used if only a low cooling effect
is required.
5. The air is distributed by means of air outlet nozzles.
❍ You may open or close the nozzles individually.
❍ The exhaust direction can be varied using the diffusing

disks.
❍ You can direct the air ventilation nozzles onto the front
windshield and the air ventilation nozzles (arrows) onto
the side windows.
G0065014c
WA100M-5 – VEAM280201 3-33

3.3. Operation Operation
3.3. Operation
3.3.1. Pre-start checks
Visual inspection
WARNING
Danger of fire! Oil or fuel leaking out or accumulated com-
bustible materials may catch fire at hot parts of the machine,
e.g. the exhaust!
Prior to starting the machine, check the oil and fuel lines for
leaks and immediately repair any leaks. Store combustible
material in a safe place.
Before you start the engine
Check that there are no loose nuts or screws lying around the
machine. Check that neither oil, nor fuel nor coolant are leaking
out. Check the condition of the work unit and the hydraulic sys-
tem. Check that there are no loose cables and accumulated dirt.
Remove accumulated dirt and eliminate faults.
Before starting working with the machine
Perform daily the following measures:
1. Check work unit

Check work unit, cylinder, connecting rods, and hoses for
cracks, premature wear and tear, and play. Repair damaged
parts.
2. Remove dirt and dust

Check the area around the engine and the radiator for accu-
mulated dirt or dust. Additionally check whether combustible
material has accumulated near the battery or near hot parts of
the machine, e.g. the exhaust. Remove completely any accu-
mulated dirt or dust.
3. Check for leakage of water or oil around engine

Check that there is no oil leakage from the engine or water
leakage from the cooling system. If any abnormality is found,
repair it.
4. Check the gear unit, axles, hydraulic tank and hoses and
the connecting points
Check whether oil is leaking out of the gear unit, axles,
hydraulic tank and hoses, and connecting points. Repair
damaged parts.
5. Check brake hoses

Check that there is no oil leaking out at the brake hoses.
Repair damaged parts.
3-34 WA100M-5 – VEAM280201

Operation 3.3. Operation
6. Check wheels
Check the tyres for cracks, damages and wear and tear.
Check the wheel rims and lock rings for cracks, damage, and
wear and tear. Tighten loose wheel nuts. Repair damaged
parts. Replace missing valve caps.
7. Check handrails
Check handrails for damage and loose screws. Repair
damaged parts and tighten loose screws.
8. Check measuring and control indicators

Check measuring and control indicators for damage and
loose screw connections. Replace defective parts. Remove
dirt from surfaces.
9. Check air filter

Check the fastening screws of the air filter. Tighten loose
screws.
10. Check battery terminals

Tighten loose battery terminals.
11. Check the automatic seat belt

If t he aut oma tic se at belt has been subjected t o
excessive loads, e.g. full braking manoeuvre or if the
machine rolls over, the automatic seat belt must be
replaced.
Check the belt, the mountings and the seat belt’s buckle.
If the seat belt system’s belt, mountings or buckle have been
damaged the automatic seat belt must be replaced.
Check that the mounting’s fastening screws are securely
fixed in place.
Tighten any loose screws. Tightening torque: 2.5 - 3.0 kpm
(25 - 30 Nm)
12. Check ROPS

Check whether screws are loose or damaged. Have loose
screws tightened and damaged screws replaced by a
Komatsu-dealer. Loose screws must only be tightened with
the specified tightening torque. Damaged screws must only
be replaced by original parts.
13. Check cab windows

Prior to start of work, clean the cab windows.
WA100M-5 – VEAM280201 3-35

Pre-start checks
Cooling system – checking the coolant level, topping up

coolant
CAUTION
● A wrong water/coolant mixing ratio will damage the
radiator! Always mix water and coolant in the ratio 50:50.
This also applies to countries with a hot climate.
● Danger of fire! Coolant may ignite at hot engine!
● Do not top up coolant, unless the engine has cooled
down sufficiently.
1. Open the bonnet.
2. Check that the coolant level in the expansion tank is between

the MAX and MIN markings. If the coolant level does not
reach up to the MIN marking, top up coolant.
3. Therefore remove the cover cap of the expansion tank.
4. Top up coolant until the level reaches up to the MAX marking.
5. After topping up, firmly close the cover cap.
6. Usually, the radiator needs not to be opened. However, for

safety reasons it is required to check the refrigerant level in
the radiator after 2000 operating hours (see "Cooling system
– e x c ha ng i ng c oo l an t a nd c le a ni n g th e s y s t em " o n
page 5-68).
7. If the expansion tank is empty again after a short period of

time, immediately have the cooling system checked for leaks
and have any leaks repaired in the garage.
Checking the engine oil level – topping up oil
NOTE
1
After you have switched off the engine, wait at least 5
minutes before you check the engine oil level. The machine
must stand on an even surface.
1. Pull out the oil dipstick (1) and wipe off the oil with a clean
cloth.
2. Completely re-insert the oil dipstick and pull it out again after
a few seconds. The oil level must be between the (H) and (L) 2
markings on the oil dipstick.
3. If the oil level does not reach up to the (L) marking, top up
engine oil. For detailed information on recommended oils, see
section "5.3. Lubricants, fuels and filling capacities" on
page 5-18.
3-36 WA100M-5 – VEAM280201

NOTE
Do not fill in too much oil in one go via the filler!
4. Wait three minutes before you check the oil level again. If the
oil level is above the (H) marking, drain off some oil. (see
section "Draining engine oil" on page 3-37).
5. Close the oil filler (2).
Draining engine oil
If you have topped up too much oil, you must drain off the excess
oil. Have an oil trough with a sufficient capacity ready.
1. Put the oil trough under the drain screw.
2. Remove the cover cap (1) from the drain valve.
3. Screw on the drain hose (2) on the drain valve. This will
cause the drain valve to open.
4. Drain the oil.
5. Remove the drain hose (2) from the drain valve. This will
cause the drain valve to close.
1
6. Check oil level again.
7. Fit cap (1) back onto drain valve.
WA100M-5 – VEAM280201 3-37

Checking the fuel level, refuelling
WARNING
● Danger of fire! Fuel that has spilled over may ignite!
● Immediately remove fuel that has spilled over.
1. Turn the start switch to the operating position 'I' and check the
fuel level indicated on the fuel level indicator.
0
F - fuel tank full I
P
E - fuel tank empty II
2. Then, return the start switch to the stop position '0'.
75_209
3. If required, refuel via the filler (1). For detailed information on

fuels, see section "5.3. Lubricants, fuels and filling capacities"
on page 5-18. 1
4. After refuelling, firmly close the filler.
3-38 WA100M-5 – VEAM280201

Checking the controls
1. Turn the start switch to the operating position 'I'.
An alarm buzzer sounds until the machine is started. 0

I
P
II
75_209
2. Check that the following alarm and control indicators are on

until the engine is started: 4 1 2 3
1 Parking brake
2 Charging current
3 Engine oil level
4 Intake air preheater
3. Check that the fuel level indicator (5) indicates the fuel level in
the fuel tank. 5
NOTE
Contact your responsible Komatsu dealer, if one or several of
the indicators do not light up.
Do not only use the indicators to perform the checks prior to start.
Always perform the work described as regular maintenance, too.
Checking the electrical connections
CAUTION
Danger of ignition! Inflammable material (leaves, twigs,
grass, etc.) may ignite within the electrical system!
Remove inflammable material from the electrical system.
NOTE
If a fuse blows, or if there are any signs of a short-circuit
within the electrical system, inform your responsible
Komatsu dealer.
Regularly check that the terminals are fastened tightly, retighten

loose terminals.
WA100M-5 – VEAM280201 3-39

Heating/Air conditioning: checking rate of air flow
1. Turn start switch to position '1'.
0
I
P
II
75_209
2. Open all air circulation nozzles and air outlet nozzles (see
arrows).
3. Switch blower on.
4. Check if air flow at the air-outlet nozzles to the right and left of
the steering column is strong enough.
5. If insufficient air is coming out of the jets, either the filter

fleece in the heating/air conditioning unit is dirty and will have
to be cleaned or replaced or the condenser in the air condi-
tioning system is dirty and will have to be cleaned; see
"Heater/air conditioning – cleaning/replacing filter fleece" on
page 5-59.
Other maintenance measures prior to start
● Check that the lighting equipment operates correctly; check it

for dirt and damage.
● Check the measuring instruments.
● Check both the horn and the reversing warning horn.
● Check both clearance and operation of the steering wheel.
● Check the function of the rear-view mirror; check it for dirt and
damage.
3-40 WA100M-5 – VEAM280201

Adjustments prior to machine start
Adjusting the driver’s seat
After each change of the driver, newly adjust the driver’s seat.
Before you start operation, check that the seat is adjusted in such
a way that you can fully floor the brake pedal when you lean
against the backrest.
Proceed as follows to adjust the seat according to your

requirements:
Modell: ISRI
(1) Weight adjustment
Turn the handwheel (1) to set the vibration absorbing system

to the weight of the driver.
(2) Adjustment of horizontal position
To adjust the horizontal seating position, pull the lever (2) and
slide the seat forward or backward. To lock the position of the
seat, release the lever again.
(3/4)Adjusting height and angle of inclination

5
You may adjust the height and the angle of inclination of the
driver’s seat with the spring-supported levers (3) and (4). 1
4
Use lever (3) to set the front part of the seat, use lever (4) to
set the rear part of the seat. .
3
Adjusting the seat’s height 2
Adjust the front and the rear section of the seat uniformly.
For this purpose, pull lever (3) and hold it in this position. To
lift up the front part of the seat, it is necessary to relieve your
weight from the front section of the seat cushion by standing
up. Then, sit down on the front part in order to press down the
front section of the seat. Release the lever if you have
reached the right position. The seat is now locked in its
position.
Then, pull lever (4) and hold it in this position. To lift up the
rear part of the seat, it is necessary to relieve your weight
from the rear section of the seat cushion by standing up.
Then, sit down on the rear part in order to press down the
rear section of the seat.
Release the lever if you have reached the right position. The
seat is now locked in its position.
Adjusting the angle of inclination of the seat

Adjust the front and rear section of the seat with different
settings.
Proceed as described above.
WA100M-5 – VEAM280201 3-41

(5) Adjusting the backrest
To adjust the position of the backrest, slightly lean against the

backrest, pull lever (5) and hold it in this position.
Relieve the backrest in order to bend it to the front. Press it to

the back in order to bend it to the back.
Release lever (5) if the backrest is in the desired position.
The backrest will lock in automatically in this position.
Modell: EURO SEAT
(1) Weight adjustment
Turn the handwheel (1) to set the vibration absorbing system

to the weight of the driver.
(2) Adjustment of horizontal position
To adjust the horizontal seating position, pull the lever (2) and
slide the seat forward or backward. To lock the position of the
seat, release the lever again.
(3) Adjusting the height
You can use the handwheel (3) to adjust the height of the
driver's seat.
(4) Adjusting the backrest
To adjust the position of the backrest, slightly lean against the

backrest, pull lever (4) and hold it in this position.
Relieve the backrest in order to bend it to the front. Press it to

the back in order to bend it to the back.
Release lever (4) if the backrest is in the desired position.
The backrest will lock in automatically in this position.
3-42 WA100M-5 – VEAM280201

Adjusting the steering column
WARNING
● Do not change the angle of inclination of the steering
column while you are driving, since this may lead to
severe accidents!
● Stop the machine, before you change the angle of

inclination of the steering column.
You may use this lever for continuous adjustment of the steering
column’s (1) angle of inclination. (Adjustment range 4.921 inch
(125 mm))
Proceed in the following manner:
1. Release the locking lever (2).
2. Adjust it in such a way that you can reach the steering wheel
from a comfortable seating position while at the same time
having an optimum view of the work unit. Hold the steering
wheel in this position.
3. You can lock the steering column in this position by tightening

the locking lever again.
Adjusting the armrest
Proceed as follows to adjust the height of the armrest:
1. Loosen the screw (1).
2. Either pull out or push back the armrest to reach the

multifunctional lever.
Your forearm should rest on the armrest at an angle of 90° to

your upper arm.
3. Re-tighten the screw (1).
WA100M-5 – VEAM280201 3-43

Adjusting the rear-view mirrors
Sit down on the driver’s seat and adjust the rear-view mirrors to
their required positions. You should be able to view the traffic
coming from behind without having to change your seating posi-
tion.
Putting on the safety belt
WARNING
● Danger of injury! A damaged safety belt, a safety belt that
has been stretched in an accident, or a safety belt the
belt fixings or fastening screws of which have not been
mounted correctly will not protect you sufficiently in
case of accident!
● Replace the safety belt, if it is damaged, or if the machine

has been involved in an accident. Check that the belt
fixings and fastening screws are in perfect condition,
before you put on the safety belt.
● If you have not put on the safety belt and are involved in
an accident, this may lead to severe injuries!
● Put on the safety belt, before you start work and do not
take it off during work. Put on the safety belt in such a
way that it is not twisted and fits tightly.
The machine is provided with a lap belt which automatically

retracts. When pulled slowly, automatic belts ensure full freedom
of action, but block immediately, if you suddenly brake or
accelerate, or if you drive downhill or take corners.
Putting on the safety belt
1. Sit down on the driver's seat.
2. Slowly and continuously pull out the belt.
3. Insert the lock tongue into the lock socket until the lock
engages.
4. Then, pull the belt to check whether or not the lock tongue is
fully engaged.
NOTE
The belt cannot be pulled out unless it is completely wound
up.
Taking off the safety belt
Press the orange button to release the lock of the safety belt and
allow the belt to wind up.
3-44 WA100M-5 – VEAM280201

3.3.2. Starting the engine

1. Pull the parking brake lever.
2. Set the drive direction switch to its neutral position 'N'.
NOTE
You may only start the engine, if the driving direction switch
is set to the neutral position 'N'.
CAUTION
● Unintentional start-up of the engine may lead to severe
accidents!
● Before starting up the engine, make sure that there are
no persons or obstacles near the engine. In addition,
sound the horn before you start the engine.
3. Turn the ignition key to operating position 'I'.

0
❍ Fuel level (1) displayed. I
P
❍ The parking brake warning light (2) illuminates when the
parking brake is applied. II
❍ The charging current (3) and engine oil pressure (4)
warning lights illuminate.
❍ The air intake preheater control lamp (5) illuminates when 75_209
the air intake preheater is running.
5 2 3 4
The running period of the air preheater depends on the
ambient temperature. If the ambient temperature is low,
the preheating process may take more time.
4. Press down slightly the accelerator pedal.
5. If the control lamp of the air preheater has gone out, you can
turn the ignition key to the start position 'II' in order to start up
the engine.
NOTE 1
Do not operate the starter for longer than 15 seconds. If the

engine does not start up, wait at least two minutes before try-
ing a restart. If the engine does not start up after several
tries, find out the cause using the information indicated in
the chapter "4.6. Other troubles" on page 4-10.
6. Release the ignition key as soon as the engine started. It

automatically returns to the operating position 'I'.
7. Check whether all warning lights have gone out. Only the
control lamp of the intake air heater (5) remains lit for another
30 s at temperatures below 32°F (0°C).
WA100M-5 – VEAM280201 3-45

NOTE
For starting up the engine in cold weather, see chapter:
"3.5. Cold weather operation" on page 3-83.
Warming up the engine
NOTE
● You must not accelerate the engine abruptly before the
warm-up phase is finished.
● Do not let the engine run idle for longer than 20 minutes
at its lower or top speed. If it is necessary to let the
engine run idle for a longer time, you must load the
engine briefly from time to time or let it run at medium
speed.
Do not immediately begin with work after starting the engine. Prior
to operation, perform the following preparations and checks:
1. Press down slightly the accelerator pedal and let the engine
run without load at medium speed for approx. 5 minutes.
2. Proceed as follows in order to heat up the hydraulic oil at low

ambient temperatures:
Allow the engine to run consistently during the warm-up

phase. For warming the hydraulic oil, reset the multi-function
lever for the work hydraulic system in short intervals from
position '0' (holding) into position 'E' (tip-in position). Then
reset it to its '0' position.
Make sure not to exceed the maximum time (10 seconds)

permitted for the multi-function lever in the tip-in position.
3. While the engine is warming up, observe all measuring

instruments and warning lights and eliminate immediately any
fault.
4. Let the engine run with lightweight load further until the 1
engine coolant temperature indicator (1) lights up in the green
range.
5. Ensure that the exhaust gas colour is normal and that the
exhaust pipe produces neither abnormal noises nor vibra-
tions. Eliminate possible defects.
3-46 WA100M-5 – VEAM280201

3.3.3. Driving with the machine
Start-up
CAUTION
Careless driving may lead to accidents! Before starting to
drive, ensure that no persons are near the machine and
sound the horn before you drive up.
1. Start up the engine as described in chapter "3.3.2. Starting

the engine" on page 3-45
2. Raise the work unit into its transport position. If the work unit
is in transport position, the two red arrows of the transport
position marking on the lifting cylinder are next to each other.
3. Turn the lock lever for the work unit to position '1'. The boom
will then be blocked during rides on public roads and cannot
be moved.
4. Press down the brake pedal and hold it in this position.
5. Release the parking brake. Press the celebration adjustment

knob to this at the parking brake lever. Press down the lock-
ing button of the parking brake lever. The, release the locking
button. The parking brake warning light goes out.
WA100M-5 – VEAM280201 3-47

6. Set the drive direction switch to the desired direction setting.
Position F = Driving forward

Position N = Neutral
Position R = Reversing
NOTE
If you set the drive direction switch in to forward or reverse
driving, without having released the parking brake , the horn
will sound.
7. Release the brake pedal and press down the accelerator

pedal at the same time in order to start the machine.
Limiting the maximum speed
You can use the stepless speed regulator to set the maximum
speed of the machine, in all gears, to a value between slow 2
(regulator at position ‚0') and fast (regulator at position ‚10').
1
1. Stop the machine.
2. First set the speed regulator to the lowest speed level. To do

so, turn the speed regulator (1) to the left until it stops (posi-
tion ‚0').
G0070163.eps
3. Step on the accelerator pedal. The machine stays stationary.
4. Slowly turn the speed regulator to the right to increase the

speed to the desired maximum speed. The machine slowly
starts moving and accelerates to the speed that matches the
setting on the speed regulator.
5. Lock the speed regulator against being adjusted unintentio-

nally, by moving the locking device (2) to the right until it
stops.
NOTE
Depending on the surface of the road, the same speed
regulator settings can lead to different speeds.
3-48 WA100M-5 – VEAM280201

Starting the machine on slopes
CAUTION
Careless driving may lead to accidents! Before starting up,
ensure that no persons are near the machine and sound the
horn before driving.
1. Start up the engine as described in chapter "3.3.2. Starting

the engine" on page 3-45.
2. Make sure that the parking brake is pulled. The parking brake
warning light lights up.
3. Press down the brake pedal.
4. Release the parking brake.
5. Set the drive direction switch to the desired direction setting.

6. Press down the accelerator pedal and release slowly the

brake pedal at the same time in order to start the machine.
WA100M-5 – VEAM280201 3-49

3.3.4. Changing the driving direction
WARNING
Careless changes of the driving direction may cause severe
accidents!
Before you change the driving direction from forward to
reverse driving or vice versa, you must make sure that no
persons or obstacles are in your way.
CAUTION
The engine may be damaged if you are driving at a high
speed and then change abruptly from forward to reverse
driving or vice versa!
Brake until the machine has nearly come to a standstill
before you change the driving direction.
The drive direction switch is used to switch between forward and

reverse gear or vice versa. The machine may still roll, if you
change the driving direction.

Reverse driving
The machine can drive forward or backwards (reversing) at the

same speed.
Before driving backwards, make sure that nobody is in your way.

If necessary, rely on another person for aid. Sound the horn
before starting to drive to make sure, that anybody who might be
in your way is appropriately warned.
While driving backwards, turn your head into the driving direction.
It is not sufficient to rely on the rear view mirrors.
3-50 WA100M-5 – VEAM280201

3.3.5. Turning and steering
NOTE
● The machine may fall over if you turn abruptly at a high
speed.
● If the machine is halted during the ride, the servo-

assisted steering will be deactivated. You may then only
proceed with steering the machine with considerably
higher effort.
Turning on slopes, dams or hills
Keep sufficient distance to ridges and steep slopes. There is

slopes, embankments, or hill flanks. The limiting values are
defined in chapter "6.4. Limit values for slopes" on page 6-5.
Do not turn on a slope or drive across a slope. Turn or cross the

section only level ground. When driving on slopes, avoid driving
on grass, fallen leaves, or steel plates. Driving sideways on these
surfaces types may result in the machine sliding. Drive very
slowly and carefully.
To keep the centre of gravity as low as possible when driving on

slopes, embankments, and hill flanks, you must set the bucket to
a position just above the ground (approx. 7.874 to 11.811 inch
(200 to 300 mm)). In the event of an emergency, displace the
bucket fast on the bottom in order to stabilise the engine.
WA100M-5 – VEAM280201 3-51

3.3.6. Braking
While driving, you may reduce your speed with the service brake
(1).
3
After the machine has stopped, you must secure it with the 1
parking brake (2).
Pulling the parking brake
1. Press the locking button.
2. Pull up the parking brake lever.
3. Release the locking button. The control lamp of the parking

brake lights up.
Releasing the parking brake 2
1. Lift up the parking brake lever a little.
2. Press the locking button.
3. Push the parking brake lever down.
4. Release the locking button. The control lamp of the parking

brake goes out.
Braking with the service brake
If the braking delay is not sufficient by relieving the pressure from

the accelerator pedal, you must brake the machine with the
service brake. For this purpose, press down the brake pedal.
The service brake (1) can also be used to adapt the driving speed
to the respective driving and operating situation (3), independent
of the accelerator pedal position.
If it is required to press down the accelerator pedal completely, in

order to be able to use the full-load output of the engine of the
work hydraulic system, you can nevertheless use the brake pedal
to reduce the speed of the machine or to stop it completely.
If the service brake breaks down
If the machine is not stopped after pressing down the brake pedal,
you must use the parking brake.
3-52 WA100M-5 – VEAM280201

Braking on slopes
CAUTION
● The service brake may overheat and be damaged while
driving downhill!
Let the engine run while driving downhill. If required,
brake in addition using the brake pedal.
● Danger of accidents due to unintentional braking!

