Komatsu WA100M-5 Wheel Loader Operation & Maintenance Manual (SN:H50051 & up) Komatsu WA100M 5 – PDF DOWNLO

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Komatsu WA100M-5 Wheel Loader Operation & Maintenance Manual (SN:H50051 & up) Komatsu WA100M 5

KOMATSU WA100M-5 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:H50051 & UP) KOMATSU WA100M 5 – PDF DOWNLO:

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Komatsu WA100M-5 Wheel Loader Operation & Maintenance Manual (SN:H50051 & up) Komatsu WA100M 5

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 operating 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 Conformity (CE), and the licence are to be handed over to the new owner.

TABLE OF CONTENTS:

Komatsu WA100M-5 Wheel Loader Operation & Maintenance Manual (SN:H50051 & up) Komatsu WA100M 5

1. Introduction..................................................................................................  3
	1.1. Product publications information........................................................................  4
	1.2. Foreword................................................................................................  6
		EU Directives............................................................................................  7
	1.3. Safety information......................................................................................  9
	1.4. Introduction............................................................................................ 11
		1.4.1. Intended use...................................................................................... 11
		1.4.2. Breaking-in the machine........................................................................... 12
	1.5. Location of plates...................................................................................... 13
		1.5.1. Machine identification plate (PIN)................................................................ 13
		1.5.2. Engine name-plate................................................................................. 13
		1.5.3. Axle serial no. plate............................................................................. 14
		1.5.4. Transmission serial no. plate..................................................................... 14
		1.5.5. ROPS/FOPS-Cab serial no. plate.................................................................... 14
		1.5.6. Seat operator serial no. plate.................................................................... 15
		1.5.7. Table to enter serial no. and distributor......................................................... 15
	1.6. Emission Control Warranty............................................................................... 16
		1.6.1. Emission control warranty statement (Applies to Canada only)...................................... 16
	1.7. Garantie sur le contrôle des émissions.................................................................. 17
		1.7.1. Énoncé de garantie sur le contrôle des émissions (applicable au Canada seulement)................. 17
	1.8. Table of contents....................................................................................... 18
	1.9. Dimensions, weights and operating data.................................................................. 25
	1.10. CE-conforming equipment................................................................................ 26
		1.10.1. CE-conforming equipment - part 1................................................................. 26
		1.10.2. CE-conforming equipment - part 2................................................................. 27
		1.10.3. Manufacturer-supplied CE-conforming equipment.................................................... 28
	1.11. Loading and securing................................................................................... 31
2. Safety........................................................................................................ 33
	2.1. General safety measures................................................................................. 34
		2.1.1. Safety instructions............................................................................... 34
		2.1.2. Safety devices.................................................................................... 34
		2.1.3. Emergency exit.................................................................................... 34
		2.1.4. Clothing and personal protection.................................................................. 35
		2.1.5. Machine modifications............................................................................. 35
		2.1.6. Before you leave the driver’s seat................................................................ 35
		2.1.7. Mounting and dismounting.......................................................................... 36
		2.1.8. Fire prevention and fire fighting................................................................. 36
		2.1.9. Protection against asbestos dust.................................................................. 37
		2.1.10. Protection against injuries...................................................................... 37
		2.1.11. Working at high temperatures..................................................................... 38
		2.1.12. Roll-over protection system (ROPS)............................................................... 38
		2.1.13. Attachment for protection against falling objects (FOPS)......................................... 38
		2.1.14. Attachments...................................................................................... 39
		2.1.15. Battery.......................................................................................... 39
	2.2. Safety precautions during operation..................................................................... 40
		2.2.1. Prior to daily starting up........................................................................ 40
			Workplace safety..................................................................................... 40
			In the driver's cab.................................................................................. 40
			Indoor operation..................................................................................... 41
			Gas, dust, and inflammable vapours................................................................... 41
			Mirrors, windows and lighting........................................................................ 41
		2.2.2. Machine operation................................................................................. 42
			Before you start the engine.......................................................................... 42
			Reversing............................................................................................ 42
			Driving.............................................................................................. 43
			Driving on slopes.................................................................................... 43
			Emergency Lowering System............................................................................ 44
			Working close to power lines......................................................................... 45
			Loading.............................................................................................. 46
			Good Vision.......................................................................................... 46
			Working on snow...................................................................................... 46
			Height limitation.................................................................................... 47
			Brakes............................................................................................... 47
			Working on loose soil................................................................................ 47
			Working with the forklift truck attachment........................................................... 47
			Parking the machine.................................................................................. 49