Do not use the brake pedal as a foot rest.
If you use the service brake too often while driving downhill, it
may overheat and be damaged.
You can avoid this by driving downhill in the lower speed range
and by using the braking effect of the engine.
WA100M-5 – VEAM280201 3-53

3.3.7. Stopping the machine

Avoid abrupt stopping. Proceed as follows, if you want to stop the
machine:
1. Release the accelerator pedal and press down the brake

pedal.
2. Set the drive direction switch into its neutral position 'N'.
3. Apply the parking brake.
4. Lower the work unit onto the ground.
WARNING
● Unintentional activation of the multifunctional-lever or
moving of the equipment may lead to accidents!
● Before you leave the cab, turn the locking lever for the
work hydraulic system into position '1'. As a result, the
work hydraulic system is blocked.
5. Protect the work hydraulic system against unintentional

activation by turning the locking lever of the work hydraulic
system into position ‘1’..

Parking the machine on a slope
Whenever possible, stop the machine on level ground.
● If you have to park the machine on a slope, it is required that

you park it in such a way that the front section (work unit)
points downhill.
● Lower the work unit onto the ground (1).
● Block the wheels with wheel chocks (2).
3-54 WA100M-5 – VEAM280201

3.3.8. Operating the work equipment

Multifunctional lever
The work unit is operated with the multifunctional lever. The multi-
functional lever has 6 positions which control the work unit as fol-
lows:
SW Float The multifunctional lever is locked in

â this position. The floating position is
provided for planing operations
(removing subsoil). In this switch posi-
tion, the work unit is lowered by its
own weight, and can be freely oper-
ated by external parties.
ç
S Lower The boom is lowered in this position.
If the engine is switched off, you can
lower the boom in this position.
0 Hold
å The boom is held in position.
ã
H Raise The boom is raised in position.
ä
E Tilt In this position, the bucket is tilted.
à
A Dump In this position, the bucket is dumped.
WA100M-5 – VEAM280201 3-55

Control lever for special equipment
The control lever for special equipment has three switch settings
whose functions depend on the type of the used special equip-
ment.
● If the standard bucket, the light-weight material bucket or the

forklift truck attachment is attached to the quick-change unit,
the control lever for special equipment provides the following
functions:
Position 1 = Locking pins for work unit are drawn in

Position 0 = Neutral position (locking pins are drawn in; you
can pick up the work unit in this position)
Position 2 = Locking pins for work unit are extended
● If the multi-purpose bucket is attached to the quick-change

unit, the control lever has the functional assignment
described above. If the switching lever for the bucket is in 2
position ‘1’, the multi-purpose bucket is active. You can then
operate the multi-purpose bucket via the control lever for spe-
cial equipment.
It then has the following functions: 1

Position 0 = Neutral position 75_160
● If you use attachments requiring a steady oil flow (e.g. brush,

snow remover), the control lever has the following functions:
Position 1 = Work unit turns backwards

Position 2 = Work unit turns forward
Position 3 = Work unit turns forward in permanent opera-
tion (locks in
● For permanent operation, you must set the control lever to

position ‘3’. The control lever locks in this position.
NOTE
Without connected special equipment, you must not set the
control lever for special equipment to switch settings ‘1’, ‘2’
or ‘3’. If you do not heed this note, the work hydraulic system
will operate in order to counteract overpressure thus unnec-
essarily heating up the oil.
3-56 WA100M-5 – VEAM280201

Switching lever of bucket
If you have the multi-purpose bucket attached to the machine, 2

you can use this switching lever to change the function assign-
ment of the control lever for special equipment.
Position 1 = the control lever for special equipment oper- 1

ates the multi-purpose bucket.
ates the quick-change unit. 75_160
WA100M-5 – VEAM280201 3-57

3.3.9. Working with the wheel loader

Tyre-appropriate operation
Removing heaps of loose soil or rock debris may cause prema-
ture wear and tear of the tyres due to cracks and small fissures.
As a result, the service life of the tyres is reduced. Proceed as fol-
lows to avoid unnecessary wear and tear of the tyres:
● Try to work on level ground and remove any rocks and large
stones which are sticking out of the surface.
● Always drive in straight direction into the heap or slope. This
ensures that you have always the largest intrusive force while
reducing tyre wear and tear at the same time.
● Drive slowly when removing agglomerated material and when
loading blasted solid rock (speed range 1).
● For removing operations, lift the bucket as soon as you drive
into the heap or slope. This procedure permits to increase the
load of the front wheels, prevents slipway of the front wheels
and reduces wear and tear of the tyres.
● Lower the bucket slowly onto the ground. If the bucket
touches the ground too fast, the front wheels may be lifted
from the ground, thus leading to premature wear and tear of
the rear tyres.
● To prevent the front wheels from skidding, it is recommended
to set the ground pressure of the front wheels as high as pos-
sible. Therefore, immediately lift the bucket a little after run-
ning into the heap or slope.
Switching on the 100 % differential lock (if

equipped)
On soft, slippery ground the forward thrust can be improved by

engaging the differential lock. It takes effect on all four wheels.
To engage the differential lock, press and hold the button (1) on
the multifunction lever.
NOTE
1
The differential lock may only be switched on when the
machine is in standstill.
If the differential lock is on, the control lamp (2) of the instrument
panel is lit.
2
If only one wheel on an axle turns when you start to drive with the
differential lock engaged, stop and correct the steering until the
lock engages properly.
To disengage the differential lock, release the button (1) on the
multifunction lever.
The differential lock can be disengaged while you are driving.
DANGER
When you drive in curves on hard ground, the differential
lock has to be switched off.
3-58 WA100M-5 – VEAM280201

Loading work
CAUTION
Danger of accidents! The machine may fall over if you trans-
port a load with the bucket lifted too high!
Lower the bucket during transporting loads in order to lower
the centre of gravity of the machine.
The loading operation of wheel loaders is based on the following

cycle:
Removing or digging Æ Transport Æ Dumping
In the following sections, the individual operation steps of this

cycle are explained.
Removal work
CAUTION
If you perform removal operations with bent machine, you
may damage the articulated steering and the cardan shaft!
Always drive into the material which you want to remove in
straight direction.
For removal operations, adhere to the instructions in section

"Tyre-appropriate operation" on page 3-58. For removal
operations, proceed as follows:
1. Drive in straight line to the piled up soil.
2. While driving forward, lower the bucket rapidly until it reaches

a height of approx. 11.811 inch (30 cm) over the ground and
hold the bucket in this position.
NOTE
If the bucket touches the ground, the front wheels may be
lifted from the ground, resulting in premature wear and tear
of the rear wheels.
3. Then, proceed with slowly lowering the bucket onto the

ground.
4. Brake right in front of the material to be removed using the

service brake, while pressing down the accelerator pedal at
the same time.
5. Press down the accelerator pedal and drive the bucket into
the material to be removed. In order to remove the material, it
is required that you align horizontally the cutting edge of the
bucket while driving into the material.
WA100M-5 – VEAM280201 3-59

When you are loading rock debris, it is necessary to dump the

bucket slightly down.
While removing rock debris, ensure that no rock gets under
the bucket. This may lead to the front wheels being lifted from
the ground, thus resulting in premature wear and tear of the
rear wheels.
Always hold the load in the centre of the bucket. If the load is
shifted to one side, the equilibrium of the machine will be
impaired.
6. To prevent that the bucket dig in too deep into the material to
be removed, you must lift the boom while driving into the
material. Lifting the boom ensures a sufficient thrust force.
7. Tip in the bucket.
8. If there is too much material inside the bucket, you must

briefly tip it in, dump it and lower it in order to reduce the load
and to prevent that you lose the load during the transport.
3-60 WA100M-5 – VEAM280201

Excavation work
During excavation work, ensure that you do not load the bucket
only on one side, as the equilibrium of the machine may be
impaired.
1. Drive up to the soil heap in a straight line.
2. Slow down the machine using the service brake while

keeping the accelerator pedal pressed down at the same
time.
3. Bend the bucket edge slightly down.
4. While driving forward, move slightly the multi-function lever of

the boom in order to remove only a thin layer of the surface of
the soil to be removed.
5. Move the multi-function lever of the boom slightly up and

down to reduce the resistance during driving forward.
While removing, ensure that the digging force is not applied

only on one side of the bucket.
WA100M-5 – VEAM280201 3-61

Planing
Planing operations are required for levelling the ground. For this
purpose, a straight bucket without claws is suitable. Planing
includes two operation steps - filling up and taking off ground.
Filling up
It may be necessary to fill up the uneven ground in front of the

machine with soil. Proceed as follows:
NOTE
For fill-up operations, lower the bucket max. by 15° to the
front.
Fill the bucket with soil. Drive slowly forward with the machine and
distribute the soil little by little from the bucket. If you must fill up
particularly large uneven surfaces, you should place additional
soil in front of the bucket, which will be distributed when the
machine is driving forward.
Taking off soil
If the surface is filled up, you may level the ground.
WARNING
Danger of accidents! Careless reverse driving may lead to
severe accidents!
Before you drive backwards, make sure that nobody is
behind the machine. Warn persons who are in your way by
sounding the horn.
Dump the bucket slightly down. Drive backwards and draw the
bucket over the ground.
In order to receive a particularly even surface, you must lower the

boom to its floating position. Drive slowly backwards and draw the
bucket with its plane underside over the ground.
Prospecting
Prospecting is a special type of planing. It is used to wear off the

top layer of soil.
CAUTION
The bucket teeth and bucket are damaged if you mine with
the bucket in dumping position!
For prospecting operations, align the underside of the
bucket until it is in parallel to the ground surface.
Always drive in the lower speed range while performing prospect-

ing operations.
3-62 WA100M-5 – VEAM280201

Transporting
Make sure that the transport route is in perfect condition and that
nobody is in your way. Remove any rocks or large stones which
have fallen down out of the operating range (described in chapter
"Tyre-appropriate operation" on page 3-58). Hold the bucket in
tip-in position. Lower the boom to its transport position. If the
boom is in transport position, the two red arrows of the transport
position marking on the bucket cylinder will be next to each other.
CAUTION
Only move the work equipment against the tilt-in limit stop
when in transport position.
Unloading
Always select the dumping/unloading type with the smallest

turning circle and driving effort in order to work as efficiently as
possible.
WARNING
Danger of accidents! If you turn or brake abruptly with the
lifted load, the load may fall out of the bucket and cause
accidents!
Turn slowly with the load lifted and brake cautiously.
CAUTION
The bucket and the machine are damaged if you drive into a
heap of soil or rocks with high speed!
Drive slowly into a heap of soil or rocks.
Avoid any excessive shaking of the bucket. Always operate

with respect to the condition of the tyres (see section "Tyre-
appropriate operation" on page 3-58).
Loading in diagonal direction
Align the machine in rectangular position to the heap. Drive the

machine backwards in straight line after you have filled the
bucket. Then, let the dump truck drive between heap and
machine. Drive up to the dump truck and unload the material.
This operation requires not much time and reduces considerably

the cycle times.
WA100M-5 – VEAM280201 3-63

V-shaped loading
Position the dump truck in such a way that the angle between the
dump and the dump truck is approx. 60°. Fill the bucket and
shake it. This leads to a better distribution of the cargo in the
bucket and prevents that material falls down to the back. Drive the
machine backwards from the heap and align the machine with the
dump truck. Raise the bucket to its maximum height. Drive up
forward to the dump truck and unload the material.
If you keep the turning angle of the machine as small as possible,

the work will be more efficiently.
Piling up material
Do not position the bucket in its maximum tip-in or dumping posi-

tion while piling up material. Instead, use the required mining
angle. The rear counterweight must not touch the ground.
Working with the forklift truck attachment
Operations with an forklift truck attachment on a wheel loader dif-

fer from operations with the bucket or a forklift truck. Take into
account the following notes and the instructions indicated in the 19.685 in
chapter "2.1. General safety measures" on page 2-2. (500 mm)
● Do not take up loads which are so high that you cannot see
19.685 in
onto the route.
(500 mm)
● Hold the fork tines of the forklift truck attachment as horizontal
as possible when you take up the load.
75_156
● During the ride, hold the load as low as possible in order to
have free sight onto the route.
● Always drive slowly (speed range 1) with the load.
● The boom performs a semicircular stroke while performing

the lifting movement. Raise the boom only immediately in
front of the place at which you want unload to the height at
which you want to unload. In such a way, you prevent that you
damage the load while lifting it.
● Hold the forklift truck attachment as horizontal as possible

while piling up.
3-64 WA100M-5 – VEAM280201

Picking up the load
1. Drive slowly up to the load to be picked up.
WARNING
Danger of accidents! If the load does not lie in centre of grav-
ity, the stability of the machine is impaired.
Drive under the load until it is touching the fork back of the
2. Drive so far under the load until it touches the fork back of the
3. Tip in slightly the forklift truck attachment so that the load can-
not fall down.
4. Lower the boom to its transport position. The two red arrows
of the transport position marking on the bucket cylinder will
then be lined up next to each other.
5. Then lift the load to the appropriate height only shortly before
you reach the stacking surface. Raise the load a little higher
than necessary.
6. Set the load surface slowly and from above onto the stacking.
7. Slowly lower the boom so far that you can pull out the fork
tines below the load.
8. Make sure that nobody is behind the machine and drive off
backwards from the stacking surface.
WA100M-5 – VEAM280201 3-65

3.3.10. Precautions for special operations
Permissible water depth
While operating in water or on swampy ground, the water must

not reach the underside of the axle housing.
Wash the machine after the work has been finished and check the
lubricating points.
Working on snow
Adhere to the instructions in the chapter "Working on snow" on

page 2-14.
Dumping on steep slopes
Adhere to the instructions in the chapter "Loading" on page 2-14.
Working in the vicinity of electrical overhead lines
Adhere to the instructions in the chapter "Working close to power

lines" on page 2-13.
Operation on slopes
Adhere to the instructions in the chapter "Driving on slopes" on

page 2-11.
Working on loose soil
Adhere to the instructions in the chapter "Working on loose soil"

on page 2-15.
If the service brake breaks down
If the machine is not stopped after pressing down the brake pedal,
you must use the parking brake.
3-66 WA100M-5 – VEAM280201

Precautionary measures when driving up or down
Turning on slopes, dams or hills
Keep sufficient distance to ridges and steep slopes. There is

slopes, embankments, or hill flanks. The limiting values are
defined in chapter "6.4. Limit values for slopes" on page 6-5.
Do not turn on a slope or drive across a slope. Turn or cross the

section only level ground. When driving on slopes, avoid driving
on grass, fallen leaves, or steel plates. Driving sideways on these
surfaces types may result in the machine sliding. Drive very
slowly and carefully.
To keep the centre of gravity as low as possible when driving on

slopes, embankments, and hill flanks, you must set the bucket to
a position just above the ground (approx. 7.874 to 11.811 inch
(200 to 300 mm)). In the event of an emergency, displace the
bucket fast on the bottom in order to stabilise the engine.
Braking on slopes
Adhere to the instructions in the chapter "Braking on slopes" on

page 3-53.
WA100M-5 – VEAM280201 3-67

Precautionary measures during machine travel
If the machine is driven over long routes at a high speed and

without having adapted the tyre pressure, the tyres will become
very hot.
This leads to premature wear and tear of the tyres which should
be avoided if possible. Adhere to the following instructions if you
must drive the machine over a long distance:
● Perform all pre-start checks before starting to drive (see

chapter "3.3.1. Pre-start checks" on page 3-34).
● Fix supplementary hand tools before starting to drive.
● The required tyre pressure, the driving speed or the tyre type
may vary depending on the condition or structure of the road
o be used. Contact the responsible Komatsu trader or the tyre
dealer to obtain the required information.
● The required tyre pressure can be found in the tyres and tyre
pressure table in chapter "3.3.16. Tyre handling" on
page 3-77.
● Check the tyre pressure with the tyres being cold before
driving.
● Lower the work unit to its transport position and move it

completely to its rear limit stop position.
● Always drive with empty bucket or empty forklift truck

attachment.
● Adhere to the valid motor vehicle traffic regulations and drive

very careful. Make sure that the working lights and the
warning beacon are turned off while driving on public roads.
● Take a 30 minute break after driving for one hour. Check the
tyres and all particularly strained parts during driving on public
roads whether they are still fully functioning or damaged.
3-68 WA100M-5 – VEAM280201

3.3.11. Adjusting the position of the work equipment
Selecting a work unit
Refer to chapter "1.10. CE-conforming equipment" on page 1-24

for information on the work units registered.
Picking up the work unit (except multi-purpose

bucket)
Connect the multi-purpose bucket as described in section "Pick-
ing up the multi-purpose bucket" on page 3-72.
1. Make sure that the change-over lever for the additional con-
trol unit is in position '2' (fig. 75_160).
2
2. Start the engine.
75_160
3. Unlock the quick-change unit by setting the control lever for

special equipment into position ‘1’ (fig. G0065018.eps).
4. Lift the boom a slightly by setting the multi-function lever into

position ‘H’ (fig. G0065021.eps).
5. Tilt the quick-change unit a slightly to the front by setting the

multi-function lever into position ‘A’ (fig. G0065021.eps)
WA100M-5 – VEAM280201 3-69

6. Drive the machine to the work unit until the quick-change unit
(3) is below the pickup hooks of the work unit. Then, lift the
boom until the work unit catches the quick-change unit. 3
75_280
7. Tip in the quick-change unit until the work unit is connected to

the limit stops on the the quick-change unit by setting the
multi-function lever into position ‘E’ (fig. G0065021.eps).
8. Lock the quick-change unit by setting the control lever for

The interlocking pins (4) will then be visible (fig. 75_280).
WARNING
If the work unit is not properly attached, it can suddenly fall
down and cause severe accidents!
Carefully lift the work unit and check whether it is completely
locked in by tipping it in and then dumping it.
9. Check whether the work unit is completely locked by tipping it

in and then dumping it.
3-70 WA100M-5 – VEAM280201

Removing the work unit
1. Lower the work unit onto level ground.

3. Set the quick-change unit into the dumping position ‘A’ using
the multi-function lever, until the quick-change unit is
unhooked of the work unit's pickup hooks.
4. Make sure that nobody is behind the machine and drive the
machine away from the work unit.
WA100M-5 – VEAM280201 3-71

Picking up the multi-purpose bucket
1. Set the change-over lever for the additional control unit into 2
position '2' (fig. 75_160).

1
75_160

4. Lift the boom slightly, by setting the multi-function lever into

position ‘H’ (fig. G0065021.eps).
5. Tilt the quick-change unit slightly to the front by setting the

multi-function lever into position ‘A’ (fig. G0065021.eps)
6. Drive the machine to the work unit until the quick-change unit
(1) is below the pickup hooks of the work unit. Then, lift the
boom until the work unit catches the quick-change unit.
7. Tip in the quick-change unit until the work unit is connected to

the limit stops on the the quick-change unit by setting the
multi-function lever into position ‘E’ (fig. G0065021.eps).
8. Lock the quick-change unit by setting the control lever for

3-72 WA100M-5 – VEAM280201

10. Set the change-over lever for the supplementary control cir-
cuit in position ,1' to its limit stop (figure 75_160).
2
75_160
11. Set the control lever for special equipment to position ,1' (fig-
ure G0065018.eps).
12. Connect the hydraulic hoses of the multi-purpose bucket to

the quick couplings (2) (figure 75_161) and (3) (figure
75_275).
1
You can now operate the multi-purpose bucket with the con-
trol lever for special equipment (figure G0065018.eps). 2

75_161
WARNING
If the work unit is not properly attached, it can suddenly fall
down and cause severe accidents.
Carefully lift the work unit and check whether it is completely
locked in by slowly tipping it in and dumping it. 3
14. Check whether the work unit is completely locked by tipping it

in and then dumping it. 75_275
WA100M-5 – VEAM280201 3-73

Removing the multi-purpose bucket
1. Lower the multi-purpose bucket onto level ground.
3. Set the control lever for special equipment first to position ‘1’
and then to position ‘2’ (figure G0065018.eps).
4. Turn the change-over lever for the supplementary control cir-

cuit to position ‘2’ until it reaches the limit stop (figure
75_160). 2
5. Disconnect the multi-purpose bucket hoses from the quick

couplings.
6. Restart the engine. 1

75_160
8. Set the quick-change unit into the dumping position ‘A’ (fig.
G0065021.eps) using the multi-function lever, until the quick-
change unit is unhooked of the work unit's pickup hooks.
9. Make sure that nobody is behind the machine and drive the
machine away from the work unit.
Level indicator for the bucket
On both sides of the bucket the upper edges (see arrow) are
arranged in parallel to the bucket edge and can be used as a level
indicator for the bucket.
You can recognise the position of the cutting edge of the bucket
from the driver’s seat with the help of the level indicators.
3-74 WA100M-5 – VEAM280201

3.3.12. Parking the machine

Avoid abrupt stopping. Proceed as follows, if you want to stop the
machine:
1. Release the accelerator pedal and press down the brake

pedal.
2. Set the drive direction switch into its neutral position 'N'.
3. Apply the parking brake.
WARNING
● Unintentional activation of the multifunctional-lever or
moving of the equipment may lead to accidents!
● Before you leave the cab, turn the locking lever for the
work hydraulic system into position '1'. As a result, the
work hydraulic system is blocked.
5. Protect the work hydraulic system against unintentional

activation by turning the locking lever of the work hydraulic
system into position ‘1’..

Parking the machine on a slope
● Whenever possible, stop the machine on level ground. If you

have to park the machine on a slope, it is required that you
park it in such a way that the front section (work unit) points
downhill.
● Lower the work unit onto the ground (1).
● Block the wheels with wheel chocks (2).
WA100M-5 – VEAM280201 3-75

3.3.13. Switching off the engine
NOTE
If you switch off the engine abruptly after heavy operations
without prior cool down period, the service life of the engine
may be severely impaired. It is recommended to switch off
the engine abruptly only in the event of an emergency.
1. Check the temperature of the engine with the help of the

coolant temperature indicator (1).
2. If the engine is overheated, you must let it run at medium

speed or 5 minutes before you switch it off, so that the engine
can cool down sufficiently.
3. Lower the work unit.
4. Turn the ignition key into its stop position '0' in order to switch
off the engine.
1
5. Pull the key from the start switch.
3.3.14. Check after stopping the engine

1. Walk around the machine and visually inspect the work unit,
the car body and the chassis. In addition, pay attention to
emerging oil and water. Eliminate immediately any fault or
defect.
2. Fill up the fuel tank.
3. Remove highly flammable material from the engine room

since it represents a fire risk.
4. Clean the chassis landing gear roughly.
3.3.15. Locking
Lock the following places:
1 Engine hood
2 Cab doors
1
NOTE
The ignition key fits all locks.
3-76 WA100M-5 – VEAM280201

3.3.16. Tyre handling
Precautionary measures when handling tyres
If the following defects are found in tyres, they must be replaced

for safety reasons. Tread
● Bead wire is broken or bent, or the tyre is greatly deformed. Breakers

Sidewalls
● Excessive wear and the carcass ply (excluding breaker) is
exposed for more than 1/4 of the circumference.
● Damage to the carcass exceeds 1/3 of the tire width.
● Tyre layers are separated. Beads

Carcass
● Radial cracks reach the carcass.
● Deformation or damage which makes the tyre unsuitable for

use.
Tyre pressure
Measure the tyre pressure before starting the machine operation,

when the tyres are cool.
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. To prevent these
problems, adjust the tyre inflation pressure according to the table
on the next page.
● For operations on normal road surfaces, rock digging

operations:
____________ Upper range values in air pressure chart
● Stockpile operations on soft ground:
____________ Average pressure values in air pressure chart
● Operations on sand (operations not using much digging

force)
____________ Lower range values in air pressure chart
H–h
Deflection ratio = ------------- × 100
H
As a guideline for visual inspection, the deflection ratio of the front

tyre (deflection/free height) is as follows:
When carrying normal load (lift arm horizontal): approx. 15 - 25%
When digging (rear wheels off ground): approx. 25 - 35%
WA100M-5 – VEAM280201 3-77

When checking the tyre inflation pressure, check also for small
scratches or peeling of the tire, for nails or pieces of metal which
may cause punctures, and for any abnormal wear.
Clearing fallen stones and rocks from the working area and main-
taining the surface will extend the tyre life and improve the eco-
nomical case of the machine..
TYRES RECOMMENDED AIR PRESSURE
Manufacturer Designation Tread Front axle Rear axle
bar psi bar psi
DUNLOP 16/70-20 E91-2 2.5 36 2 29

DUNLOP 405/70R20 SPT9 3 44 2.6 38
DUNLOP 455/70R20 SPT9 2.75 40 2.2 32
DUNLOP 405/70R24 SPT9 3 44 2.75 40
DUNLOP 16/70-24 E91-2 2.5 36 2 29
DUNLOP 455/70R24 SPT9 2.5 36 2 29
CONTI 455/70R24 MPT,70E 2.5 36 2 29
BARUM 405/70R24 NB38 3 44 2.75 40
CONTI 405/70R20 MPT,70E 3 44 2.4 35
GOODYEAR 400/70R24 IT530 2.8 41 2.2 32
GOODYEAR 400/80R24 IT520 2.5 36 2 29
BRIDGESTONE 405/70R20 VUT 3 44 2.4 35
BRIDGESTONE 17,5/65-20 FG 2.5 36 2 29

MICHELIN 405/70R20 XZSL 3 44 2.5 36
MICHELIN 15,5R25 XTLA 3 44 2.25 33
MICHELIN 15,5R25 XHA 3 44 2.25 33

MICHELIN 425/75R20 XZSL 2.5 36 2 29
MICHELIN 425/75R20 XM27 2.5 36 2 29
The specified air pressure values might deviate from the standard values under special conditions. If this is the
case, please contact an authorised Komatsu dealer.
Correct inflation pressure levels have a significant impact on the service life and efficiency of the tyres. Only cor-
rect inflation pressures protect the tyres from getting damaged. Should the pressure rise as a result of heating, do
not deflate the tyres. Check and adjust inflation pressures before moving off, i.e., with the tyres cold.
In extremlely severe applications and in load and carry applications involving lenghty hauls, the correct inflation
pressure should be determined by the respective tyre manufacturer or an authorised service outlet on the spot.
If the deflection of the tyre is excessive, raise the inflation pressure accordingly (see section "Tyre pressure" on
page 3-77).
3-78 WA100M-5 – VEAM280201

Operation 3.4. Transporting the machine
3.4. Transporting the machine

If you have to transport the machine over far distances, either use
a low bed loader or a railway wagon. You may lift the machine
onto the transport vehicle. Optionally, you may drive it onto the
low bed loader or railway wagon via loading ramp (also refer to
"2.2.3. Transport" on page 2-18). Before you start driving, check
that the following requirements are fulfilled: the roads are broad
enough, the bridges are wide enough, the clearance heights of
tunnels and the like are sufficient, the carrying capacities of roads
and bridges are sufficient.
When transporting the machine, observe all related laws and reg-
ulations, and be careful to assure safety.
3.4.1. Securing the articulated steering

Secure the articulated steering before you lift up the machine or
start to perform repair measures.
1. Set the machine to straight driving.

1
spring bolt.
WA100M-5 – VEAM280201 3-79

3.4. Transporting the machine Operation
3.4.2. Lifting the machine
CAUTION
● Danger of pinching! An unlocked articulated steering
may suddenly move! Secure the articulated steering
before you lift up the machine.
● Danger of accidents! Carrying ropes with insufficient car-
rying capacities may tear so that the machine may fall
down! Only lift up the machine using carrying ropes with
sufficient carrying capacities.
● Hoisting equipment with insufficient carrying capacities
may suddenly bend and cause severe accidents! Only
us e h oi st i ng e qu ip me nt c apa bl e of c ar r y ing t he
machine's operating weight.
● Objects lying on the machine may fall down and cause
injuries when the machine is lifted up! Remove all loose
objects from the machine before you lift up the machine.
CAUTION
Incorrectly attached ropes may damage the machine! Only
fasten the eye hooks of the carrying ropes at the marked
attachment points.
There are two attachment points each at the front part and the
rear part of the machine. These attachment points are shown in
the following figure. Information signs attached to the machine
indicate the attachment points.To avoid damage to the machine,
attach the eye hooks only to the attachment points.
When selecting the lifting equipment, take the operating weight of
the machine into account. Insufficient carrying capacities of the
lifting equipment may cause severe accidents. Also use carrying
ropes with appropriate carrying capacities for the operating
weight of the machine. Carrying ropes with insufficient carrying
capacities may tear when the machine is lifted up and cause
severe accidents. The operating weight of the machine depends
on the attached bucket.
3-80 WA100M-5 – VEAM280201

Operation 3.4. Transporting the machine
3.4.3. Driving the machine onto loading area of transport vehicle
WARNING
If the transport vehicle or the loading ramp starts skidding
while you are driving up the loading ramp, the machine may
fall off the ramp and cause severe accidents! Secure the
transport vehicle against accidental movement. Secure the
wheels of the low bed loader with wheel chocks or wedges.
The transport vehicle for the machine must have an appropriate

work load. The operating weight of the machine depends on the
attached equipment. The operating weights of the machine can
be found in the respective table in the chapter "1.9. Dimensions,
weights and operating data" on page 1-23"
● The articulated steering must be unlocked before the

machine is driven onto the transport vehicle to ensure that the
machine remains steerable.
● Remove any mud, snow, or ice adhering to the wheels to

ensure that you can drive onto the ramps without danger of
skidding.
● Do not load the machine via landing stage unless you have
checked that the landing stage is broad enough and that its
strength is sufficient to carry the load.
● The loading ramps (3) must be aligned to the wheel tracks (5)
of the machine.
● The ramps must be long enough to ensure that the maximum

loading gradient (4) of 15% is not exceeded. Support the
loading ramps by placing support blocks (2) under both 3
ramps.
● Make sure that the transport vehicle may neither tip over, start
to skid, or roll away while you are driving it onto the transport 4 1
vehicle. Secure the wheels of the low bed loader with wheel
chocks (1) or wedges. 5 2
● Position the machine straight in front of the loading ramp and

slowly drive up the loading ramp. Do not perform steering
movements on the ramp.
● If required, drive off the ramp, correct the position of the

machine on the ground and drive up the ramp again.
WA100M-5 – VEAM280201 3-81

3.4. Transporting the machine Operation
3.4.4. Securing the machine during the transport
DANGER
If the machine is insufficiently secured, it may start to skid or
fall off the transport vehicle and cause severe accidents!
Always secure the machine with ropes and wheel chocks or
wedges to avoid falling down and skidding.
CAUTION
Stay ropes that are incorrectly attached may damage the
machine! Only fasten the eye hooks of the stay ropes at the
marked attachment points.
● When the machine is on the loading area of the transport

vehicle, secure the articulated steering as described in the
chapter "3.4.1. Securing the articulated steering" on
page 3-79.
● Then, block the wheels of the machine with wheel chocks or

wedges and secure the machine with ropes in such a way
that it will neither start to skid nor tip over during transport.
● To avoid damage to the machine, only fasten the eye hooks

of the stay ropes at the marked attachment points.
● The attachment points to be used are the two eye hooks at

the front frame and the tie bolt at the rear frame of the
machine. The positions of the attachment points are shown in
the figure on the previous page.
3.4.5. After transport

● After transport, remove all securing devices, such as wheel
chocks or wedges and ropes.
● Remove the catch of the articulated steering before you drive

the machine off the transport vehicle. For this purpose,
reverse the steps 1 through 4 described in the chapter
"3.4.1. Securing the articulated steering" on page 3-79.
3-82 WA100M-5 – VEAM280201

Operation 3.5. Cold weather operation
3.5. Cold weather operation
3.5.1. Before the cold season

Before the cold season begins, you should perform the following
preparatory measures to ensure troublefree operation also in the
winter months.
● The machine is provided with a aluminium radiator. There-

fore, the cooling system must be set to -34.6°F (-37°C) for the
whole year.
● Use oils with the prescribed viscosities which are suitable for
the cold weather to be expected in your region (see
"5.3. Lubricants, fuels and filling capacities" on page 5-18).
● Fill up with winter diesel fuel. At low temperatures, paraffin

deposits of diesel fuel may block the filters and lines (see
"5.3. Lubricants, fuels and filling capacities" on page 5-18).
● If the injection system, the starter, the battery and the genera-
tor are in perfect condition, it is ensured that the engine can
be easily started and that the machine can be operated trou-
blefree even in extremely cold weather. Let these important
components be checked at an authorised garage before the
winter starts.
● Insufficient compression pressure impairs the start-up behav-

iour of the engine, especially at low temperatures. Let the
compression pressure be measured at an authorised garage.
● If the speed is continuously increased, the starter may remain

switched on until the engine finally starts up.
● Let the engine warm up with increased idle speed for some
minutes before starting to work. During the warm-up phase,
operate the hydraulics devices several times without load.
● Add a standard antifreeze to the water in the windshield

washer assy. If required, add 25 vol. % of alcohol (spirit) to
the water.
WA100M-5 – VEAM280201 3-83

3.5. Cold weather operation Operation
3.5.2. Precautions after completion of work

Realise the following actions to make sure that the machine can
be started the next time without problems:
● Remove mud and water from the car body. This prevents that
sealings are damaged due to freezing.
● Park the machine on hard and dry ground. If this is not possi-
ble, you must park the machine on wooden planks. The
planks prevent that the wheels are freezing to the ground.
● Drain off collected water from the fuel system.
● The battery capacity drops clearly at low temperatures.

Therefore, dismount the battery in frost periods and store it in
a warm place. Re-install it the next morning, before starting to
work.
3.5.3. After the cold season

If the weather becomes warmer, you must fill up the prescribed
fuel and use oils with prescribed viscosities (see chapter
"5.3. Lubricants, fuels and filling capacities" on page 5-18.
3-84 WA100M-5 – VEAM280201

Operation 3.6. Long-term storage
3.6. Long-term storage
3.6.1. Before storage

Perform the following actions, if the machine is to be shut down
over a longer period of time:
● Clean the entire machine, including the engine room, and let
it dry.
● If possible park the machine at a dry, roofed location. A sup-

plementary cover with a canvas cover is recommended.
● If the machine must be parked outside, you need to put

wooden planks on the ground on which the machine is to be
parked and covered with a canvas cover.
● Fill up the fuel tank. Lubricate the machine and change the
oils.
● Apply a thin grease film to the piston rods of the hydraulic cyl-
inders.
● Disconnect the negative terminals of the battery. Cover the

battery or remove it and store filled up and completely
charged it in a dry room which is frost-free in winter.
● Check whether the coolant is set to a temperature of -34.6°F

(-37° C). Refill antifreeze, if necessary.
3.6.2. During storage

Perform the following actions in order to keep the machine in
operating condition during the standstill:
CAUTION
Danger of poisoning, if the engine is run in-doors! Open the
windows and doors before you start the engine in-doors.
● Let the engine run once a month.
● Wipe away the grease from the piston rods of the hydraulic
cylinders.
● Drive the machine over a short route so that the movable

parts are coated with a new oil film.
● Recharge the battery.
WA100M-5 – VEAM280201 3-85

3.6. Long-term storage Operation
3.6.3. After storage
NOTE
If the machine was not moved once a month, contact the
responsible Komatsu trader to arrange a maintenance
appointment.
After a longer standstill period, perform the following works before

starting up the machine:
● Remove the grease from the piston rods of the hydraulic cyl-
inders.
● Check the oil levels and, if necessary, refill oil.
● Lubricate the machine, see chapter "5.6. Maintenance sched-

ule chart" on page 5-24.
3-86 WA100M-5 – VEAM280201

Troubleshooting
4. Troubleshooting
WA100M-5 – VEAM280201 4-1

4.1. Towing the machine Troubleshooting
4.1. Towing the machine
WARNING
Towing with a tractor of insufficient weight may cause acci-
dents! Perform towing using a machine weighing at least as
much as the machine that you want to tow off.
CAUTION
Towing to start the engine will damage the hydrostatic drive
system! Do not give the machine a tow to start the engine.
This will not start the engine, but may damage the hydro-
static drive system.
To avoid damage to the hydrostatic drive system, do not tow the

machine for more than 0.0621 mile (0.1 km). The towing speed
must not exceed 1.24 mph (2 km/h).
Perform towing using a machine weighing at least as much as the

machine that you want to tow off. Connect both machines with
appropriate towing attachments.
CAUTION
Towing attachments fastened to inappropriate points may
damage the machine! Only fasten the towing attachment to
the points provided for this purpose.
At the front part of the machine, fasten the towing attachment at

the marked eyes. At the rear part of the machine, fasten the tow-
ing attachment at the hitch.
Before you tow a machine with a hydrostatic drive system, estab-

lish a short-circuit connection between the high-pressure side and
the low-pressure side of the variable pump. For this purpose, turn
the high-pressure valves in the valve block about 2 revolutions.
Proceed as follows:
4-2 WA100M-5 – VEAM280201

Troubleshooting 4.1. Towing the machine
1. Set the driving-direction switch to position 'N'.
2. Tip up the driver's cab. Proceed as described in the Safety

chapter, under "Tipping up the driver's cab" on page 2-22.
3. Remove the protective caps (2) of the valves.
4. Hold the valve (3) with a wrench.
5. Loosen the lock nut (4) and screw in the threaded pin (5)
clockwise by means of an Allen key until it is level with the top
of the lock nut (4).
6. Retighten the lock nut (4). Perform this task on both valves.
7. Tip down the driver's cab. Proceed as described in the Safety

chapter, under "Tipping down the driver's cab" on page 2-24.
WA100M-5 – VEAM280201 4-3

4.1. Towing the machine Troubleshooting
After towing:
1. Tip up the driver's cab. Proceed as described in the Safety

chapter, under "Tipping up the driver's cab" on page 2-22.
2. After the towing is finished, loosen the lock nut (4) and
unscrew the threaded pin (5) counter-clockwise until it stops.
Hold the valve (3) with a wrench and retighten the lock nut (4).
Perform this task on both valves.
3. Put the protective caps (2) on the valves.
4. Tip down the driver's cab. Proceed as described in the Safety

chapter, under "Tipping down the driver's cab" on page 2-24.
NOTE
When the engine is switched off, the power-assisted steering
is not operational, i.e. you have to apply much more force to
steer the machine.
If you lift up the rear axle of the machine with a lorry-mounted

crane, you can tow off the machine over longer distances and at
speeds exceeding 1.24 mph (2 km/h). Before you do this you
must, however, remove the cardan shaft of the front axle. In addi-
tion, secure the articulated steering with the locking bar, in the
same way as it is required for transport of the machine on a low
bed loader or by train.
4-4 WA100M-5 – VEAM280201

Troubleshooting 4.1. Towing the machine
Towing a machine with defective brakes
WARNING
If the brakes of the machine that you want to give a tow are
defective, uncontrolled movement of the machine may cause
a crash while it is being towed!
Always use two machines to tow off a machine with defective
brakes. Connect all three machines with appropriate towing
attachments.
If you want to tow a machine with defective brakes, or if you have

to tow a machine driving downhill, use two machines for towing.
Attach the machine that you want to give a tow to a larger

machine with sufficient tractive and braking force. Attach a
second machine to the rear part of the machine that you want to
give a tow. In this way, you avoid uncontrolled movement of the
machine.
Towing can be performed under various conditions. Thus, it is

impossible to determine all the requirements that may apply to a
particular condition.
When towing on an even and horizontal surface, the tractive force

that you need is much less than the tractive force that you need
when towing on a slope or uneven surface.
Please ask your responsible Komatsu dealer for details, if you

want to give a particular machine a tow.
WA100M-5 – VEAM280201 4-5

4.2. Starting the engine with a booster cable Troubleshooting
4.2. Starting the engine with a booster cable

For starting the engine with a booster cable, proceed as follows:
Precautions for connecting and disconnecting the booster
WARNING
● When connecting the cables, never contact the positive
INCORRECT
(+) and negative (-) teminals.
● When starting the engine with a booster cable, always

wear safety goggles.
● Be careful not to let the normal machine and defective

machine contact each other. This prevents sparks from
being generated near the battery which could ignite the
hydrogen gas leaking from the battery. If hydrogen gas
explodes, it may cause serious injury.
● Make sure that there is no mistake in the booster cable

connections. The final connection is made to the engine
block of the defective machine, but sparks will be
generated when this is done, so connect it to a place as
far as possible from the battery.
● Be careful when removing the cables from the machine

that has been started. Do not allow the cable ends to con-
tact each other or the machine to avoid hydrogen explo-
sion.
NOTE
● The size of the booster cable and clip should be suitable
for the battery size.
● The battery of the normal machine must have the same

capacity as that of the engine to be started.
● Check the cables and clips for damage or corrosion.
● Make sure that the cables and clips are firmly connected.
4-6 WA100M-5 – VEAM280201

Troubleshooting 4.2. Starting the engine with a booster cable
Connecting the booster cables
Keep the start switch set to OFF.

Connect the booster cable as follows, in the order of the numbers A
marked in the diagram. 2 1
1. Make sure that the start switches of the normal and defective
machine are both set to OFF.
3
2. Connect one clip of booster cable (A) to the positive (+) Battery of the Battery of the
terminal of the defective machine. normal machine B problem machine
4
3. Connect the other clip of booster cable (A) to the positive (+) Engine block of the
terminal of the normal machine. problem machine
4. Connect one clip of booster cable (B) to the negative (-)

terminal of the normal machine.
5. Connect the other clip of booster cable (B) to the engine block
of the defective machine.
6. Let the engine run with a high speed.
Starting the engine
1. Make sure the clips are firmly connected to the battery

terminals.
2. Turn the start switch of the defective machine to the START

position and start the engine. If the engine does not start at
first, wait for at least 2 minutes before trying again.
Disconnecting the booster cables
After the engine has started, disconnect the booster cables in

reverse order in which they were connected. A
3 4
1. Remove one clip of booster cable (B) from the engine block of
the defective machine.
2. Remove the other clip of booster cable (B) from the negative 2
(-) terminal of the normal machine. Battery of the Battery of the
normal machine B problem machine
3. Remove one clip of booster cable (A) from the positive (+) 1
terminal of the normal machine. Engine block of the
problem machine
4. Remove the other clip of booster cable (A) from the positive
(+) terminal of the defective machine.
WA100M-5 – VEAM280201 4-7

4.3. For insufficient braking effect Troubleshooting
4.3. For insufficient braking effect
4.3.1. Checking the service brake

Drive the machine at a speed of 12.42 mph (20 km/h) on a dry flat
concrete road surface, and check whether the stopping distance
is less than 16.404 ft (5 m).
NOTE
All repairs conducted on the braking system must be con-
ducted at a Komatsu workshop.
4.3.2. Checking the parking brake function

1. Start the engine, set the machine to straight driving, and drive
the machine with an empty bucket up a gradient of 25%.
2. Stop the machine with the service brake and do not release
your foot again to keep the service brake applied.
3. Lower the bucket.
4. Set the driving direction switch (1) to its neutral position 'N'.
6. Apply the parking brake (2) and slowly release the pedal of
the service brake.
2 1
The machine must stand still.
NOTE
All repairs conducted on the braking system must be con-
ducted at a Komatsu workshop.
4-8 WA100M-5 – VEAM280201

Troubleshooting 4.4. Emergency steering properties
4.4. Emergency steering properties

You can continue to steer the machine even if the engine cuts out
during a journey. This will require more force however.
If the engine cuts out, move over straight to the side of the road,
switch on the hazard warning lights and secure the machine.
4.5. Emergency lowering

The machine is equipped with a pressure accumulator for the
working hydraulics. If the engine is not running you can lower the
working attachment to the ground using the multifunction lever –
once only (emergency lowering).
NOTE
If you have secured the working hydraulics with the safety
lever, you will however be unable to lower the working
attachment.