		2.2.3. Transport......................................................................................... 50
			Loading and unloading the machine.................................................................... 50
			Transport............................................................................................ 50
	2.3. Precautions for maintenance............................................................................. 51
		2.3.1. Personnel......................................................................................... 51
		2.3.2. Before carrying out maintenance................................................................... 51
		2.3.3. During maintenance................................................................................ 60
		2.3.4. Tyres............................................................................................. 64
	2.4. Safety labels on the machine............................................................................ 66
		2.4.1. Positions and order numbers of information labels................................................. 66
		2.4.2. Positions and order numbers of safety labels...................................................... 67
3. Operation..................................................................................................... 69
	3.1. General view............................................................................................ 70
		3.1.1. General view of the machine....................................................................... 70
		3.1.2. Controls and indicators........................................................................... 71
			Overall view......................................................................................... 71
			Switches, controls and warning lights................................................................ 72
	3.2. Description of the individual elements.................................................................. 73
		3.2.1. Instrument panel.................................................................................. 73
			Warning lights....................................................................................... 74
			Control lamps........................................................................................ 76
			Measuring indicators................................................................................. 81
		3.2.2. Switches.......................................................................................... 83
		3.2.3. Control levers and pedals......................................................................... 91
		3.2.4. Articulated steering catch........................................................................ 96
		3.2.5. Traction device................................................................................... 96
		3.2.6. Socket (12 V)..................................................................................... 97
		3.2.7. Door unlocking system............................................................................. 97
		3.2.8. Alarm horn for reverse driving - option........................................................... 97
		3.2.9. Fuses............................................................................................. 98
		3.2.10. Slow-blowing fuses............................................................................... 99
		3.2.11. Adjusting the heater and ventilation system......................................................100
		3.2.12. Air-conditioning.................................................................................101
	3.3. Operation...............................................................................................102
		3.3.1. Pre-start checks..................................................................................102
			Visual inspection....................................................................................102
			Pre-start checks.....................................................................................104
			Adjustments prior to machine start...................................................................109
			Adjusting the driver’s seat..........................................................................109
		3.3.2. Starting the engine...............................................................................113
			Warming up the engine................................................................................114
		3.3.3. Driving with the machine..........................................................................115
			Start-up.............................................................................................115
			Limiting the maximum speed...........................................................................116
		3.3.4. Changing the driving direction....................................................................118
		3.3.5. Turning and steering..............................................................................119
		3.3.6. Braking...........................................................................................120
		3.3.7. Stopping the machine..............................................................................122
		3.3.8. Operating the work equipment......................................................................123
			Multifunctional lever................................................................................123
			Control lever for special equipment..................................................................124
			Switching lever of bucket............................................................................125
		3.3.9. Working with the wheel loader.....................................................................126
			Tyre-appropriate operation...........................................................................126
			Switching on the 100 % differential lock (if equipped)...............................................126
			Loading work.........................................................................................127
			Removal work.........................................................................................127
			Excavation work......................................................................................129
			Planing..............................................................................................130
			Transporting.........................................................................................131
			Unloading............................................................................................131
			Working with the forklift truck attachment...........................................................132
		3.3.10. Precautions for special operations...............................................................134
			Permissible water depth..............................................................................134
			Working on snow......................................................................................134
			Dumping on steep slopes..............................................................................134
			Working in the vicinity of electrical overhead lines.................................................134
			Operation on slopes..................................................................................134
			Working on loose soil................................................................................134
			If the service brake breaks down.....................................................................134
			Precautionary measures when driving up or down.......................................................135
			Precautionary measures during machine travel.........................................................136
		3.3.11. Adjusting the position of the work equipment.....................................................137
			Selecting a work unit................................................................................137
			Removing the work unit...............................................................................139