1. Make sure that no one is standing underneath the working

attachment.
2. Move the multifunction lever slowly into position 'S'.
The working attachment is lowered.
WA100M-5 – VEAM280201 4-9

4.6. Other troubles Troubleshooting
4.6. Other troubles
4.6.1. Electrical system

If faults or causes of faults are not listed below, have them
rectified by a local dealer.
ELECTRICAL SYSTEM
Fault Fault cause Remedy
Warning light charging current:

warning light charging current is
Electrical connection without *) Check terminals, connections,
off, when the engine is switched off
function and cables
and the start switch is set to its
operating position 'I'

function and cables
Warning light charging current:
warning light charging current does *) Check function of generator;
Generator without function
not go out when engine is running replace defective generator
Tension generator drive belt to low Tension drive belt
Generator produces unusual noise Generator defective Replace generator

function and cables
Starter does not start the engine Re-charge battery

Battery charge insufficient
*) Check function of battery;
replace defective battery
Starter pinion repeatedly engages Battery charge insufficient Re-charge battery

and disengages Starter defective *) Replace starter
Battery charge insufficient Re-charge battery

Starter turns engine only slowly
Starter defective *) Replace starter
Starter disengages before engine Battery charge insufficient Re-charge battery

is started Starter defective *) Replace starter
*) Have this work performed by local dealer.
4-10 WA100M-5 – VEAM280201

Troubleshooting 4.6. Other troubles
4.6.2. Engine
rectified by local dealer.
ENGINE
Oil level in engine too low Top up engine oil
Engine oil filter (filter cartridge) Replace engine oil filter (filter
dirty cartridge)
Check lines and hoses (visual

check: oil leaks)
Lines or hoses of engine
lubricating system damaged
Warning light engine oil pressure: *) Replace defective lines and
with the engine running the hoses
warning light is on and an acoustic
alarm signal is given Check line and hose connections
(visual check: oil leaks)
Line or hose connections of engine
lubricating system leaky
*) Repair leaky line and hose
connections
*) Check function of oil pressure

Oil pressure switch without
switch; replace defective oil
function
pressure switch
Vapour is let off at the pressure Top up coolant

Coolant level in radiator too low
valve of the radiator cap (make sure mixture ratio is correct)
Check lines and hoses (visual
check: coolant leaks)
Coolant level too low Leak in cooling system
*) Replace defective lines and
hoses
WA100M-5 – VEAM280201 4-11

ENGINE (continued)
Let the engine run idle without

load, until the engine has
sufficiently cooled down and the
Engine is overheated
temperature indicator of the
coolant has returned to the green
range
Tension of fan's drive belt too low Tension drive belt

The background of the
temperature display lights up in red Internal surface of engine cooling *) Clean internal surface of engine
and the acoustic warning signal system furred or dirty cooling system
sounds.
Radiator (radiator surfaces, fins) Clean radiator (radiator surfaces,
dirty fins)
*) Check function of thermostat;

Thermostat without function
replace defective thermostat
Radiator cap either defective or Replace defective radiator cap; re-

loose tighten loose radiator cap
On the temperature display, the No contact to the temperature *) Check the contacts or replace
two LCD bars on the right are lit. sensor, or the temperature sensor the temperature sensor.
is defective.
Temperature display coolant:

with the engine at operating *) Check function of temperature
Temperature display without
temperature, the temperature display; replace defective
function
display coolant does not indicate a temperature display
temperature
Fuel tank empty Refill fuel and bleed fuel system

Air in fuel system Bleed fuel system
Injection pump or injection nozzles *) Replace injection pump or

Engine does not start
without function injection nozzles
Starting speed too low See "Electrical System"

Engine compression too low *) Check tappet clearance
Oil level in engine too high Correct oil level

Exhaust fumes colour white or blue
Wrong fuel Use prescribed fuel
Air filter insert dirty Clean or replace air filter insert
Exhaust fumes colour temporarily
Injection nozzle defective *) Replace injection nozzles
black
Engine compression too low *) Check tappet clearance
Temporarily, combustion sounds
Injection nozzles defective Replace injection nozzles*)
like breathing
4-12 WA100M-5 – VEAM280201

ENGINE (continued)
Wrong fuel Use prescribed fuel
Allow engine to cool down

Unusual combustion noise Engine temperature too high
(engine overheated) See "Engine - temperature display
coolant"
Defective silencer *) Replace silencer
Unusual mechanical noise
Tappet clearance too wide *) Adjust tappet clearance
The motor does not start or goes

out during operation and the
Fuel tank empty Refill fuel and bleed fuel system
background of the fuel display
lights up in red.
Warning light air filter:
Clean or replace filter insert of air
warning light air filter is on when Air filter of filter insert dirty
filter
engine is running
WA100M-5 – VEAM280201 4-13

4.6.3. Hydraulic system

HYDROSTATIC DRIVE UNIT
Parking brake applied

Oil level in hydraulic oil tank too Release parking brake
low
Driving direction switch in position Set driving direction switch to

Machine does not drive 'N' either position 'F' or 'R'
Driving direction switch without *) Check function of driving

function direction switch
Oil level in hydraulic oil tank too

Top up hydraulic oil
low
Check hydrostatic motor for

contamination; clean dirty hydraulic
Hydrostatic motor motor does not motor
swivel
*) Check function of hydrostatic
motor
*) Check function of on-off valve;

On-off-valve without function
replace defective on-off-valve
Hydrostatic pump defective *) Replace hydrostatic pump
*) Check control pressure; reset, if

Machine does only drive slowly Wrong control pressure
required
and performance is poor
*) Check high pressure; reset, if
Wrong high pressure
required
*) Check setting of inch valve

Inch valve defective or set
incorrectly
*) Replace defective inch valve
Replace filter element of hydraulic

Hydraulic filter dirty
filter
*) Check function of switching

Switching relay without function relay; repair or replace defective
switching relay
4-14 WA100M-5 – VEAM280201

HYDROSTATIC DRIVE UNIT (continued)
*) Check function (pressure) of

Faulty operation of charge pump
charge pump
Hydraulic oil radiator (radiator Clean hydraulic oil radiator

surfaces, fins) dirty (radiator surfaces, fins)
Hydrostatic drive unit overheated Faulty operation of radiator Check tension of drive belt
Replace filter element of hydraulic
Hydraulic filter dirty
filter
Oil level in hydraulic oil tank either

Correct oil level in hydraulic oil tank
too high or too low

low
Unusual noise Inclusions of air in lines and units
of the hydraulic system (faulty Bleed hydraulic system
bleeding)
WORK HYDRAULIC SYSTEM
Lifting power too low Oil level in hydraulic tank too low Top up hydraulic oil
Filter insert of hydraulic oil filter Replace filter insert of hydraulic oil
Lifting power too slow
dirty filter
Wrong hydraulic oil quality Fill in prescribed hydraulic oil

Air bubbles in hydraulic oil Oil level in hydraulic oil tank too
low
Cylinders move jerky Top up hydraulic oil
low
WA100M-5 – VEAM280201 4-15

4.6.4. Brakes
BRAKES
Multi-disks of brake worn *) Replace multi-disks of brake

Brake has no effect
Air in brake system *) Bleed brake system
Top up brake oil

Warning light brake oil reserve: Brake oil level in brake oil tank too
Check brake system for damage
warning light brake oil reserve is on low
and leaks (visual check: brake oil
leaks)
PARKING BRAKE
Parking brake's brake lever is too

*) Adjust parking brake
loose
Brake is ineffective
Worn brake pads *)Worn brake pads
Worn brake discs *)Worn brake discs
4.6.5. Steering
STEERING
*) Check function of hydraulic

Steering reacts slowly Hydraulic system malfunctions
system
*) Check fastenings of steering

Clearance of steering cylinder bolt
cylinder; replace defective cylinder
too large
Steering wobbles bolt.
Faulty operation of hydraulic *) Check function of hydraulic

system system
4-16 WA100M-5 – VEAM280201

4.6.6. Axles
AXLES
Noise Oil level in axle too low Top up oil
4.6.7. Driver's cab

DRIVER'S CAB
Blower: insufficient air flow Blower filter clogged Clean or replace filter
WA100M-5 – VEAM280201 4-17

4-18 WA100M-5 – VEAM280201

Maintenance 5
5. Maintenance
WA100M-5 – VEAM280201 5-1

5 Maintenance
5.1. Maintenance guide
5.1.1. Guidelines
Maintenance work is to be conducted by skilled personnel only.
See section "2.3. Precautions for maintenance" on page 2-19.
Perform maintenance work on hard, flat ground.
Always move the machine to the proper maintenance and repair

position.
The machine must be positioned as follows for maintenance,

unless other specifications are expressly provided.
● Lower the working attachment onto the ground.
● Move the multifunction lever to the HOLD '0' position.
● Switch the working hydraulics safety lever to position ‘1’.

● Apply service brake
● Lock the centre pivot steering when performing maintenance

work by using the centre pivot steering locking lever.
● Place chocks before and behind the wheels.
5-2 WA100M-5 – VEAM280201

Maintenance 5
Tipping up the driver's cab

NOTE
5. Open the bonnet.
1
2
7. Take the hand pump lever out of its holder on the radiator (2)
and insert it into the receptacle of the pump (3).
WA100M-5 – VEAM280201 5-3

5 Maintenance
8. Set the lever at the pump to "pump up" and pump the cab
upward until it reaches the limit stop.
9. Move the safety rod on the right side upward until it reaches
the pin at the cab floor.
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 floor.
11. Take the lever out of the pump.
5-4 WA100M-5 – VEAM280201

Maintenance 5
Tipping down the driver's cab
1. Insert the lever into the pump. Set the lever at the pump to
"pump up" and pump the cab upward until it reaches the limit
stop.
position (arrow).
3. Set the lever to "pump down" and pump the cab downward
until the cylinder is entirely retracted (the resistance at the
lever increases markedly).
4. Remove the lever from the pump and fasten it to the radiator.
WA100M-5 – VEAM280201 5-5

5 Maintenance

2 1
1
Tipping up the driver's cab (option with electric actuator)

NOTE
5. Open the bonnet.
1
2
the cab reaches the upper limit stop.
3
4
G0090003
5-6 WA100M-5 – VEAM280201

Maintenance 5
8. The top final position has been reached if the slipping clutch
of the electric actuator (6) is activated, with a clearly audible
sound.
9. Move the safety rod (7) on the right side upward until it
reaches the cylinder linkage. 7 7
until the safety rod is secure against the cab floor.
3
5
G0090003
Tipping down the driver's cab (option with electric actuator)
the cab reaches the upper limit stop. Remove the safety rod.
3
4
G0090003
WA100M-5 – VEAM280201 5-7

5 Maintenance
position (arrow).

until the cab reaches the lower limit stop. The
"Retracted" position has been reached if the slipping clutch of
the electric actuator (6) is activated, with a clearly audible
sound.
3 G0090003

2 1
1
Check service meter

Check the service meter every day to see if any maintenance is
due.
Komatsu original replacement parts

Only use Komatsu original parts specified in the Parts Book as
replacement parts.
Oils and grease

Use only original oils and grease by Komatsu. Choose oils and
grease with the specified viscosity depending on the ambient
temperature.
Use only clean oil and grease. Keep also containers for oil and
grease clean. Be careful not to operate with foreign substances in
the vicinity of oil and grease.
5-8 WA100M-5 – VEAM280201

Maintenance 5
Washer fluid
Use automobile window washer fluid and make sure it is not
contaminated with dust or dirt.
Keep the machine clean

Always keep the machine clean. This facilitates troubleshooting
considerably. In particular, keep grease fitting, breathers and oil
level gauges clean and avoid any contamination with foreign
materials.
Be careful with hot fluids

Draining hot oils and coolants and removing their filters
immediately after stopping the engine are hazardous. Allow the
engine to cool before.
If the oil has to be drained when it is cold, warm it up to a suitable

temperature (approx. 68 - 104°F / 20 - 40°C), then drain!
Check for foreign particles in drained oil and on filters

After oil is changed or filters are replaced, check the oil and filters
for metallic particles and foreign materials. If large quantities of
metallic particles or foreign materials are found, consult your
Komatsu dealer.
Refilling fuel or oil, fuel strainer

Refill only fuel or oil in sufficiently ventilated places. If your
machine is equipped with a fuel strainer, do not remove it while
fueling. Re-close it after fueling.
Spilled fuel or oil may cause accidents due to slipping. It may also
ignite. For this reason, always remove any spilled oil or fuel.
Never use fuel for cleaning or rinsing parts. Be careful not to

contaminate soil or water with oil or fuel. Dispose oil and fuel in an
appropriate manner.
Oil check or change

Check or change oils only in dust-free places to keep foreign
particles away from oils.
Warning tag
Attach the warning tag to the start switch or other related control
elements to avoid that somebody starts the engine during
maintenance.
The warning tag is supplied together with the tools.
Safety labels
During the operation, always observe the precautions on the
safety label attached to the machine.
Welding instructions
● Turn off the engine start switch (OFF position).
● Disconnect the negative terminal on the battery.
WA100M-5 – VEAM280201 5-9

5 Maintenance
● Do not apply more than 200V continuously.

● Connect grounding cable within 3.28 ft (1 m) from the area to
be welded.
● No seals or bearings may be between the area to be welded
and the grounding point.
● Never weld any pipe or tube containing fuel or oil.
● Keep a safety distance of min. 3.28 ft (1 m) between the area
to be welded and the battery.
Fire prevention
Use nonflammable cleaners or light oil for cleaning parts. Keep
flame or cigarette light away from light oil.
Clamp faces
When O rings or gaskets are removed, clean the clamp faces and
replace the O rings and gaskets with new ones. Be sure to fit O
rings and gaskets during re-assembly!
Objects in your pockets

Keep your pockets free of loose objects which can fall out and
drop into the machine (especially when bending over the
machine).
Tyres check
When working in rocky areas, check the tyres for damage and for
looseness, flaws, wear and tear. Re-tighten loose bolts and nuts.
Precautions when washing the machine

● Place the machine on a plane, even surface.
● Lower the work equipment to the ground.
● Apply the parking brake.
● Lock the wheels using support wedges to prevent the
machine from rolling away.
Proceed the following general measures, if you want to clean
the machine:
● Never spray steam or water directly on the radiator.
● Do not allow water to get on any electrical component.
Pre- and post-work checks

Before starting work in mud, rain, snow or at the seashore, check
plugs and valves for tightness. Wash the machine immediately
after the work to protect components from rusting.
Lubricate components more frequently than usual. Be sure to
lubricate work equipment pins daily if they are submerged in
water.
On worksites where heavy-duty operations are common, reduce
the maintenance and lubricating intervals.
Dusty worksites
When working at dusty worksites, take the following precautions:
5-10 WA100M-5 – VEAM280201

Maintenance 5
● Inspect the air cleaner clogging warning lamp to see whether

the air cleaner is blocked. Clean the air cleaner more
frequently than specified.
● Clean the radiator core frequently to avoid clogging.
● Clean and replace the fuel filter frequently.
● Clean electrical components, especially the starter and
alternator to avoid accumulation of dust.
Avoid mixing oils

Never mix oils of different brands. If you have only oil which is dif-
ferent from the oil brand used in the machine, do not add it but
replace the entire oil.
WA100M-5 – VEAM280201 5-11

5 Maintenance
5.2. Maintenance basics
5.2.1. Oil, fuel and coolant specifications
Oil
● Oil is used in the engine and work equipment under extremely

severe conditions (high temperature, high pressure), and it
deteriorates with use.
Always use oil that matches the grade and temperature given
in the Operation and Maintenance Manual. Even if the oil is
not dirty, always replace the oil after the specified interval.
● Oil can be compared to blood in the human body, so always

be careful when handling it to prevent any impurities (water,
metal particles, dirt, etc.) from penetrating.
The majority of problems with machines are caused by the
entry of such impurities.
Take particular care not to let any impurities penetrate when
storing or adding oil.
● Never mix oils of different grades or brands. If only an oil is

available which does not match the oil grade/brand in the
machine then do not top up the oil, but replace all of it.
● Always add the specified amount of oil.

Having too much oil or too little oil may both cause problems.
● If the oil in the work equipment is not clear, there is probably

water or air getting into the circuit. In such cases, please
contact your Komatsu distributor.
● When changing the oil, always replace the related filters at

the same time.
● We recommend to have an analysis of the oil made

periodically to check the condition of the machine. Those who
wish to use this service, are requested to their Komatsu
distributor.
5-12 WA100M-5 – VEAM280201

Maintenance 5
Fuel
● The fuel pump is a precision instrument; if fuel containing

water or dirt is used, it cannot work properly.
● Be extremely careful not to let impurities penetrate when

storing or adding fuel.
● Always use the fuel specified in the Operation and

Maintenance Manual.
Fuel may congeal depending on the temperature (particularly
at low temperatures below 5° F (-15°C)), so change to a fue
matching this temperature.
● To prevent the moisture in the air from condensing and

forming water inside the fuel tank, always fill the fuel tank
after completing the day's work.
● Before starting the engine, or when 10 minutes have passed

after adding fuel, drain the sediment and water from the fuel
tank.
● If the engine runs out of fuel, or if the filters have been

replaced, you must fill up the fuel pre-filter with fuel and may
then restart the engine. For details, see "Bleeding the fuel
system" on page 5-57.
● If the fuel sulphur content is between 0.5 and 1.0%, the oil
change interval must be 1/2 normal.
If the fuel sulphur content is more 1.0%, the oil change inter-
val must be 1/4 normal.
WA100M-5 – VEAM280201 5-13

5 Maintenance
Coolant
● River water contains large amounts of calcium and other

impurities, so if it is used, scale will stick to the engine and
radiator causing a defective heat exchange and overheating.
● Do not use water that is not suitable for drinking.
● When using anti-freeze, always observe the precautions

given in the Operation and Maintenance Manual.
● Komatsu machines are supplied with Komatsu original anti-

freeze in the coolant when the machine is shipped.
This anti-freeze prevents corrosion in the cooling system.
Therefore, it can be used as it is even in hot areas.
● Anti-freeze is flammable, so be extremely careful not to

expose it to open flame or fire.
● The proportion of anti-freeze to water differs according to the

ambient temperature.
For details of the mixing ratios, see "Cooling system –
exchanging coolant and cleaning the system" on page 5-68
● If the engine overheats, wait for the engine to cool before

adding coolant.
● If the coolant level is low, it will cause overheating and

corrosion due to the air in the coolant.
Grease
● Grease is used to prevent twisting and noise at the joints.
● The nipples not included in the maintenance section are

nipples for overhaul, so they need not be lubricated.
If any part becomes stiff after being used for a long time, add
grease.
● 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 in the grease would cause the rotat-
ing parts to wear.
5-14 WA100M-5 – VEAM280201

Maintenance 5
Storing oil and fuel
● Keep oil and fuel indoors to prevent any water, dirt or other
impurities from penetrating.
● When keeping barrels for a long period, lay down the barrel
on its side so that the filler port is at the side (to prevent
moisture from being sucked in).
If barrels have to be stored outside, cover them with a
waterproof sheet or take other measures to protect them.
● To prevent any change in quality during long term storage, be

sure to use in the order of 'first in - first out' (use the oldest oil
or fuel first).
Filters
● Filters are extremely important safety parts. They prevent

impurities in the fuel and air circuits from entering important
equipment and causing problems.
● Replace all filters periodically. For details, see the Operation

and Maintenance Manual.
However, when working under severe conditions, it is
necessary to consider replacing the filters at shorter intervals
according to the oil and fuel (sulfur content) being used.
● Never try to clean the filters (cartridge type) and use them
again. Always replace with new filters.
● When replacing oil filters, check if any metal particles are

stuck to the old filter. If any metal particles are found, please
contact your Komatsu distributor.
● Do not open packs of spare filters until just before they are to
be used.
● Always use original Komatsu filters.
Biodegradable hydraulic oil and lubricants
The use of biodegradable hydraulic oils and lubricants - on the

basis of synthetic esters - for Komatsu machines is permitted. For
information on the products cleared for use and best suited for
your application contact our authorized service workshops.
WA100M-5 – VEAM280201 5-15

5 Maintenance
5.2.2. Specifications of the electrical system

● If the wiring gets wet or the insulation is damaged, the
electrical system leaks resulting in hazardous malfunctions of
the machine.
● Maintenance work at the electrical system includes:
1. check fan belt tension,

2. check damage or wear to the fan belt ,
3. check battery fluid level.
● Never remove or disassemble any electrical components

installed in the machine.
● Never install any electrical components other than those

specified by Komatsu.
● Be careful to keep the electrical system free of water when

washing the machine or when it is raining.
● When working on the seashore, carefully clean the electrical

system to prevent corrosion.
● The optional power source must never be connected to the

fuse, start switch, or battery relay.
5-16 WA100M-5 – VEAM280201

Maintenance 5
5.2.3. Wearing parts list

Wearing parts such as filter elements, air cleaner elements, bolt-
on edges, etc. are to be replaced at the time of periodic
maintenance or before their abrasion limits, are reached.
The wearing parts should be changed correctly in order to use the
machine economically.
For replacement, KOMATSU genuine parts of excellent quality

should be used.
*: See Part No. in Parts Book (KOMATSU).
When ordering parts, please check the part number in the Parts
Book
The parts in parentheses are to be replaced at the same time.
Position Part no. Part name Q'ty Replacement interval
Engine Oil Filter * Cartridge 1 Maintenance every 500 operating hours
Fuel Filter * Cartridge 1 Maintenance every 500 operating hours
Filter Element 1 First maintenance after 50 operating hours

Hydraulic Oil Filter * (O-Ring) (1)
(O-Ring) (1) Maintenance every 1000 operating hours
Engine Valve Gasket 1 First maintenance after 250 operating hours

*
Cover Gasket O-ring 3 Maintenance every 2000 operating hours
Filter Insert 1
Air Filter * Maintenance every 500 operating hours
Safety Filter 1
WA100M-5 – VEAM280201 5-17

5 Maintenance
5.3. Lubricants, fuels and filling capacities

Lubricants, fuels and filling capacities
WA100M-5 Temperature
Approx. filling
Lubricants, fuel etc. BI code **) Quality grades Viscosity ranges capacity in
ranges
US gal. (litres)
Engine Engine Oil EO EO 1540 A ACEA E5 5°F to 113°F SAE 15W-40 1) 2.64 / 2.51*
EO 1030 A or, if not available: (-15°C to 45°C) (10 / 9.5*)
NRS API CE oder -4°F to 86°F SAE 10W-30
API CF-4 2) (-20°C to 30°C)
5°F to 68°F SAE 5W-30
(-15°C to 20°C)
Transfer Gear Box AGIP ROTRA MULTI THT GO 80 API-GL4 – SAE 80 1) 0.34
Standard Type ESSO TORQUE FLUID 56 API-GL4 SAE 80 (1.3)
High Speed Version MOBILFLUID 424 API-GL4 SAE 80
MOBILLUBE D LS 80W-90 API GL-5 SAE 80W-90
SHELL SPIRAX LS API-GL4 SAE 80W-90
ESSO TORQUE FLUID 62 API-GL4 SAE 10W-30
Front Axle AGIP ROTRA MULTI THT GO 80 API-GL4 – SAE 80 1) Planet Gear:
ESSO TORQUE FLUID 56 API-GL4 SAE 80 2 x 0.34 (1.3)
MOBILFLUID 424 API-GL4 SAE 80 Differential: 2.1
MOBILLUBE D LS 80W-90 API GL-5 SAE 80W-90 (8.0)
Rear Axle AGIP ROTRA MULTI THT GO 80 API-GL4 – SAE 80 1) Planet Gear:
ESSO TORQUE FLUID 56 API-GL4 SAE 80 2 x 0.34 (1.3)
MOBILFLUID 424 API-GL4 SAE 80 Differential: 2.1
MOBILLUBE D LS 80W-90 API GL-5 SAE 80W-90 (8.0)
Hydraulic system, Hydraulic Oil HYD HYD 0530 HVLP 5°F to 68°F ISO VG 46 1) 19.8 / 13.2*
steering HYD 1030 HVLP D (-15° to 20°C) (75 / 50*)
HYD 1540 -4°F to 86°F ISO VG 68
(-20° to 30°C)
-5°F to 113°F ISO VG 100
(-15° to 45°C)
or Engine Oil EO EO 1540 A ACEA E5 5°F to 113°F SAE 15W-40 1)
EO 1030 A or, if not available: (-15°C to 45°C)
NRS API CE or -4°F to 86°F SAE 10W-30
API CF-4 2) (-20°C to 30°C)
5°F to 68°F SAE 5W-30
(-15°C to 20°C)
or BIO-E-HYD HEES 5°F to 68°F ISO VG 46
Hydraulic Oil BIO-E-HYD 0530 (acc. to VDMA fluid (-15°C to 20°C)
technology)
Service Brake AGIP LHM Super HYD – – – 0.26
(1.0)
Cooling system TEXACO: HAVOLINE XLC1), 4) 3.43
Tanigawa Oil: NA2001 (13)
Antifreeze and
AF-NAC CCI: L246
Corrosion Protection
TOTAL FINA ELF:GLACELF CHP SUPRA
Showa: MCR20
Fuel tank Diesel fuel ³) CFPP Class B DIN-EN 590 to 32°F (0°C) – 29.06
CFPP Class D to 14°F (-10°C) (110)
CFPP Class E to 5°F (-15°C)
CFPP Class F to -4°F (-20°C)
Grease nipples Multi-purpose grease MPG on MPG-A KP 2N-20 – NLGI 2
a lithium base
Air conditioning Coolant NRS R134a (CFC-free) - - 2.64 lb. (1200 g)
Refrigerating machine oil NRS PAG (polyalkyleneg- 0.047 (180 cm³)
lycol)
The specified filling capacities are approximate guidelines; test specifications are binding. The selection of the viscosity class depends on the
predominantly existing outside temperature. The temperature limits are to be regarded as guidelines which can be exceeded up or down for a brief
period.
*) Topping-up quantity
1
) Works filling
²) If no engine oil of the API CE or API CF-4 specification is available, API CC or API CD-classified engine oil can be used alternatively. The oil change
intervals must be split in half in this case, however.
³) If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal. With a sulphur content of more than 1.0 %, the oil
change interval must be 1/4 normal.
4) Proportion of Mixture: 50% Coolant : 50% Water, Min. Freeze Proofing: -31°F (-35° C)
**) BI codes are the "standard lubricants" for construction machinery and vehicles of the Hauptverband der Deutschen Bauindustrie e.V. (BI). The
brochure "Regelschmierstoffe für Baumaschinen- und Fahrzeuge" (Standard Lubricants for Construction Machinery and Vehicles" can be obtained from
bookstores or Bauverlag GmbH, Wiesbaden and Berlin, under the ISBN no. 3-7625-3102-1."
5-18 WA100M-5 – VEAM280201