			Picking up the multi-purpose bucket..................................................................140
			Removing the multi-purpose bucket....................................................................142
			Level indicator for the bucket.......................................................................142
		3.3.12. Parking the machine..............................................................................143
		3.3.13. Switching off the engine.........................................................................144
		3.3.14. Check after stopping the engine..................................................................144
		3.3.15. Locking..........................................................................................144
		3.3.16. Tyre handling....................................................................................145
			Precautionary measures when handling tyres...........................................................145
			Tyre pressure........................................................................................145
	3.4. Transporting the machine................................................................................147
		3.4.1. Securing the articulated steering.................................................................147
		3.4.2. Lifting the machine...............................................................................148
		3.4.3. Driving the machine onto loading area of transport vehicle........................................149
		3.4.4. Securing the machine during the transport.........................................................150
		3.4.5. After transport...................................................................................150
	3.5. Cold weather operation..................................................................................151
		3.5.1. Before the cold season............................................................................151
		3.5.2. Precautions after completion of work..............................................................152
		3.5.3. After the cold season.............................................................................152
	3.6. Long-term storage.......................................................................................153
		3.6.1. Before storage....................................................................................153
		3.6.2. During storage....................................................................................153
		3.6.3. After storage.....................................................................................154
4. Troubleshooting...............................................................................................155
	4.1. Towing the machine......................................................................................156
	4.2. Starting the engine with a booster cable................................................................160
	4.3. For insufficient braking effect.........................................................................162
		4.3.1. Checking the service brake........................................................................162
		4.3.2. Checking the parking brake function...............................................................162
	4.4. Emergency steering properties...........................................................................163
	4.5. Emergency lowering......................................................................................163
	4.6. Other troubles..........................................................................................164
		4.6.1. Electrical system.................................................................................164
		4.6.2. Engine............................................................................................165
		4.6.3. Hydraulic system..................................................................................168
		4.6.4. Brakes............................................................................................170
		4.6.5. Steering..........................................................................................170
		4.6.6. Axles.............................................................................................171
		4.6.7. Driver's cab......................................................................................171
5. Maintenance...................................................................................................173
	5.1. Maintenance guide.......................................................................................174
		5.1.1. Guidelines........................................................................................174
	5.2. Maintenance basics......................................................................................184
		5.2.1. Oil, fuel and coolant specifications..............................................................184
			Oil..................................................................................................184
			Fuel.................................................................................................185
			Coolant..............................................................................................186
			Grease...............................................................................................186
			Storing oil and fuel.................................................................................187
			Filters..............................................................................................187
			Biodegradable hydraulic oil and lubricants...........................................................187
		5.2.2. Specifications of the electrical system...........................................................188
		5.2.3. Wearing parts list................................................................................189
	5.3. Lubricants, fuels and filling capacities................................................................190
		5.3.1. Lubrication chart.................................................................................191
	5.4. Tools and standard tightening torques (bolts, nuts).....................................................192
		5.4.1. Introduction of recommended tools.................................................................192
		5.4.2. Torque list.......................................................................................193
	5.5. Periodical replacement of safety-critical parts.........................................................195
	5.6. Maintenance schedule chart..............................................................................196
	5.7. Service procedure.......................................................................................198
		5.7.1. Pre-start checklist...............................................................................198
			Cooling system - checking the coolant level, topping up coolant......................................198
			Cleaning the radiator segments.......................................................................199
			V-Belt, checking the condition.......................................................................199
			Engine, checking the oil level, topping up oil.......................................................200
			Checking the fuel level - refuelling.................................................................202
			Water separator at the fuel filter - Draining water and dirt sediments...............................203
			Checking the controls................................................................................203
			Checking the electrical connections..................................................................204
			Heater/air conditioning - checking rate of air flow..................................................204
			Miscellaneous tests before starting work.............................................................205
		5.7.2. Maintenance upon demand...........................................................................205