Maintenance 5
5.3.1. Lubrication chart
17 24 31 6 18 20
WA90/100M-5
LUBRICATION CHART CHECK ADD 22/28
CHANGE
25
LUBRI-
CATION
POINT
15 27 23
1 DISPLAY 1 12 11 9 10 1 2 5
2 FUEL LEVEL F 1
DAILY 3 ENGINE OIL EO 1 4
4 COOLANT CL 1
6 HYDRAULIC TANK HO 1
10h 7 ARTICULATED JOINT G 2 3
8 LIFT CYLINDER PIN 2

9 DUMP CYLINDER PIN 2 10 8 16 7 15/32 26 16 19 21
50h 10 LIFT ARM PIVOT PIN 6

G LUBRI-
11 BELLCRANK PIN 1 CATION
POINT
12 LINK 2
5 BRAKE SYSTEM SHO 1,0 1

20 AIR CLEANER 1 1000h 24 *HYDRAULIC OIL FILTER 1
15 STEERING CYLINDER PIN G 4 31 HYDRAULIC TANK BREATHER 1
250h 32 REAR AXLE G 2
27 HAND PUMP HO 1 1x8,0
17 **FRONT AXLE WA90-5 2x0,6 1
28 WATER SEPARATOR 1 2x1,3
WA100M-5
1500h UTTO 1x8,0
18 **REAR AXLE WA90-5 2x0,6 1
21 *ENGINE OIL EO 10,0 1 WA100M-5 2x1,3
23 *ENGINE OIL FILTER 1 19 **GEAR BOX 1,3 1
22 FUEL FILTER 1
20 AIR CLEANER 1 27 HAND PUMP HO 1
500h
17 FRONT AXLE 1 2000h 25 COOLING SYSTEM 13,0 1
18 REAR AXLE UTTO 1 26 HYDRAULIC OIL HO 75 1
19 GEAR BOX 1
5 BRAKE SYSTEM SHO 1 4000h 16 UNIVERSAL SHAFT SG 2
1. LUBRICATION INTERVALS ARE BASED O N THE SERVICE METER READING. 3. NUMBERS AT THE LEFT SIDE OF THE C HART INDICATE THE NUMBER OF
MAINTENANCE POINTS. REFER TO THE ABOVE ILLUSTRATION.
2. ABBREVIATIONS
CL: COOLING LIQUID, EO: ENGINE O IL, F: DIESEL FUEL 4. ITEMS MARKED * SHOULD BE PERFORME D IN THE FIRST
G: LITHIUM GREASE NO.2, HO: HYDR AULIC OIL SERVICE FOR NEW WHEEL-LOADER AFTER 50-HOURS DRI VING.
SG: SPECIAL GREASE, SHO: BRAKE OIL, UTTO: AXLE OIL
FOR THE BRANDS OF CL, EO, F, G, HO, SG, SHO AND UTTO ITEMS MARKED ** SHOULD BE PERFORM ED IN THE FIRST
REFER TO THE OPERATION AND MAINT ENANCE MANUAL. SERVICE FOR NEW WHEEL-LOADER AFTER 250-HOURS DR IVING.
5. REFER TO THE OPERATION AND MAINTE NANCE MANUAL FOR DETAILS.
42W-93-21A90
WA100M-5 – VEAM280201 5-19

5 Maintenance
5.4. Tools and standard tightening torques (bolts, nuts)
5.4.1. Introduction of recommended tools
No. Name of tool Part No. Remarks
Applicable width across flats

42T-09-H0450 8/10 mm
1 Wrench set 42T-09-H0460 13/15 mm
42T-09-H0470 17/19 mm
42T-09-H0440 24/27 mm
2 Screwdriver 421-98-H1120 –
3 Screwdriver 421-98-H1110 –
6 Grease gun 424-98-H1010 –

7 Hose 424-98-H1020 (for grease gun)
8 Grease cartridge 07950-90403 (Lithium base grease: 400g)
9 Hammer 421-98-H1140 –
10 Pocket 421-98-H1130 –
If any of the above tools are broken, please order them from your
KOMATSU distributor.
5-20 WA100M-5 – VEAM280201

Maintenance 5
5.4.2. Torque list

Unless otherwise specified, tighten the metric bolts and nuts to
the torque shown in the table.
The tightening torque is determined by the width across flats of

the nut and bolt.
b
If it is necessary to replace any nut or bolt, always use a Komatsu
genuine part of the same size as the part that was replaced..
a AD053380
Metric Fine Screw Thread - Strength Class 10.9
Tread diameter of Width over flats Steel Aluminium Cas

the bolt (mm) (mm)
(a) (b) Nm kpm Nm kpm
M6 10 14.0 1.4 7.7 0.77
M8 13 35.0 3.5 19.0 1.9
M10 17 (15) 70.0 7.0 37.0 3.7
M12 19 115.0 11.5 64.0 6.4
M14 22 185.0 18.5 101.5 10.15
M16 24 280.0 28.0 158.0 15.8
M18 27 390.0 39.0 218.0 21.8
M20 30 560.0 56.0 306.5 30.65
M22 32 750.0 75.0 416.0 41.6
M24 36 960.0 96.0 528.5 52.85
M27 41 1400.0 140.0 774.0 77.4

M30 46 1900.0 190.0 1053.0 105.3
M33 50 2600.0 260.0 – –
M36 55 3300.0 330.0 – –

M39 60 4300.0 430.0 – –
NOTE
When tightening panels or other parts having tightening fix-
tures made of plastic, be careful not to use excessive tight-
ening torque: doing so will damage the plastic parts.
WA100M-5 – VEAM280201 5-21

5 Maintenance
Metric Fine Screw Thread - Strength Class 10.9
Tread diameter of Width over flats Steel Aluminium Cas

the bolt (mm) (mm)
(a) (b) Nm kpm Nm kpm
M8 × 1 13 35.0 3.5 20.0 2.0
M10 × 1 17 (15) 75.0 7.5 42.0 4.2
M10 × 1.25 17 (15) 70.0 7.0 39.0 3.9

M12 × 1.25 19 125.0 12.5 70.0 7.0
M12 × 1.5 19 120.0 12.0 67.0 6.7
M14 × 1.5 22 200.0 20.0 110.0 11.0

M16 × 1.5 24 300.0 30.0 167.5 16.75
M18 × 1.5 27 440.0 44.0 243.0 24.3
M18 × 2 27 420.0 42.0 230.0 23.0

M20 × 1.5 30 620.0 62.0 338.5 33.85
M20 × 2 30 – – 322.5 32.25
M22 × 1.5 32 820.0 82.0 454.5 45.45

M22 × 2 32 – – 436.0 43.6
M24 × 1.5 36 1090.0 109.0 596.0 59.6
M24 × 2 36 1040.0 104.0 573.0 57.3
M27 × 2 41 1500.0 150.0 832.0 83.2
M30 × 2 46 2120.0 212.0 1158.0 115.8
M33 × 2 50 2800.0 280.0 – –
M36 × 3 55 3500.0 350.0 – –
M39 × 3 60 4600.0 460.0 – –
5-22 WA100M-5 – VEAM280201

Maintenance 5
5.5. Periodical replacement of safety-critical parts

To ensure trouble-free operation of the machine, the user of the
machine must always carry out periodic maintenance. In addition,
to maintain safety standards, the user should also periodically
replace all safety related parts, which are particularly closely
connected to safety and fire prevention.
● The standard service life under normal conditions should not

exceed 6 years.
● Hoses must be replaced as soon as the following damage is

noticeable:
❍ damage to the outer layer through to the intermediate

layer,
❍ brittleness in the outer layer,
❍ distortions in pressurised or unpressurised state not

conforming with the original shape of the installed hose,
❍ leakages,
❍ damage to the hose fittings or to the connection between

fittings and hose,
❍ storage damage (the shelf life of the hose should not

exceed 2 years).
When replacing the hoses, always replace the O-rings, gaskets,

and other such parts at the same time.
Ask your Komatsu distributor to replace the safety critical parts.
WA100M-5 – VEAM280201 5-23

5 Maintenance
5.6. Maintenance schedule chart
Service Procedure see page
5.7.1 Pre-start checklist 5-26

Cooling system – checking the coolant level, topping up coolant 5-26
Cleaning the radiator segments 5-27
V-Belt, checking the condition 5-27
Engine, checking the oil level, topping up oil 5-28
Checking the fuel level – refuelling 5-30
Water separator at the fuel filter – Draining water and dirt sediments 5-31
Checking the controls 5-31
Checking the electrical connections 5-32
Heater/air conditioning – checking rate of air flow 5-32
Miscellaneous tests before starting work 5-33
5.7.2 Maintenance upon demand 5-33
Checking the air-conditioning system 5-33
Checking the window washing-fluid level, adding fluid 5-35
Re-charging a built-in battery 5-36
5.7.3 Maintenance after the first 50 operating hours 5-37
Hydraulic system, replacing the filter insert 5-37
Checking and tightening the wheel nuts 5-38
5.7.4 Maintenance after the first 250 operating hours 5-39
Front and rear axle – oil change 5-39
Transfer box gearing – changing oil 5-40
Checking and adjusting the valve clearance 5-40
5.7.5 Maintenance every 10 operating hours 5-41
Lubrication, articulated steering 5-41
Battery – checking the acid level 5-42
Lubrication, work unit 5-43
Service brake – Checking the brake pads 5-44
V-Belt, generator – checking and adjusting the tension 5-44
Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert 5-46
Lubrication, steering cylinder 5-49
Lubrication, self-aligning bearings of rear axle 5-50
Checking and tightening the wheel nuts 5-51
Hand pump - Checking the oil level 5-52
5-24 WA100M-5 – VEAM280201

Maintenance 5
Service Procedure see page
Service brake - Checking the brake pads and brake discs, checking the oil level 5-52
Engine – changing oil 5-54
Replacing the oil filter cartridge 5-55
Changing the fuel filter element 5-56
Bleeding the fuel system 5-57
Bleeding the low pressure side: 5-57
Bleeding the high pressure side: 5-57
Air filter, replacing the filter insert, replacing the safety filter 5-58
Heater/air conditioning – cleaning/replacing filter fleece 5-59
Cleaning the condenser of air conditioning 5-60
Multi-functional lever accumulator - checking gas pressure 5-60
E.C.S.S.-pressure accumulator (Option) - checking gas pressure 5-60
Front and rear axle – checking the oil level 5-61
Transfer box gearing – checking the oil level 5-62
V-Belt, generator – checking and adjusting the tension 5-63
Service Brake - Checking and adjusting oil 5-63
Checking and adjusting system pressures 5-63
Hydraulics – Exchanging the venting filters 5-64
Hydraulic system, replacing the filter insert 5-65
Front and rear axle – oil change 5-66
Transfer box gearing – changing oil 5-67
Cooling system – exchanging coolant and cleaning the system 5-68
Checking and adjusting the valve clearance 5-70
Hydraulic system, oil change 5-71
Ventilating the hydraulic oil tank 5-72
Checking the fuel pump 5-73
Checking the fuel and coolant tubes, replacing the tubes (if required) 5-73
Checking the water pump 5-73
Lubrication, universal joint 5-74
WA100M-5 – VEAM280201 5-25

5 Maintenance
5.7. Service procedure
5.7.1. Pre-start checklist
Cooling system – checking the coolant level, top-

ping up coolant
CAUTION
● A wrong water/coolant mixing ratio will damage the
radiator! Always mix water and coolant in the ratio 50 :
50. This also applies to countries with a hot climate.
● Danger of fire! Coolant may ignite at hot engine!
● Do not top up coolant, unless the engine has cooled

down sufficiently.
1. Open the bonnet.
2. Check that the coolant level in the expansion tank is between

the MAX and MIN markings. If the coolant level does not
reach up to the MIN marking, top up coolant.
3. Therefore remove the cover cap of the expansion tank.
4. Top up coolant until the level reaches up to the MAX marking.
5. After topping up, firmly close the cover cap.
6. Usually, the radiator needs not to be opened. However, for

safety reasons it is required to check the refrigerant level in
the radiator after 50 operating hours (see "5.7.9. Maintenance
every 1000 operating hours" on page 5-63).
7. If the expansion tank is empty again after a short period of

time, immediately have the cooling system checked for leaks
and have any leaks repaired in the garage.
5-26 WA100M-5 – VEAM280201

Maintenance 5
Cleaning the radiator segments
The radiator ribs have to be checked daily and cleaned if neces-

sary.
1. Stop the vehicle.
2. Lower the work unit onto the floor.
3. Set the drive direction switch into its neutral position 'N'. Apply
the parking brake.
4. Press the "Fan Reversal" (1) switch and keep it pressed.
5. Press the gas pedal down entirely for 30 s. The engine is run-
ning at its max. speed.
6. Release the gas pedal. The engine is running at idle speed.
7. Release the "Fan Reversal" switch (1).
8. Switch off the motor and visually check the radiator ribs for
impurities.
9. If the radiator ribs are still dirty, use compressed air or a jet of
water to clean them.
G0065034A
1
NOTE
Do not hold the compressed air nozzle or water nozzle too
close to the radiator segments. Use no scrubber for cleaning
since the plates may be damaged
V-Belt, checking the condition
Check the drive belt for fissures.
● Transversal fissures in direction of the belt width are permit-

ted.
● Longitudinal fissures in direction of the belt length crossing

transversal fissures, missing parts, or damaged tissue layers
are not permitted.
● In these cases, replace the drive belt.
WA100M-5 – VEAM280201 5-27

5 Maintenance
Engine, checking the oil level, topping up oil
NOTE
1
After you have switched off the engine, wait at least 5 min-
utes before you check the engine oil level. The machine must
stand on an even surface.
1. Pull out the oil dipstick (1) and wipe off the oil with a clean
cloth.
2. Completely re-insert the oil dipstick and pull it out again after
a few seconds. The oil level must be between the (H) and (L)
markings on the oil dipstick. 2
3. If the oil level does not reach up to the (L) marking, top up
engine oil. For detailed information on recommended oils, see
section "5.3. Lubricants, fuels and filling capacities" on
page 5-18.
NOTE
Do not fill in too much oil in one go via the filler!
4. Wait three minutes before you check the oil level again. If the
oil level is above the (H) marking, drain off some oil (see
"Engine, draining off oil" on page 5-29).
5-28 WA100M-5 – VEAM280201

Maintenance 5
Engine, draining off oil
If you have topped up too much oil, you must drain off the excess
oil. Have an oil trough with a sufficient capacity ready.
1. Put the oil trough under the drain screw (arrow).
4. Drain the oil.
5. Detach drain hose (2) from drain valve. This causes the drain
valve to close. 1
6. Check oil level again.
7. Fit cap back onto drain valve (1).
WA100M-5 – VEAM280201 5-29

5 Maintenance
Checking the fuel level – refuelling
WARNING
● Danger of fire! Fuel that has spilled over may ignite!
● Immediately remove fuel that has spilled over.
1. Turn the start switch to the operating position 'I' and check the
fuel level indicated on the fuel level indicator.
0
F - tank full I
P
E - tank empty II
Then, return the start switch to the stop position '0'.
75_209
2. If required, refuel via the filler (1). For detailed information on

fuels, see section "5.3. Lubricants, fuels and filling capacities"
on page 5-18.
1
3. After refuelling, firmly close the filler.
5-30 WA100M-5 – VEAM280201

Maintenance 5
Water separator at the fuel filter – Draining water

and dirt sediments
1. Keep a container ready for collecting the fluid from the water
separator.
2. Unscrew the valve (1) at the bottom of the water separator by

4 rotations.
3. Drain off the water and dirt sediments until pure fuel flows out.
4. Screw the valve (1) tight again, clockwise.
WARNING
Do not pull the valve too tight, it could damage the thread!
NOTE
If you have drained more than 60 ml, it is recommended that
you fill the filter with fuel to prevent problems when starting
the motor.
1. Loosen the vent screw (1) on the injection pump.
2. Move the pump button (2) on the fuel filter until there are no
more bubbles in the fuel flowing from the vent screw.
3. Retighten the vent screw (1).
Checking the controls
1. Turn the start switch to the operating position 'I'.
An alarm buzzer sounds until the machine is started. 0

I
P
II
75_209
WA100M-5 – VEAM280201 5-31

5 Maintenance
2. Check that the following alarm and control indicators are on

until the engine is started: 4 1 2 3
1 Parking brake
2 Charging current
3 Engine oil level
4 Intake air preheater
3. Check that the fuel level indicator (5) indicates the fuel level in 5
the fuel tank.
NOTE
Contact your responsible Komatsu dealer, if one or several of
the indicators do not light up.
Do not only use the indicators to perform the checks prior to start.
Always perform the work described as regular maintenance, too.
Checking the electrical connections
CAUTION
● Danger of ignition! Inflammable material (leaves, twigs,
grass, etc.) may ignite within the electrical system!
● Remove inflammable material from the electrical system.
NOTE
If a fuse blows, or if there are any signs of a short-circuit
within the electrical system, inform your responsible
Komatsu dealer.
Regularly check that the terminals are fastened tightly, retighten

loose terminals.
Heater/air conditioning – checking rate of air flow
1. Turn start switch to position 'I'.
0
I
P
II
75_209
5-32 WA100M-5 – VEAM280201

Maintenance 5
arrows).
3. Switch blower on.
4. Check whether sufficient air flows out of the air outlet nozzles.
5. If insufficient air is coming out of the jets, either the filter

fleece in the heating/air conditioning unit is dirty and will have
to be cleaned or replaced or the condenser in the air condi-
tioning system is dirty and will have to be cleaned; see
"Heater/air conditioning – cleaning/replacing filter fleece" on
page 5-59.
Miscellaneous tests before starting work
● Check that the lighting equipment operates correctly; check it

for dirt and damage.
● Check the measuring instruments.
● Check both the horn and the reversing warning horn.
● Check both clearance and operation of the steering wheel.
● Check the function of the rear-view mirror; check it for dirt and
damage.
5.7.2. Maintenance upon demand
Checking the air-conditioning system
Check the air-conditioning system twice a year, in spring and

autumn.
Cleaning the condenser of air conditioning
NOTE
Do not wash the condenser with a steam cleaner. Otherwise,
the condenser will get hot and may break down.
If there is mud or dust sticking to the air conditioner condenser,

clean it with water.
WA100M-5 – VEAM280201 5-33

5 Maintenance
If the water pressure is too high, the fins may get deformed. When
washing with a high pressure washing device, apply the water
from a reasonable distance.
Checking the coolant level
WARNING
If the liquid gets into your eyes or on your hands, it may
cause loss of sight or frostbite: Therefore never loosen any
part of the refrigerant circuit.
Operate the cooler of the air-conditioning system for 5 - 10

minutes, then touch the high pressure portion and low pressure Sight glass
portion of the compressor (or high pressure hose and low
pressure hose joint) with your hand. At the same time, inspect the
flow of coolant (R134a) through the sight glass to check the gas
level.
Contact your Komatsu dealer for this inspection.
The sight glass is installed next to the receiver at the side of the Receiver
condenser. To this end the ladder at the right must be removed
and the condenser folded out.
Color condition Normal Abnormal

High pressure pipe is hot. High pressure pipe is
Amost no difference in
Temperature of high and Low presure pipe is cold. warm. Low pressure pipe is
temperature between high
low pressures pipes Clear difference in cold. Little difference in
and low pressure pipes.
temperature. temperature.
Almost transparent. All Bubbles are always visible. Opaque substance is
bubbles disappear if the Sometimes becomes visible in the fluid.
engine speed is increased transparent, or white
or reduced. bubbles appear.
Sight glass
Some parts contaminated Some parts heavily stained

Pipe connections Properly connected.
with oil. with oil.
Coolant level correct, no Ther may be a leak Almost all coolant has
General conditions of
abnormalitities. Ready for somewhere. Call service leaked out. Contact service
cooler
use. repair shop for inspection. repair shop immediately.
5-34 WA100M-5 – VEAM280201

Maintenance 5
Checking the window washing-fluid level, adding

fluid
Check the washing-fluid level in washer tank. When the fluid has
run short, add window washing fluid for cars.
To prevent the nozzles from clogging, be careful not to let dust get
into the fluid
WA100M-5 – VEAM280201 5-35

5 Maintenance
Re-charging a built-in battery
● Disconnect the cable of the negative pole before re-charging

or pull the battery main switch, in order to interrupt the power
supply. Otherwise, the alternator is damaged due to high volt-
age peaks.
● Remove all battery plugs before re-charging to ensure suffi-

cient ventilation.
To prevent gas explosions, do not come near the battery with
fire and do not produce any sparks.
● Interrupt the charging process if the temperature of the bat-

tery acid exceeds 113°F (45° C).
● Switch off the battery charger, as soon as the battery is re-

charged. If the battery is overloaded, the following situations
may occur:
❍ The battery may be overheated
❍ Decrease in the battery acid volume
❍ Damage of the electrode plates.
● Do not mix up the cables (positive (+) and negative (-)
Before performing maintenance operations, remove all cables

from the battery poles. Only exceptions: acid level check or the
measurement of the specific density.
5-36 WA100M-5 – VEAM280201

Maintenance 5
5.7.3. Maintenance after the first 50 operating hours
Hydraulic system, replacing the filter insert
WARNING
● Frequent contact between used hydraulic oil and skin
may cause skin lesions and other physical damage!
● Wear rubber gloves when changing the filter. Thoroughly

wash off any hydraulic oil adhering to your skin.
● Use only the prescribed supporting prop to support the

work unit. Never use other objects as supports

2. Raise the boom and tilt out the bucket.
WARNING
1

6. Turn the venting filter (1) several revolutions to let the pres-
sure escape.
7. Clean the surface of the filter cap (2) and the area around the
filter cap.
8. Unscrew the filter cap.
2
9. Pull out the filter element (3) at the handle (4) .
10. Pull the filter element off the handle and dispose of the filter
element.
11. Clean the inner surface of the filter housing. Before you start
cleaning, check that there is no undesired material in the filter
housing.
12. Put the handle onto the new filter element.
13. Insert the new filter element into the housing.
14. Screw on the filter cap and tighten it with 20 Nm.
15. Loosen the venting filter by turning it a couple of rotations.
16. Start up the engine.
17. Bring the boom into its highest position.
18. Bring bucket into its tip-in position (up to its limit stop).
19. Re-tighten the venting filter.
20. Perform a test run and check that the system is tight.
WA100M-5 – VEAM280201 5-37

5 Maintenance
Checking and tightening the wheel nuts
WARNING
Loose wheel nuts may cause severe accidents!
Regularly check and tighten the wheel nuts.
Tightening of loose nuts (1).
Nut torque: 45 - 55 kpm (450 - 500 Nm)
NOTE
If a threaded bolts breaks, replace all threaded bolts of the
respective wheel.
1
5-38 WA100M-5 – VEAM280201

Maintenance 5
5.7.4. Maintenance after the first 250 operating hours
Front and rear axle – oil change
Before you start maintenance work, park and secure the machine
as described in the chapter "5.1. Maintenance guide" on page 5-
2.
WARNING
● Wear rubber gloves when changing the oil. Thoroughly

DANGER
● There is danger of severe accidents, if you perform
mainte-nance work at a machine that has not been
parked and secured correctly!
● Park the machine on a solid, even surface and secure it,

before you start to perform maintenance work.
Planetary gearing
1. Start engine. Raise work unit and drive the machine until the
drain plug (1) for the planetary gearing on the wheel where
you want to change the oil has reached its lowest point.
Switch off engine. Lower work unit and apply parking brake.
2. Place drip pan or container underneath the drain plug (1).
3. Unscrew drain plug (1) and drain oil into container.
4. Drive machine until the planetary gearing drain plug hole (1)
is in a horizontal (3 o'clock") position.
5. Fill planetary gearing with oil until the oil reaches the lower lip
of the drain plug hole (1).
6. Clean drain plug and attach clean, undamaged (or new)

washer.
7. Screw drain plug in tight.
8. Change oil in other wheels of the front and rear axle following
the same procedure as described under no. 1 - 7 above.
WA100M-5 – VEAM280201 5-39

5 Maintenance
Differential
1. Put a container under the oil drain hole (2)
Remove the screw plugs of the oil drain hole (2) and the fill
and check hole (1). Drain the oil.
2. Clean the screw plugs and equip with seals that are in perfect
order.
3. Screw tight the screw plug (2).

1 2
4. Fill in oil through the fill and check hole (1), until the oil
reaches the lower edge.
6. Perform this task at the front and the rear axles.
Transfer box gearing – changing oil
WARNING
● Frequent contact between used oil and skin may cause
skin lesions and other physical damage!
wash off any oil adhering to your skin.
DANGER
mainte-nance work at a machine that has not been
parked and secured correctly!
Have an oil trough with a sufficient capacity ready.
1. Before you start maintenance work, park and secure the

machine as described in the chapter "5.1. Maintenance
guide" on page 5-2.
2. Unscrew the screw plugs (1) and (2) .
3. Drain the oil.
4. Clean the screw plugs and replace the gaskets.
5. Tightly screw in the screw plug (2).
6. Fill in oil via the check drill hole (1), until the oil reaches up to
the bottom edge of the check drill hole.
7. Tightly screw in the screw plug (1)
Checking and adjusting the valve clearance
Have the valve clearance checked and adjusted at an authorised

Komatsu garage.
5-40 WA100M-5 – VEAM280201

Maintenance 5
5.7.5. Maintenance every 10 operating hours
Lubrication, articulated steering
DANGER
There is danger of severe accidents, if you perform mainte-
nance work at a machine that has not been parked and
secured correctly!
Park the machine on a solid, even surface and secure it,

machine as described in the chapter "5.1Maintenance guide
5-2".
2. Clean the grease nipples marked by arrows.
Articulated steering (2 points)
3. Use a grease gun to fill the grease nipples with a sufficient

volume of lubricating grease.
4. Remove the used lubricating grease that is pressed out of the

bearings.
NOTE
Perform lubrication more frequently, when working in a con-
tinually wet or salty environment.
WA100M-5 – VEAM280201 5-41

5 Maintenance

All maintenance operations to be performed after 10 hours of
operation also fall into this maintenance category.
Checking the service brake and oil level, refilling

oil
Battery – checking the acid level
WARNING
● Danger of injury! The battery contains strongly
aggressive battery acid which may squirt out and burn
your eyes!
● Carry goggles and rubber gloves if you work on the

battery. Immediately rinse your eyes or skin using plenty
of water and go to see a doctor.
● Gases which may explode can form inside in the battery!
● Go not come with open fire or sparks into proximity of

the battery. Do not smoke.
1. For maintenance operations, park and secure the machine as

described in chapter "5.1. Maintenance guide" on page 5-2.
2. Check the battery and pole terminals for proper fit.
3. Clean the environment of the plugs.
4. Remove all plugs and check whether the battery acid is at the
acid level markings. Refill distilled water if the acid level is too
low.
NOTE
In cold weather, refill distilled water only immediately before
the starting the machine. The water can then mix with the
battery acid and does not freeze.
5. Measure the specific density of the battery acid and read off
the battery charging using the following conversion table.
Temperature
Battery 68°F 41°F 14°F -13°F
(20°C) (5°C) (-10°C) (-25°C)
Charge Specific Density (kg/l)
full 1,28 1,29 1,30 1,31

half 1,20 1,21 1,22 1,23
empty 1,12 1,13 1,14 1,15
6. Recharge insufficiently charged batteries.
5-42 WA100M-5 – VEAM280201

Maintenance 5
7. Lock the cells with the cleaned plugs.
Lubrication, work unit
Lubricating points of the work unit
DANGER
● If you perform maintenance operations at a machine
which is not properly parked and secured, severe acci-
dents may occur!
● Park the machine on firm, level ground and secure it

before starting the maintenance operations.
1. Park and secure machine for the maintenance operations as

2. Clean the grease nipples which are indicated by the arrows.
3. Use a grease gun to press sufficient grease into the grease

nipples.
(1) Lifting cylinder right and left side (4 locations)

(2) Rocker arm (2 locations)
(3) Boom (2 locations)
(4) Tipping cylinder (2 locations)
(5) Quick-change unit (2 locations)
(6) Clamshell bucket (6 locations)
4. Remove the old grease which is extruding at the bearings. 5
NOTE
If you operate in humid conditions or in a salty environment,
you must reduce the lubricating intervals.
6
75_263
WA100M-5 – VEAM280201 5-43

5 Maintenance

All maintenance operations to be performed after 10 and 50 hours
of operation fall also into this maintenance category.
Service brake – Checking the brake pads
WARNING
● Danger of accidents! If the oil level is too low, the service
brake may break down! 1
● If the brake fluid supply control lamp (1) lights up, you
must immediately stop and check the oil level.
CAUTION
● Danger of accidents! If you use usually available brake
fluid for filling up, the operational efficiency of the brake
system may be impaired!
● Use only the prescribed oil for filling up! Do not use
brake fluid! Pay attention to utmost cleanness!
as described in the chapter "5.1. Maintenance guide" on
page 5-2.
1. Check the brake discs and brake pads for wear and damage.
V-Belt, generator – checking and adjusting the ten-

sion
DANGER
● There is danger of severe accidents, if you perform main-
tenance work at a machine that has not been parked and
secured correctly!

● Danger of injuries! When the engine is in operation, there

is danger of severe injuries by moving parts within the
engine compartment! Do not work within the engine com-
partment, while the engine is in operation.

guide" on page 5-2.
2. Press down the V-belt in the middle of the longest straight

part. You should be able to press the V-belt down about 0.394
- 0.590 inch (10 - 15 mm).
5-44 WA100M-5 – VEAM280201

Maintenance 5
If you can press down the V-belt more than 0.394 - 0.590 inch
(10 - 15 mm), adjust the tension as follows:
3. Loosen the fastening screw (1) at the generator.
4. Loosen the connecting screw (2) between the generator and

the guide rail. 2
5. Loosen the fastening screw (3) at the guide rail.
6. Tilt the generator to adjust the tension of the V-belt.
7. Fasten the generator and the guide rail.

1
8. Check the tension of the V-belt and re-adjust it, if required.

3 75_220
WA100M-5 – VEAM280201 5-45

5 Maintenance
Air filter, removing and re-installing the filter

insert, checking and cleaning the filter insert
Structure of the air filter
The air filter consists of the air filter housing, the dust exhaust
valve, the filter cartridge and the safety filter.
Maintenance demand
If the air filter warning indicator (1) lights up, the air filter cartridge
is dirty. You must clean or exchange it immediately. 1
The filter insert has to be checked for perfect condition and be
cleaned every 250 operating hours, no matter whether the control
light is lit or not. If the filter insert is damaged or deformed, it must
be exchanged.
A dirty safety filter indicates that the filter cartridge is damaged. In

this case, both - filter cartridge and safety filter - must be
exchanged.
Removing the filter cartridge
WARNING
2
Danger of injury! When the engine is running, you may hurt
yourself on the movable components inside the engine
room!
Do not perform any operation in the engine room with the
engine running!
1. For maintenance operations, park and secure machine as

described in chapter "5.1. Maintenance guide" on page 5-2 .
2. Open the twistlocks on the cover of the air filter housing (2).
3. Remove the cover of air filter housing.
4. Pull out the filter cartridge (3).
5. Clean thoroughly the interior of the filter housing with a cloth.
5-46 WA100M-5 – VEAM280201

Maintenance 5
Cleaning or exchanging the filter cartridge
Depending on the degree of contamination, the air-filter insert can

be cleaned using compressed air or water to which a mild deter-
gent can be added.
NOTE
● The air-filter insert must be replaced, if the air-filter con-
trol light lights up only short time after cleaning.
● Do not clean the safety filter (refer to chapter "Air filter,

replacing the filter insert, replacing the safety filter" on
page 5-58).
● Cleaning with compressed air
CAUTION
Whirled up dust particles may hurt the eyes! Carry goggles if
you clean the filter cartridges with compressed air.
Dangerous dust particles may irritate the lung! Carry a dust-
protection mask if you clean the filter cartridges with com-
pressed air.
Blow out the air filter cartridge with dry compressed air (max.
87 psi / 6 bars) starting with the interior and then proceeding
to the outside. The air nozzle is to be moved up and down the
paper with a minimum distance of 1.18 inch (3 cm). You can
stop the cleaning if no more dust comes out.
Do not clean the cartridge by hitting it or by beating it against

other objects.
● Cleaning with water and cleaning agents
After the dust has been blown out, the filter cartridge can also
be additionally cleaned using warm water with a mild cleaning
agent max. 122°F (50°C) to remove adhering oil, grease,
soot, etc. For this purpose, swing the cartridge back and forth
in the solution.
Then, rinse the filter cartridge with clean water starting with
the inside and then proceeding to the outside (max. 43.5 psi /
3 bars) and let it dry at a temperature of max. 122°F (50°C).
WA100M-5 – VEAM280201 5-47

5 Maintenance
Checking the filter cartridge
Usually, it is required to check each air filter cartridge before it is

re-installed. For this purpose, insert a into the cartridge and visu-
ally check the filter paper against the transmitted light. If you
detect small holes or spots on which the paper is thin, the insert is
defective and must be replaced.
Check filter cartridges for damaged seals.
NOTE
Also new filter cartridges must be checked before they are
assembled.
Assembling the air filter cartridge
1. Check the safety filter for proper fit.
2. Insert the filter cartridge into filter housing in such a way that
the seal of the insert locks firmly on the collar of the housing
rear panel.
3. Assemble the air filter cap.
NOTE
If the control lamp lights up again after a short time, you
must replace both, the air filter cartridge and the safety filter
(refer to chapter "Air filter, removing and re-installing the fil-
ter insert, checking and cleaning the filter insert" on
page 5-46).
5-48 WA100M-5 – VEAM280201

Maintenance 5
Lubrication, steering cylinder
NOTE
you must shorten the lubricating intervals.
DANGER
dents may occur!

1. For maintenance operations, park the machine as described

in chapter "5.1. Maintenance guide" on page 5-2

nipples.
4. Remove the old grease which is extruding at the bearings.
(1) Front steering cylinder (1 location)

(2) Rear steering cylinder (1 location)
1
WA100M-5 – VEAM280201 5-49

5 Maintenance
Lubrication, self-aligning bearings of rear axle
NOTE
you must shorten the lubricating intervals.
DANGER
dents may occur!

1. For maintenance operations, park the machine as described

in chapter "5.1. Maintenance guide" on page 5-2

nipples.
4. Remove the old grease which is extruding at the bearings.
Self-aligning bearings of rear axle (1) (2)
5-50 WA100M-5 – VEAM280201

Maintenance 5
Checking and tightening the wheel nuts
WARNING
Loose wheel nuts may cause severe accidents!
Regularly check and tighten the wheel nuts.
Tightening of loose nuts (1).
Nut torque: 45 - 55 kpm (450 - 500 Nm)
NOTE
If a threaded bolts breaks, replace all threaded bolts of the
respective wheel.
1
WA100M-5 – VEAM280201 5-51

5 Maintenance

All maintenance operations to be performed after 10, 50, 100 and
250 hours of operation also fall into this maintenance category.
Hand pump - Checking the oil level
1. The oil level in the hand pump is checked with the cab tipped
down.
2. Remove the screw plug (1).

1
3. The oil level has to be up to the lower edge of the filling hole
(arrow).
4. If required, add oil (cross-reference to the list of consum-

ables).
5. Replace the screw plug into the filling hole (1) and pull it
hand-tight.
Service brake - Checking the brake pads and brake discs, checking the oil level
WARNING
● Danger of accidents! If the oil level is too low, the service
1
brake may break down!
● If the brake fluid supply control lamp (1) lights up, you
must immediately stop and check the oil level.
CAUTION
● Danger of accidents! If you use usually available brake
fluid for filling up, the operational efficiency of the brake
system may be impaired!
● Use only the prescribed oil for filling up! Do not use
brake fluid! Pay attention to utmost cleanness!
5-52 WA100M-5 – VEAM280201

Maintenance 5

described in chapter "5.1. Maintenance guide" on page 5-2 .
2. Check the brake fluid level at the expansion tank. The oil level max
must be 0.394 - 0.787 inch (10 - 20 mm) below the upper
edge of the expansion tank (marking). min
3. If you detect a significant oil loss, inform the responsible

Komatsu dealer.
4. Check the brake discs and brake pads for wear and damage.
5. Only move the sub-tank to position (1) to refill it.
POS1
WA100M-5 – VEAM280201 5-53

5 Maintenance
Engine – changing oil
WARNING
● Frequent skin contact with used engine oil may cause
skin lesions!
Thoroughly remove any engine oil adhering to your skin.
● Hot engine oil may cause scalding!

Wear rubber gloves and place the oil trough under the
discharge opening in such a way that you do not get in
contact with the oil when it is running out.
CAUTION
maintenance work at a machine that has not been parked
and secured correctly!

NOTE
Do not perform an oil change, unless the engine is switched
off and at operating temperature.

guide" on page 5-2. 1
2. Put the oil trough under the drain screw (arrow).
5. Drain the oil.
6. Check the removed oil for metal parts or undesired material. If

the oil contains such particles, inform the responsible
Komatsu dealer.
Detach drain hose (2) from drain valve. This causes the drain
valve to close.
7. Fit cap back onto drain valve (1).
5-54 WA100M-5 – VEAM280201

Maintenance 5
Replacing the oil filter cartridge
1. Turn the filter screwdriver anti-clockwise to unscrew the filter

cartridge (1).
2. Clean the filter holder. Completely fill up the new filter car-
tridge with engine oil. Slightly oil both the gasket and the
thread of the cartridge with engine oil. Screw in the filter car-
tridge again.
3. When installing the filter cartridge, make sure that the sealing
surface of the cartridge slightly touches the filter holder. Then,
tighten the filter cartridge according to the filter manufac-
turer's specification.
1
4. After replacing the filter cartridge, fill in clean engine oil

through the oil filler (2) until the oil level reaches up to the (H)
marking on the oil dipstick.
For details on recommended engine oils see section
6. Let the engine run in idle for about five minutes and check
whether oil is leaking out.
8. Wait about ten minutes, then check the oil level again. The oil 2
level must be between the 'H' and 'L' markings on the oil dip-
stick.
For further details see section "Engine, checking the oil level,
topping up oil" on page 5-28.
WA100M-5 – VEAM280201 5-55

5 Maintenance
Changing the fuel filter element
DANGER
● Danger of fire! Fuel may ignite on hot surfaces!
● Only change the filter elements if the engine has suffi-

ciently cooled down. Stay away with open fire or sparks
while handling with fuel. Do not smoke.
1. For maintenance tasks, park and secure the machine as

2. Clean the area around the fuel filter (1).
3. Unplug the connector (2) of the sensor (3).
4. Use the filter wrench to unscrew the filter cartridge counter-

clockwise.
5. Unscrew and remove the sensor (3) and O-ring (4) from the
fuel filter. 1
6. Screw the sensor (3) and new O-ring (4) onto the new fuel fil- 1
ter.
7. Clean the filter head (5).
8. Fill the new filter cartridge (1) with clean fuel.
9. Apply a thin layer of oil to the sealing surfaces of the filter car-
tridge.
10. When reinstalling the filter cartridge, screw it in by hand until

the seal makes contact. Subsequently tighten the filter car-
tridge (observe the instructions of the filter manufacturer).
11. Reconnect the connector (2) of the sensor (3).
12. Subsequently vent the fuel system.
13. Start the engine and check for leaks.
5-56 WA100M-5 – VEAM280201

Maintenance 5
Bleeding the fuel system
DANGER
Fuel in the injection system is under pressure. Carry goggles
and rubber gloves if you work on the injection pump. If you
are hit by a high-pressure fuel beam, immediately go into
medical treatment.
For maintenance operations, park and secure machine as

Bleeding the low pressure side:
1. Loosen the vent screw (1) on the injection pump.
2. Move the pump button (2) on the fuel filter until there are no
more bubbles in the fuel flowing from the vent screw.
3. Retighten the vent screw (1).
Bleeding the high pressure side:
WARNING
Danger of injury! When the engine is running, you may hurt
yourself on the movable components inside the engine
room.
1. Crank the engine (max. 30 seconds) and vent the lines con-
secutively, until the engine is running smoothly.
NOTE
If the fuel system has run empty during driving, or if repairs
or maintenance operations are to be performed, it is neces-
sary to bleed the system.
WA100M-5 – VEAM280201 5-57

5 Maintenance
Air filter, replacing the filter insert, replacing the

safety filter
Replacing the filter insert
Filtereinsatz auswechseln
NOTE
If the filter element is replaced for the third time in sequence,
it is required to replace also the safety filter.
1. Open the air filter and remove the air-filter insert (1). Proceed
as described in chapter "Air filter, removing and re-installing
the filter insert, checking and cleaning the filter insert" on
page 5-46
2. Use a source of light (e.g. torch) to check the new air filter for
damages
3. Re-install the air-filter insert as described in chapter "Air filter, AE063690
removing and re-installing the filter insert, checking and

cleaning the filter insert" on page 5-46
Replacing the safety filter
NOTE
If the filter element is replaced for the third time in sequence,
it is required to replace also the safety filter.
1. Open the air filter and remove the air-filter insert (1). Proceed
as described in chapter "Air filter, removing and re-installing
the filter insert, checking and cleaning the filter insert" on
page 5-46.
2. Pull out the safety filter (2).
3. In order to prevent that dust enters the interior of the engine, it

is required to the air aspiration opening of the engine with a
clean cloth or similar.
4. Clean the interior of the air-filter enclosure and remove the

cloth from the air aspiration opening.
5. Use a source of light (e.g. torch) to check the new safety filter
for damages. If it is in perfect condition, press it firmly into
place.
6. Re-install the air-filter insert as described in chapter "Air filter,

removing and re-installing the filter insert, checking and
cleaning the filter insert" on page 5-46.
5-58 WA100M-5 – VEAM280201

Maintenance 5
Heater/air conditioning – cleaning/replacing filter

fleece
Clean filter fleece of heater unit
NOTE
If the filter fleece is too dirty it must be replaced.
1. Remove screws on the front cover (1) on the driver's cab

(4 screws).
2. Withdraw filter (2) from the heater unit (3).
3. Clean the filter in warm water (86°F - 104°F / 30 - 40°C) which

has had a little household cleaning solvent added to it.
Caution: Neither rub the filter fleece nor wring it out.
4. Allow the filter fleece to dry.
5. Insert dried filter fleece (2) back into the heater unit (3).
arrows).
7. Switch on the blower and check the air flow at the air-outlet
nozzles to the right and left of the steering column.
Caution: The air circulation nozzles in the floor room

must be open.
8. If the air flow is still too weak the filter fleece must be
replaced.
9. Screw front cover (1) back on.
WA100M-5 – VEAM280201 5-59

5 Maintenance
Cleaning the condenser of air conditioning
NOTE
Do not wash the condenser with a steam cleaner. Otherwise,
the condenser will get hot and may break down.
If there is mud or dust sticking to the air conditioner condenser,

clean it with water.
If the water pressure is too high, the fins may get deformed. When
washing with a high pressure washing device, apply the water
from a reasonable distance.
Multi-functional lever accumulator - checking gas

pressure
Ask your Komatsu dealer to check the accumulator gas pressure.