			Checking the air-conditioning system.................................................................205
			Checking the window washing-fluid level, adding fluid................................................207
			Re-charging a built-in battery.......................................................................208
		5.7.3. Maintenance after the first 50 operating hours....................................................209
			Hydraulic system, replacing the filter insert........................................................209
			Checking and tightening the wheel nuts...............................................................210
		5.7.4. Maintenance after the first 250 operating hours...................................................211
			Front and rear axle - oil change.....................................................................211
			Transfer box gearing - changing oil..................................................................212
			Checking and adjusting the valve clearance...........................................................212
		5.7.5. Maintenance every 10 operating hours..............................................................213
			Lubrication, articulated steering....................................................................213
		5.7.6. Maintenance every 50 operating hours..............................................................214
			Checking the service brake and oil level, refilling oil..............................................214
			Battery - checking the acid level....................................................................214
			Lubrication, work unit...............................................................................215
		5.7.7. Maintenance every 250 operating hours.............................................................216
			Service brake - Checking the brake pads..............................................................216
			V-Belt, generator - checking and adjusting the tension...............................................216
			Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert....218
			Lubrication, steering cylinder.......................................................................221
			Lubrication, self-aligning bearings of rear axle.....................................................222
			Checking and tightening the wheel nuts...............................................................223
		5.7.8. Maintenance every 500 operating hours.............................................................224
			Hand pump - Checking the oil level...................................................................224
			Service brake - Checking the brake pads and brake discs, checking the oil level......................224
			Engine - changing oil................................................................................226
			Replacing the oil filter cartridge...................................................................227
			Changing the fuel filter element.....................................................................228
			Bleeding the fuel system.............................................................................229
			Bleeding the low pressure side:......................................................................229
			Bleeding the high pressure side:.....................................................................229
			Air filter, replacing the filter insert, replacing the safety filter.................................230
			Heater/air conditioning - cleaning/replacing filter fleece...........................................231
			Cleaning the condenser of air conditioning...........................................................232
			Multi-functional lever accumulator - checking gas pressure...........................................232
			E.C.S.S.-pressure accumulator (Option) - checking gas pressure.......................................232
			Front and rear axle - checking the oil level.........................................................233
			Transfer box gearing - checking the oil level........................................................234
		5.7.9. Maintenance every 1000 operating hours............................................................235
			V-Belt, generator - checking and adjusting the tension...............................................235
			Service Brake - Checking and adjusting oil...........................................................235
			Checking and adjusting system pressures..............................................................235
			Have the system pressures checked and adjusted at an authorised Komatsu garage.......................235
			Hydraulics - Exchanging the venting filters..........................................................236
			Hydraulic system, replacing the filter insert........................................................237
		5.7.10. Maintenance every 1500 operating hours...........................................................238
			Front and rear axle - oil change.....................................................................238
			Transfer box gearing - changing oil..................................................................239
		5.7.11. Maintenance every 2000 operating hours...........................................................240
			Cooling system - exchanging coolant and cleaning the system..........................................240
			Checking and adjusting the valve clearance...........................................................242
			Hydraulic system, oil change.........................................................................243
			Ventilating the hydraulic oil tank...................................................................244
			Checking the fuel pump...............................................................................245
			Checking the fuel and coolant tubes, replacing the tubes (if required)...............................245
			Checking the water pump..............................................................................245
		5.7.12. Maintenance every 4000 operating hours...........................................................246
			Lubrication, universal joint.........................................................................246
6. Technical data................................................................................................247
	6.1. Technical data..........................................................................................248
	6.2. Noise emission levels...................................................................................249
	6.3. Vibration levels........................................................................................249
	6.4. Limit values for slopes.................................................................................251
7. Special equipment and attachments.............................................................................253
	7.1. E.C.S.S.................................................................................................254
		7.1.1. Structure and functioning principle of the E.C.S.S................................................254
		7.1.2. Precautionary measures for switching on the E.C.S.S...............................................254
		7.1.3. Operating the E.C.S.S.............................................................................255
			Switching ON the E.C.S.S.............................................................................255
			Switching OFF the E.C.S.S............................................................................255
		7.1.4. Precautions when handling the accumulator.........................................................256
8. Index.........................................................................................................257
9. Notes.........................................................................................................263

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⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.