(Gas pressure: 290 psi / 20 bar).
E.C.S.S.-pressure accumulator (Option) - checking

gas pressure
Ask your Komatsu dealer to check the accumulator gas pressure.

(Gas pressure: 290 psi / 20 bar).
5-60 WA100M-5 – VEAM280201

Maintenance 5
Front and rear axle – checking the oil level
CAUTION

as described in the chapter "5.1. Maintenance guide" on
page 5-2.
Planet gear
1. Start engine, raise work unit and drive the machine until the
oil level marking at the planetary gearing of the wheel which
you are checking is in horizontal position. Switch off engine.
Lower work unit and apply parking brake.
2. Unscrew the locking screw (1) of the drill hole.
3. Check the oil level. The oil level must reach up to the bottom
edge of the check drill hole.
4. If the oil level is too low, top up oil via the check drill hole of
the screw plug.
2
For details on recommended oils, see section
5. Tightly screw in the screw plug.
6. Check the oil level at the other wheel of the front and rear
axle. For this purpose, proceed as described under points 1
through 5.
Differential
1. Unscrew the locking screw (2) of the drill hole at the front
axle. Check the oil level as described under points 3 through
5 in section "Planet gear".
2. Unscrew the locking screw (3) of the drill hole at the rear axle.
Check the oil level as described under points 3 through 5 in
section "Planet gear".
WA100M-5 – VEAM280201 5-61

5 Maintenance
Transfer box gearing – checking the oil level
NOTE
If the engine is not running, the oil level in the transfer box
can significantly rise. Therefore, only check the gear oil level
with the engine running idle at operating temperature. The
gearshift assembly must be in neutral position.
DANGER
dents may occur!


2. Clean the screw plug (1) and the adjacent environment.
3. Unscrew the screw plug.
4. Check the oil level. The oil level must be at the lower edge of
the control drill hole of the screw.
5. If the oil level is too low, fill up with oil using the control drill
hole of the screw (1).
6. Clean the screw plug and insert a new packing ring.
7. Re-tighten firmly the screw plug.
5-62 WA100M-5 – VEAM280201

Maintenance 5

All maintenance operations to be performed after 10, 50, 100, 250
and 500 hours of operation also fall into this maintenance cate-
gory.
V-Belt, generator – checking and adjusting the ten-

sion
DANGER
● There is danger of severe accidents, if you perform main-
tenance work at a machine that has not been parked and
secured correctly!
● Danger of injuries! When the engine is in operation, there
is danger of severe injuries by moving parts within the
engine compartment! Do not work within the engine com-
partment, while the engine is in operation.

machine as described in the chapter "5.1Maintenance guide
5-2".
2. Press down the V-belt in the middle of the longest straight
part. You should be able to press the V-belt down about 0.394
- 0.590 inch (10 - 15 mm).
If you can press down the V-belt more than 0.394 - 0.590 inch
(10 - 15 mm), adjust the tension as follows:
3. Loosen the fastening screw (1) at the generator.
4. Loosen the connecting screw (2) between the generator and
the guide rail. 2
5. Loosen the fastening screw (3) at the guide rail.
6. Tilt the generator to adjust the tension of the V-belt.
7. Fasten the generator and the guide rail.
8. Check the tension of the V-belt and re-adjust it, if required. 1
3 75_220
Service Brake - Checking and adjusting oil

Alll repairs on the brake system must be performed by a garage
which is authorised by Komatsu.
● Changing oil
● Checking tubes and lines
● Check the brake discs and brake pads for wear and damage.
● Adjusting the clearance of the brake disks
Checking and adjusting system pressures

Have the system pressures checked and adjusted at an
authorised Komatsu garage.
WA100M-5 – VEAM280201 5-63

5 Maintenance
Hydraulics – Exchanging the venting filters
WARNING
● Repeated skin contact with used hydraulic oil can cause
skin damage and other bodily harm!
● Wear rubber gloves when exchanging the filter. Carefully

wash off the hydraulic oil that has come into contact with
the skin.
1. Lower the work unit to the ground.
2. Switch off the machine.
3. Unscrew the cover on the hydraulic tank (arrow).
4. Clean the filter (1) and the area surrounding it.
5. Unscrew the old filter (1) and O-ring.
6. Screw in a new filter (1) with O-ring and hand-tighten.
7. Do a trial run to check that the system is free of leakage.
8. Screw the cover back onto the hydraulic tank.
5-64 WA100M-5 – VEAM280201

Maintenance 5
Hydraulic system, replacing the filter insert
WARNING
● Wear rubber gloves when changing the filter. Thoroughly

● Use only the prescribed supporting prop to support the

work unit. Never use other objects as supports.
2. Raise the boom and tilt out the bucket.
WARNING
1
6. Turn the venting filter (1) several revolutions to let the pres-
sure escape.
7. Clean the surface of the filter cap (2) and the area around the
filter cap.
8. Unscrew the filter cap.

2
9. Pull out the filter element (3) at the handle (4) .
10. Pull the filter element off the handle and dispose of the filter
element.
11. Clean the inner surface of the filter housing. Before you start
cleaning, check that there is no undesired material in the filter
housing.
12. Put the handle onto the new filter element.
13. Insert the new filter element into the housing.
14. Screw on the filter cap and tighten it with 20 Nm.
15. Loosen the venting filter screw by turning it a couple of rota-

tions.
19. Re-tighten the venting filter screw.

20. Perform a test run and check that the system is tight.
WA100M-5 – VEAM280201 5-65

5 Maintenance

All maintenance operations to be performed after 10, 50, 100,
250, 500 anfd 1000 hours of operation also fall into this mainte-
nance category.
Front and rear axle – oil change
WARNING

DANGER

Planetary gearing
1. Start engine. Raise work unit and drive the machine until the
drain plug (1) for the planetary gearing on the wheel where
you want to change the oil has reached its lowest point.
Switch off engine. Lower work unit and apply parking brake.
2. Place drip pan or container underneath the drain plug (1).
3. Unscrew drain plug (1) and drain oil into container.
4. Drive machine until the planetary gearing drain plug hole (1)
is in a horizontal (3 o'clock) position.
5. Fill planetary gearing with oil until the oil reaches the lower lip
of the drain plug hole (1).
6. Clean drain plug and attach clean, undamaged (or new)

washer.
7. Screw drain plug in tight.
8. Change oil in other wheels of the front and rear axle following
the same procedure as described under no. 1 - 7 above.
5-66 WA100M-5 – VEAM280201

Maintenance 5
Differential
1. Put a container under the oil drain hole (2)
Remove the screw plugs of the oil drain hole (2) and the fill
and check hole (1). Drain the oil.
2. Clean the screw plugs and equip with seals that are in perfect
order.

1 2
4. Fill in oil through the fill and check hole (1), until the oil
reaches the lower edge.
6. Perform this task at the front and the rear axles.
Transfer box gearing – changing oil
WARNING
● Frequent contact between used oil and skin may cause
skin lesions and other physical damage!
wash off any oil adhering to your skin.
DANGER
Have an oil trough with a sufficient capacity ready.

guide" on page 5-2.
2. Unscrew the screw plugs (1) and (2) .
3. Drain the oil.
4. Clean the screw plugs and replace the gaskets.
5. Tightly screw in the screw plug (2).
6. Fill in oil via the check drill hole (1), until the oil reaches up to
the bottom edge of the check drill hole.
7. Tightly screw in the screw plug (1)
WA100M-5 – VEAM280201 5-67

5 Maintenance

250, 500 and 1000 hours of operation also fall into this mainte-
nance category.
Cooling system – exchanging coolant and

cleaning the system
WARNING
● Danger of being burnt! The coolant is under pressure if
the engine is hot. Hot coolant may squirt out during
opening.
● Check the coolant level only after the engine has

sufficiently cooled down. Open the cover of the radiator
(arrow) by turning it slowly so that the pressure can
escape.
DANGER
Danger of fire! Antifreeze may ignite at the hot engine! Wait
until the engine has cooled down, before refilling antifreeze.
NOTE
● The coolant must be exchanged after max. two years.
● While preparing the coolant, make sure to adhere to the

prescribed mixing proportions to ensure a freezing
protection up to -34.6°F (-37°C)! This is also valid for
countries with moderate climate.
The coolant has to consist of 50 vol.% coolant additive and

50 vol.% water. Only monoethylene glycol and dieethylene glycol
are permitted as coolant additives which are both contained in
commercially available standard coolants.
If the water contains too much lime, the cooling system may be
impaired. In this case, use a mixture of potable water and distilled
or deionized water.
In areas where the water is hard, always add KOMATSU genuine

corrosion resistor agent KI. One packet of corrosion resistor (No.
600-411-1120) agent contains 100g (0.22 lb). The standard den-
sity of the mixture should be 7g/liter (0.065 oz/US gal).
5-68 WA100M-5 – VEAM280201

Maintenance 5
Draining off the coolant
1. Switch off the engine and let it cool down.
2. Swivel the radiator cap (arrow) slowly to the side, up to the

first fixed stop, and let the pressure escape. Then press down
the cover, while proceeding with swivelling. Then, remove the
cover.
3. Stretch a tube onto the drain opening (1) of the discharge

cock and insert the other tube end into the collecting con-
tainer.
4. Open the discharge cock and let the coolant run off.
5. Close the discharge cock.
Cleaning the cooling system
NOTE
The cooling system may only be filled slowly since otherwise
the included air cannot escape completely. After filling up,
wait approx. 3 minutes and refill liquid, if required.
1. Fill up the cooling system slowly with cleaning fluid
(Adhere to the specifications of the cleaning agent manufac- 1

turer)
2. With the radiator cap opened, let the engine run for 5 minutes
with a coolant temperature of approx. 176°F (80°C).
3. After the cleaning, switch off the engine and open the drain
valve (1) to let the entire cooling system run empty.
Re-lock the drain valve (1) and slowly fill the cooling system
with clean water.
4. Let the engine run for five minutes with a coolant temperature
of approx. 176°F (80°C).
5. Then, let the cooling system run empty again. If the extruding
water is not clean, the cooling system must be re-flushed until
the extruding water is clean.
6. Close the drain valve.
WA100M-5 – VEAM280201 5-69

5 Maintenance
Filling Up Coolant
1. Empty and clean the expansion tank.
2. Prepare the coolant as prescribed.
3. Fill up the coolant slowly into the cooling system up to the

overflow shoot of the radiator.
4. To bleed the cooling system while the radiator cap is

removed, let the engine run idle for three minutes with its
lower speed (rpm) and then for another five minutes with its
top speed. Fill up with coolant if the coolant level in the radia-
tor is dropping.
5. Switch off the engine, wait approx. three minutes and then
refill coolant up to overflow shoot of the radiator. Re-lock the
radiator.
6. Fill up coolant into the expansion tank, until the coolant level
is between the MAX and MIN markings.
Checking and adjusting the valve clearance
Have the valve clearance checked and adjusted at an authorised

Komatsu garage.
5-70 WA100M-5 – VEAM280201

Maintenance 5
Hydraulic system, oil change
WARNING
● Frequent skin contact with used hydraulic oil may cause
skin damages and other injuries! Carry rubber gloves for
exchanging the filter. Wash any spilled hydraulic oil thor-
oughly from your skin.
● Danger of being burnt! The hydraulics tank is under pres-

sure. Hot hydraulic oil may squirt out and cause injuries!
Carry rubber gloves and hold the oil trough under the
discharge hole in such a way that you cannot come into
contact with the extruding oil.
Keep a collecting container with sufficient capacity ready.
1. Park the machine on level ground.
4. Secure on the right side the articulated steering with the lock-
ing bolt.
5. Unlock the feeding and ventilation screw (1) by turning it

slowly to let the pressure escape.
WA100M-5 – VEAM280201 5-71

5 Maintenance
6. Loosen the screw plug (2) of the hydraulic oil tank and let the
oil run off.
7. Open drain valve (3) gradually to drain the oil.
8. After draining the oil, close drain valve (3).

2
9. Re-tighten the screw plug with its seal being in perfect condi-
tion.
10. Unscrew the feeding and ventilation screw (1).
11. Fill up oil until the oil level is between the centre and top edge
of the inspection glass.
13. Raise and lower the work unit several times, while operating
the bucket at the same time.
14. Lower the bucket onto the ground and bring it into mining
position.
15. Check the oil level with the engine running idle in its low
speed position.
16. Ventilate the hydraulic oil tank (see section "Ventilating the
hydraulic oil tank" on page 5-72).
3
NOTE
Do not fill up with too much hydraulic oil! Otherwise, the
pressure in the hydraulic oil container increases inadmissi-
bly high.
Ventilating the hydraulic oil tank
1. Loosen the feeding and ventilation screw by turning it a cou-

ple of rotations.
5. Re-tighten the feeding and ventilation screw.
5-72 WA100M-5 – VEAM280201

Maintenance 5
Checking the fuel pump
Let the fuel pump be checked at a garage which is authorised by

Komatsu.
Checking the fuel and coolant tubes, replacing the

tubes (if required)
Have the fuel and coolant tubes checked and replaced, if

required, at an authorised Komatsu garage.
Checking the water pump
Let the water pump be checked at a garage which is authorised

by Komatsu
WA100M-5 – VEAM280201 5-73

5 Maintenance

250, 500, 1000 and 2000 hours of operation also fall into this
maintenance category.
Lubrication, universal joint
DANGER
l If you perform maintenance tasks on a machine that is
not properly parked and secured, there is danger of
severe accidents!
● Park the machine on hard, level ground and secure the

machine before you start with the maintenance tasks.
1. For maintenance tasks, park and secure the machine as

2. Unscrew the sealing plug (arrow) from the cardan shaft.
3. Screw a grease nipple (1) into the cardan shaft.
4. Lubricate the cardan shaft with special grease (2), until

grease escapes at the bearings.
5. Remove the grease that escaped at the bearings.
6. Unscrew the grease nipple from the cardan shaft.
7. Screw the sealing plug back in and pull it tight.
8. Perform this maintenance task at the front and rear of the car-
dan shaft.
NOTE
Only "Staburags NBU 12/300 KP" special grease may be
used for maintenance. Using different grease will reduce the
life span of the cardan shaft.
Pos. Name Order number
1 Grease nipple 42Y-00-H3040
2 Grease 42S-09-H1030
5-74 WA100M-5 – VEAM280201

Technical data
6. Technical data
WA100M-5 – VEAM280201 6-1

6.1. Technical data Technical data
6.1. Technical data

WA100M-5
Performance
Model Komatsu S4D95LE-3
Engine Output (ISO 9249) 61.5 kW (82.5 Hp)
Torque, max. (ISO 9249) 291 Nm

Engine
Starting motor 12 V - 2.2 kW
Alternator 12 V - 60 A
Battery 92 Ah
Driving Speed Standard type 1st Drive range 0 - 3.1 mph (5 km/h)
forwards and backwards 2nd Drive range 0 - 12.43 mph (20 km/h
Driving Speed 30 km/h type 1st Drive range 0 - 4.2 mph (6.8 km/h)
forwards and backwards 2nd Drive range 0 - 18.6 mph (30 km/h)
12.43 mph (20 km/h) 53.96 kN

Tractive force, max.
18.6 mph (30 km/h) 50.39 kN
Over bucket 14’ 9" ft. in. (4,570 mm)

Turning radius
Over tires 13’ 4" ft. in. (4,080 mm)
42W-70-22000
Bucket, Standard
(42.38 cu ft / 1.2 m3)
6-2 WA100M-5 – VEAM280201

Technical data 6.2. Noise emission levels
6.2. Noise emission levels

Two labels indicating the machine noise level are affixed on the
machine.
● Sound pressure level at the operator’s station, measured

according to ISO6396 (Dynamic test method, simulated work-
ing cycle).
● Sound power level emitted by the machine, measured

according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
6.3. Vibration levels

When used for its intended purpose, levels of vibration for the
earth-moving machine transmitted from the operator’s seat are
lower than or equal to the tested vibrations for the relative
machinery class in compliance with ISO 7096.
The actual acceleration value for the hands and arms is less than
or equal to m/s². The actual acceleration value for the body is less
than or equal to m/s².
These values were determined using a representative machine

and measured during the typical operating condition indicated
below according to the measurement procedures that are defined
in the standards ISO 2631/1 and ISO 5349.
Operating condition:
(WHEEL LOADER:) V-shape loading
Guide to Reduce Vibration Levels on Machine

The following guides can help an operator of this machine to
reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual

● Tire pressures (for wheeled machines)
WA100M-5 – VEAM280201 6-3

6.3. Vibration levels Technical data
● Brake and steering systems
● Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling

in good condition
● Remove any large rocks or obstacles
● Fill any ditches and holes
● Site manager should provide machine operators with

machine and schedule time to maintain terrain conditions
4. Use a seat that meets ISO 7096 and keep the seat main-
tained and adjusted
● Adjust the seat and suspension for the weight and size of the
operator
● Wear seat belt
● Inspect and maintain the seat suspension and adjustment

mechanisms
5. Steer, brake, accelerate, shift gears (for wheeled machines),

and move the attachment levers and pedals slowly so that the
machine moves smoothly
6. Adjust the machine speed and travel path to minimize the

vibration level
● When pushing with bucket or blade, avoid sudden loading;

load gradually
● Drive around obstacles and rough terrain conditions
● Slow down when it is necessary to go over rough terrain
● Make the curve radius of traveling path as large as possible
● Travel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance trav-

eling
● Reduce speed to prevent bounce
● Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of

low back pain
● Operate the machine only when you are in good health.
● Provide breaks to reduce long periods of sitting in the same

posture
● Do not jump down from the cab or machine
● Do not repeatedly handle and lift loads
6-4 WA100M-5 – VEAM280201

Technical data 6.4. Limit values for slopes
6.4. Limit values for slopes

Maximum slope angle for machine operation
If operating the machine on a slope, its angle must not exceed

35° uphill, downhill or sideways. If you angle the machine at more
than 35° during operation, the motor, transmission, hydraulic sys-
tem or axles, will not be supplied with sufficient oil and can be
damaged.
A uphill 30°
B downhill 30°
C sideways 30°
75_046
WA100M-5 – VEAM280201 6-5

6.4. Limit values for slopes Technical data
6-6 WA100M-5 – VEAM280201

Special equipment and attachments
7. Special equipment and

attachments
WA100M-5 – VEAM280201 7-1

7.1. E.C.S.S. Special equipment and attachments
7.1. E.C.S.S.
Always read this section before installing and operating the
E.C.S.S. as safe as possible.
7.1.1. Structure and functioning principle of the E.C.S.S.

● The E.C.S.S. uses the hydraulic spring effect of the hydraulic
accumulator installed to the circuit at the lift cylinder base end
to absorb the vibration of the chassis when the machine is
travelling. This enables the machine to travel smoothly at high
speed.
● The E.C.S.S. consists of the E.C.S.S. switch, hydraulic

accumulator and solenoid valves. When the travel damper
switch is turned ON, the solenoid valves open, the circuit at
the lift cylinder base end is connected with the hydraulic
accumulator.
7.1.2. Precautionary measures for switching on the E.C.S.S.
WARNING
If the E.C.S.S. system is switched on during a journey, or
when the working attachment is in raised position, it may
move up or down depending upon the bucket load.
For this reason, extreme caution is advised when operating
the switch.
When inspecting and servicing the machine, E.C.S.S. lower the

work equipment to the ground then turn the E.C.S.S. switch OFF
before beginning to service.
NOTE
The E.C.S.S. system is activated when the transmission is
shifted in 2nd gear and the machine is traveling at a speed
higher than 3.10 mph (5 km/h).
7-2 WA100M-5 – VEAM280201

Special equipment and attachments 7.1. E.C.S.S.
7.1.3. Operating the E.C.S.S.
Switching ON the E.C.S.S.
1. Precondition:
Speed range No. 2 must be switched on in order to ensure

that the E.C.S.S. system can be activated. To do this, press
the "Driving range up to 12 mph (20 km/h)" button.
2. Press the E.C.S.S. switch.
The green control lamp in the switch lights up.
❍ If the machine drives faster than 3.10 mph (5 km/h), the

E.C.S.S. is automatically activated and the E.C.S.S.
control lamp lights up on the dash panel.
❍ If the machine drives slower than 3.10 mph (5 km/h), the

E.C.S.S. is switched off and the control lamp on the dash
panel goes out.
❍ However, the control lamp in the E.C.S.S. switch remains

lit in green.
NOTE
● To ensure that the E.C.S.S. system can remain fully
effective when the machine is underway, do not tilt the
bucket all the way through till it touches the limit stops.
● Do not support the boom when on the road.
Switching OFF the E.C.S.S.
1. Press the E.C.S.S. switch.
The control lamp in the switch goes out.
WA100M-5 – VEAM280201 7-3

7.1. E.C.S.S. Special equipment and attachments
7.1.4. Precautions when handling the accumulator
WARNING
Danger of injury! Pressure accumulator is filled with highly
pressurised nitrogen.
Do not open or damage the pressure accumulator.
● Immediately inform your Komatsu dealer, if you detect mal-

functions or defects of pressure accumulators.
● Filling the pressure accumulator with gas or topping up gas in

the pressure accumulator is strictly limited to persons
authorised to handle highly pressurised gas.
● Do not hit against the pressure accumulator.
● Keep naked light and sources of heat away from pressure

accumulator.
● Do not drill holes into the pressure accumulator.
● Do not weld parts to the pressure accumulator.
● The service technicians must depressurise the hydraulic

system before they can remove the pressure accumulator.
● The service technician must let the gas escape before they
can disassemble the pressure accumulator.
7-4 WA100M-5 – VEAM280201

Index
8. Index
WA100M-5 – VEAM280201 8-1

Index
A Special equipment . . . . . . . . . . . . . . . . . . . . . . . 3-5

Warning beacon . . . . . . . . . . . . . . . . . . . . . . . 3-10
Accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Control lamps
Adjusting driver’s seat . . . . . . . . . . . . . . . . . . . . . 3-41
High-beam headlights . . 3-4, 3-8, 3-11, 3-16, 3-21
Adjusting operator’s seat . . . . . . . . . . . . . . . . . . . 3-41
Control lever
Air conditioning
for special equipment . . . . . . . . . . . . . . 3-26, 3-56
Condenser . . . . . . . . . . . . . . . . . . . . . . . 5-33, 5-60
Steering column adjustment . . . . . . . . . . . . . . 3-24
Filter fleece . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
Switching lever of bucket . . . . . . . . . . . . 3-27, 3-57
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Control monitors
Alarm horn for reverse driving . . . . . . . . . . . . . . . 3-29
Main control monitor . . . . . . . . . . . . . . . . . . . . . 3-5
Articulated steering catch . . . . . . . . . . . . . . . . . . 3-28
Maintenance monitor . . . . . . . . . . . . . . . . . . . . . 3-5
Attachment for protection against falling
Coolant
objects (FOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Filling up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Cooling system
B Changing coolant . . . . . . . . . . . . . . . . . . . . . . 5-68
Battery Checking coolant level . . . . . . . . . . . . . 3-36, 5-26
Connecting/disconnecting . . . . . . . . . . . . . . . . 2-7 Cleaning coolant . . . . . . . . . . . . . . . . . . . . . . . 5-68
Filling up battery acid . . . . . . . . . . . . . . . . . . . . 2-7 Topping up coolant . . . . . . . . . . . . . . . . 3-36, 5-26
Bleeding the fuel system
High pressure side . . . . . . . . . . . . . . . . . . . . . 5-57 D
Low pressure side . . . . . . . . . . . . . . . . . . . . . 5-57
Booster cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Brake Direction indicator lever . . . . . . . . . . . . . . . . . . . . 3-17
Actuating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Drive direction lever . . . . . . . . . . . . . . . . . . . . . . . 3-50
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Braking on slopes . . . . . . . . . . . . . . . . . . . . . . 3-53 High-speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Braking with the service brake . . . . . . . . . . . . 3-52 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Checking parking brake . . . . . . . . . . . . . . . . . . 4-8 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Checking the parking brake function . . . . . . . . 4-8 Driving direction switch . . . . . . . . . . . . . . . . . . . . . 3-18
Checking the service brake . . . . . . . . . . . . . . . 4-8
If the service brake breaks down . . . . . . . . . . 3-66 E
Insufficient braking action . . . . . . . . . . . . . . . . . 4-8 E.C.S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Bucket switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Level indicator . . . . . . . . . . . . . . . . . . . . . . . . 3-74 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Manual lowering . . . . . . . . . . . . . . . . . . . . . . . 2-12 Emergency lowering system . . . . . . . . . . . . 2-12, 4-9
Emergency steering system . . . . . . . . . . . . . . . . . . 4-9
C Emission Control Warranty Statement . . . . . . . . . 1-14
Engine
Changing driving direction . . . . . . . . . . . . . . . . . . 3-50
Changing engine oil . . . . . . . . . . . . . . . . . . . . . 5-54
Changing oil
Checks before starting . . . . . . . . . . . . . . . . . . 3-36
Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Machine identification plate . . . . . . . . . . . . . . . 1-11
Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Starting . . . . . . . . . . . . . . . . . . . . . . . . . 3-34, 3-45
Transfer box . . . . . . . . . . . . . . . . . . . . . . 5-40, 5-67
Checks before starting . . . . . . . . . . . . . . 2-10
Checking the service brake and oil level . . . 5-42, 5-44
with booster cable . . . . . . . . . . . . . . . . . . . 4-6
Checks before starting . . . . . . . . . . . . . . . . 3-34, 3-36
Switching off . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Cold weather operation . . . . . . . . . . . . . . . . . . . . 3-83
Check after stopping . . . . . . . . . . . . . . . . 3-76
Control lamp
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Topping up coolant . . . . . . . . . . . . . . . . . . . . . . 2-6
Air-intake preheater . . . . . . . . . . . . . . . . . . . . . 3-9
Topping up engine oil . . . . . . . . . . . . . . . . . . . . 2-6
Direction indicators . . . . . . . . . . . . . . . . . . . . . . 3-9
Warm-up phase . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Driving direction switch . . . . . . . . . . . . . . . . . . 3-9
Engine oil
E.C.S.S. electronics . . . . . . . . . . . . . . . . . . . . 3-10
Checking oil level . . . . . . . . . . . . . . . . . . . . . . 3-36
E.C.S.S. electronics, in switch . . . . . . . . . . . . 3-10
Top up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Fan reversal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Énoncé De Garantie Sur Le Contrôle
Hazard warning lights . . . . . . . . . . . . . . . . . . . . 3-9
Des Émissions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Heated rear window . . . . . . . . . . . . . . . . . . . . . 3-9
Equipment, CE-conforming . . . . . . . . . . . . . . . . . 1-24
High beam . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
in working lights switch . . . . . . . . . . . . . . . . . . 3-10
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
8-2 WA100M-5 – VEAM280201

Index
Machinery Directive . . . . . . . . . . . . . . . . . . . . . 1-5 M

Excavation work . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
Machine
Before leaving . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
F Breaking in . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Driving with high-speed gear . . . . . . . . . . . . . 3-50
First-aid kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 General view . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
FOPS (see Attachment for protection against Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
falling objects) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Front axle Loading . . . . . . . . . . . . . . . . . . . . . . . . . 1-29, 2-18
Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
Fuel Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Checking fuel level . . . . . . . . . . . . . . . . . . . . . 5-30 Parking . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17, 3-75
Fuel level indicator . . . . . . . . . . . . . . . . . . . . . 3-13 Parking on a slope . . . . . . . . . . . . . . . . . . . . . 3-54
Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Refuelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Specifications . . . . . . . . . . . . . . . . . . . . . 1-11, 1-13
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
G on slopes . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Garantie sur le contrôle des émissions . . . . . . . . 1-15 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
General view Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
H with transport vehicle . . . . . . . . . . . . . . . 3-81
Heating Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 Machine identification plate . . . . . . . . . . . . . . . . . 1-11
High beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Machine modifications . . . . . . . . . . . . . . . . . . . . . . 1-5
Hydraulic system Machine specifications . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic oil Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Topping up . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Maintenance
After storage . . . . . . . . . . . . . . . . . . . . . . . . . . 3-86
Air conditioning
I Checking the air-conditioning system . . . 5-33
Indicators (see control lamps) . . . . . . . . . . . . . . . . 3-5 Cleaning the condenser . . . . . . . . . 5-33, 5-60
Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Air filter
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 Replacing the filter insert . . . . . . . . . . . . 5-58
Before starting . . . . . . . . . . . . . . . . . . . . . . . . 3-34
K Before storage . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Checking and adjusting system pressures . . . 5-63
Komatsu distributor, address . . . . . . . . . . . . . . . . 1-13
Checking the controls . . . . . . . . . . . . . . . . . . . 5-31
Cold weather operation . . . . . . . . . . . . . . . . . 3-84
L Coolant level
Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Checking . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Lights Topping up . . . . . . . . . . . . . . . . . . . . . . . 5-26
Headlamp flasher . . . . . . . . . . . . . . . . . . . . . . 3-18 Cooling system
High beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Cleaning the radiator segments . . . . . . . 5-27
Low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Cleaning the system . . . . . . . . . . . . . . . . 5-68
Parking lights . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 Exchanging coolant . . . . . . . . . . . . . . . . 5-68
Limiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 During storage . . . . . . . . . . . . . . . . . . . . . . . . 3-85
Loading work . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 Engine
Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 Changing oil . . . . . . . . . . . . . . . . . . . . . . 5-54
Low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 Checking the oil level . . . . . . . . . . . . . . . 5-28
Lubricant, general . . . . . . . . . . . . . . . . . . . . . . . . 5-12 Draining off oil . . . . . . . . . . . . . . . . . . . . 5-28
Lubricants Replacing the oil filter cartridge . . . . . . . 5-54
Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Topping up oil . . . . . . . . . . . . . . . . . . . . . 5-28
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 every 10 operating hours . . . . . . . . . . . . . . . . 5-41
Lubrication, self-aligning bearings of rear axle . . . 5-50 every 250 operating hours . . . . . . . . . . . . . . . 5-39
every 50 operating hours . . . . . . . . . . . . 5-42, 5-63
Front and rear axle
WA100M-5 – VEAM280201 8-3

Index
Checking the oil level . . . . . . . . . . . . . . . 5-61 Maintenance every 4000 operating hours . . . . . . 5-74
Hand pump - Checking the oil level . . . . . . . . 5-52 Lubrication, universal joint . . . . . . . . . . . . . . . . 5-74
Heater/air conditioning Maintenance every 50 operating hours . . . . . . . . 5-37
Cleaning/replacing filter fleece . . . . . . . . 5-59 Checking and tightening the wheel nuts . . . . . 5-38
Hydraulic system Hydraulic system, replacing the filter insert . . . 5-37
Changing the filter insert . . . . . . . . . . . . 5-38 Maintenance every 500 operating hours . . . . . . . 5-52
Oil change . . . . . . . . . . . . . . . . . . . . . . . 5-71 Air filter, replacing the safety filter . . . . . . . . . . 5-58
Ventilating the hydraulic oil tank . . . . . . . 5-72 Engine – changing oil and replacing . . . . . . . . 5-54
Hydraulics Front and rear axle – Checking oil level . . . . . 5-61
Exchanging the filter insert . . . . . . . . . . . 5-64 Fuel system – Bleeding the fuel system . . . . . 5-57
Exchanging the venting filters . . . . . . . . 5-64 Fuel system – Changing the filter element . . . 5-56
Lubrication . . . . . . . . . . . . . . . . . . 5-43, 5-49, 5-74 Heater/air conditioning
Work unit . . . . . . . . . . . . . . . . . . . . . . . . 5-43 – cleaning/replacing filter . . . . . . . . . . . . . . . . 5-59
Maintenance guidelines . . . . . . . . . . . . . . . . . . 5-2 Hydraulic system – Changing the filter insert . 5-58
Maintenance schedule chart . . . . . . . . . . . . . 5-24 Replacing the oil filter cartridge . . . . . . . . . . . . 5-55
Miscellaneous tests before starting work . . . . 5-33 Transfer box gearing – Checking oil . . . . . . . . 5-62
Prior to start . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Maintenance upon demand . . . . . . . . . . . . . . . . . 5-33
System pressures Checking the air-conditioning system . . . . . . . 5-33
Checking and adjusting . . . . . . . . . . . . . 5-63 Checking the coolant level . . . . . . . . . . . . . . . 5-34
Transfer box gearing Checking the window washing-fluid level . . . . 5-34
Changing oil . . . . . . . . . . . . . 5-40, 5-62, 5-67 Re-charging a built-in battery . . . . . . . . . . . . . 5-36
Valve play Measuring indicators . . . . . . . . . . . . . . . . . . . . . . 3-13
Checking and adjusting . . . . . . . . . . . . . 5-40 Measuring instruments
V-belt Coolant temperature indicator . . . . . . . . . . . . . 3-14
Checking and setting the tension . . . . . . 5-64 Fuel level indicator . . . . . . . . . . . . . . . . . . . . . 3-13
Checking the condition . . . . . . . . . . 5-27, 5-64 Operating hour meter . . . . . . . . . . . . . . . . . . . 3-13
Washing-fluid level . . . . . . . . . . . . . . . . . . . . . 5-35 Multifunctional lever
Water separator at the fuel filter . . . . . . . . . . . 5-31 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55
Wheel nuts Pressure accumulator . . . . . . . . . . . . . . . . . . . 5-60
Checking . . . . . . . . . . . . . . . . . . . . 5-38, 5-51
Maintenance after the first 250 operating hours . 5-39 O
Checking and adjusting the valve clearance . 5-40
Operating conditions
Front and rear axle – oil change . . . . . . . . . . 5-39
Asbestos containing material . . . . . . . . . . . . . . 2-5
Transfer box gearing – changing oil . . . . . . . . 5-40
Working
Maintenance after the first 50 operating hours . . 5-42
at high temperatures . . . . . . . . . . . . . . . . . 2-6
Battery – Checking acid level . . . . . . . . . . . . . 5-42
close to power lines . . . . . . . . . . . . . . . . . 2-13
Checking the service brake and oil level . . . . 5-42
on snow . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Lubrication, work unit . . . . . . . . . . . . . . . . . . . 5-43
Working on loose soil . . . . . . . . . . . . . . . 2-15
Maintenance every 10 operating hours . . . . . . . . 5-41
Operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Lubrication, articulated steering . . . . . . . . . . . 5-41
Operating elements . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Maintenance every 1000 operating hours . . . . . . 5-63
Measuring indicators . . . . . . . . . . . . . . . . . . . . 3-13
Checking and adjusting system pressures . . . 5-63
Overall view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Service Brake - Checking and adjusting oil . . 5-63
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
V-Belt, generator – checking and adjusting . . 5-63
Operating hour meter . . . . . . . . . . . . . . . . . . . . . . 3-13
Operating material, general . . . . . . . . . . . . . . . . . 5-12
Front and rear axle –Changing oil . . . . . . . . . 5-66
Operation
Transfer box gearing – Changing oil . . . . . . . 5-67
Articulated steering catch . . . . . . . . . . . . . . . . 3-28
Changing direction . . . . . . . . . . . . . . . . . . . . . 3-50
Checking fuel and coolant tubes . . . . . . . . . . 5-73
in cold weather . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Checking the fuel pump . . . . . . . . . . . . . . . . . 5-73
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Checking the water pump . . . . . . . . . . . . . . . 5-73
Loading in diagonal direction . . . . . . . . . . . . . . 3-63
Cooling system – exchanging and checking . 5-68
Multifunctional lever . . . . . . . . . . . . . . . . . . . . . 3-25
Hydraulic system, oil change . . . . . . . . . . . . . 5-71
Piling up material . . . . . . . . . . . . . . . . . . . . . . . 3-64
Valve play – Checking and adjusting . . . . . . . 5-70
Precautionary measures . . . . . . . . . . . . . . . . . 3-66
Ventilating the hydraulic oil tank . . . . . . . . . . . 5-72
Preparing storage . . . . . . . . . . . . . . . . . . . . . . 3-85
Maintenance every 250 operating hours
Pre-start checks . . . . . . . . . . . . . . . . . . . . . . . 3-34
Air filter – Cleaning and checking . . . . . . . . . . 5-46
Removal work . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54
V-Belt, generator – checking and adjusting . . 5-44
V-shaped loading . . . . . . . . . . . . . . . . . . . . . . 3-64
8-4 WA100M-5 – VEAM280201

Index
Wheeled loader . . . . . . . . . . . . . . . . . . . . . . . . 3-58 Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Work equipment . . . . . . . . . . . . . . . . . . . . . . . 3-55 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
P Loading operations . . . . . . . . . . . . . . . . . . . . . 2-14
Machine transport . . . . . . . . . . . . . . . . . . . . . 2-18
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Parking the machine . . . . . . . . . . . . . . . . . . . . 2-3
Parking lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Protective clothing . . . . . . . . . . . . . . . . . . . . . . 2-3
Parking on a slope . . . . . . . . . . . . . . . . . . . 3-54, 3-75
Subsequent installation . . . . . . . . . . . . . . . . . . 1-6
Pedals
Waste material . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Workplace . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Inch-Brake pedal . . . . . . . . . . . . . . . . . . . . . . . 3-24
Safety labels on the machine . . . . . . . . . . . . . . . 2-34
Precautionary measures
Safety lever for the work hydraulic system . . . . . 3-27
Driving up/down . . . . . . . . . . . . . . . . . . . . . . . 3-67
Safety measures
During machine travel . . . . . . . . . . . . . . . . . . . 3-68
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
In-water operation . . . . . . . . . . . . . . . . . . . . . . 3-66
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Pressure accumulator
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Multifunctional lever . . . . . . . . . . . . . . . . . . . . 5-60
Workplace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Precautions for maintenance . . . . . . . . . . . . . 2-31
Serial no. plate
Pressure accumulator (E.C.S.S.) . . . . . . . . . . . 7-4
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Pre-start checklist . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Checking the controls . . . . . . . . . . . . . . . . . . . 5-31
Service procedure . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Checking the electrical connections . . . . . . . . 5-32
Slopes, limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Checking the fuel level – refuelling . . . . . . . . . 5-30
Slow-blowing fuses . . . . . . . . . . . . . . . . . . . . . . . 3-31
Cooling system – checking the coolant level . 5-26
Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Engine, checking the oil level, topping up oil . 5-28
Standards
Heater/air conditioning – checking . . . . . . . . . 5-32
EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Miscellaneous tests before starting work . . . . 5-33
Start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
V-belt, checking the condition . . . . . . . . . . . . . 5-27
Start-up
Protective clothing . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Purging the fuel system . . . . . . . . . . . . . . . . . . . . 5-57
Steering column adjustment . . . . . . . . . . . . . . . . 3-43
Steering, machine . . . . . . . . . . . . . . . . . . . . . . . . 3-51
R Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Removal work . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 Fan reversal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Repeated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Roll-over protection system . . . . . . . . . . . . . . . . . . 2-6 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . 3-21
ROPS (see Roll-over protection system) . . . . . . . . 2-6 Battery main switch . . . . . . . . . . . . . . . . . . . . 3-20
Direction indicator lever . . . . . . . . . . . . . . . . . 3-17
Driving direction switch . . . . . . . . . . . . . . . . . 3-18
S E.C.S.S.-electronics . . . . . . . . . . . . . . . . . . . . 3-20
Safety belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Safety devices Fan reversal . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Attachment for protection against falling objects Front windscreen wiper . . . . . . . . . . . . . . . . . 3-16
(FOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 General view . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Hazard flasher switch . . . . . . . . . . . . . . . . . . . 3-16
First-aid kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Heated rear windscreen . . . . . . . . . . . . . . . . . 3-19
Roll-over protection system . . . . . . . . . . . . . . . 2-6 Lamp switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Light switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Safety instructions Rear windsreen wiper . . . . . . . . . . . . . . . . . . 3-17
asbestos dust . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Temperature rotary switch . . . . . . . . . . . . . . . 3-19
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6, 2-29 Variable shift control switch . . . . . . . . . . . . . . 3-20
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Warning beacon switch . . . . . . . . . . . . . . . . . 3-21
Engine coolant . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Switching off, Engine . . . . . . . . . . . . . . . . . . . . . . 3-76
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Fan and belts . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 T
Forklift truck attachment . . . . . . . . . . . . . . . . . 2-15 Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Height limitation . . . . . . . . . . . . . . . . . . . . . . . 2-15 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
High-pressure hoses . . . . . . . . . . . . . . . . . . . . 2-30 Temperature indicator . . . . . . . . . . . . . . . . . . . . . 3-14
High-pressure oil . . . . . . . . . . . . . . . . . . . . . . . 2-30 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . 5-21
WA100M-5 – VEAM280201 8-5

Index
Tipping down the driver's cab . . . . . . . . . . . . . . . 2-24 Tyre-appropriate operation . . . . . . . . . . . . . . . 3-58

Tipping up the driver's cab . . . . . . . . . . . . . . . . . 2-22 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Workplace, Safety at the . . . . . . . . . . . . . . 2-13, 2-15
Towing, Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Traction device . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Transfer box
Changing oil . . . . . . . . . . . . . . . . . . . . . . 5-40, 5-67
Checking oil . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
Transport
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
Troubleshooting table
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Turning, machine . . . . . . . . . . . . . . . . . . . . . . . . 3-51
Tyre pressure
table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
V
V-belt
checking the condtion . . . . . . . . . . . . . . . . . . 5-27
Ventilation system
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
W
Warm-up phase . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Warning lamps
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Engine oil pressure . . . . . . . . . . . . . . . . . . . . . 3-7
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Washing fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Wearing parts list . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Work hydraulic system
Multifunction control lever . . . . . . . . . . . . . . . 3-25
Safety lever . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Work unit
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Manual lowering . . . . . . . . . . . . . . . . . . . . . . . 2-12
Multifunctional lever . . . . . . . . . . . . . . . . . . . . 3-55
Picking up the multi-purpose bucket . . . . . . . 3-72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Removing the multi-purpose bucket . . . . . . . . 3-74
Selecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Working with the machine
Excavation work . . . . . . . . . . . . . . . . . . . . . . . 3-61
Forklift truck attachment . . . . . . . . . . . . . . . . . 3-64
Loading work . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Planing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62
Removal work . . . . . . . . . . . . . . . . . . . . . . . . 3-59
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-63
8-6 WA100M-5 – VEAM280201

Notes
9. Notes
WA100M-5 – VEAM280201 9-1

Notes
9-2 WA100M-5 – VEAM280201

Notes
WA100M-5 – VEAM280201 9-3

Notes
9-4 WA100M-5 – VEAM280201

Notes
WA100M-5 – VEAM280201 9-5

Notes
9-6 WA100M-5 – VEAM280201

Operation & Maintenance Manual: Wheel Loader

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Operation & Maintenance VEAM280201

© 2006 Komatsu Hanomag GmbH

WA100M-5 – VEAM280201 1-1

1.1. Product publications information

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

OPERATION & MAINTENANCE MANUAL:

SAFETY MANUAL: ___________

1-2 WA100M-5 – VEAM280201

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

TYPE or PRINT CITY. STATE. ZIP CODE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

PARTS BOOK PUBLICATION

WA100M-5 – VEAM280201 1-3

● Notes on the Operating Instructions

● Notes on Safety Regulations

● Notes on Lubricants and Operating Agents

The operating manual belongs to the machine and is stored in the

The operating instructions are part of the machine and must

If the operating instructions have been lost or if they have become

The owner of the machine has to ensure that

● all persons in charge with operating or maintaining the

● the machine is correctly operated.

● the machine is not improperly modified.

1-4 WA100M-5 – VEAM280201

If the owner modifies safety-related parts of the machine, the cer-

Our continuous effort to improve the machine’s design may lead

If these improvements result in minor changes, these minor

These operating instructions may refer to attachments and spe-

This machine is labelled with the CE mark indicating that it meets

This means that in those cases in which the machine is modified

If a machine is used in other countries than Germany, it may be

Should you have any questions concerning standards and guide-

WA100M-5 – VEAM280201 1-5

In addition to the operating instructions, you must also adhere to

Notes on later installation of electrical and electronical

Electrical or electronical devices and/or components installed

If you later install electrical and electronical devices and/or com-

The following requirements must additionally be met for a later

● Only install devices which have a licence referring to valid

● The device must be stationary.

● Only use portable or mobile devices in the cab, if they are

● Install the sender in such a way that it is physically separated

● When installing the aerial, make sure that it is installed cor-

In addition, adhere to all information about installation and con-

1-6 WA100M-5 – VEAM280201

1.3. Safety information

Most accidents are caused by disregard of basic safety regula-

The following words are used in this manual and on stickers on

The safety instructions are listed in the chapter "2. Safety" on

WA100M-5 – VEAM280201 1-7

The transport of persons in the work equipment is strictly

We cannot foresee all circumstances which could result in poten-

1-8 WA100M-5 – VEAM280201

1.4.1. Intended use

The standard operation cycle of a loader includes filling up and

In combination with the forklift truck attachment the picking up,

Refer to chapter "3.3.9. Working with the wheel loader" on