WA80 WA100M 7 Operation Manual

Operation and VENAM03001
Maintenance Manual
WA80M-7
WA100M-7
WHEEL LOADER
SERIAL NUMBERS
WA80M-7 H62051 and up
WA100M-7 H62051 and up
DANGER
Errors in the operation and maintenance may be
dangerous and cause personal injury. Operators and the
ORIGINAL INSTRUCTIONS
maintenance personnel must read and understand this
manual thoroughly before operating the machine or
performing maintenance. Keep this manual accessible at
all times and have all personnel read it periodically.
NOTE
Komatsu has had this Operation and Maintenance
Manual translated into some other languages used in the
European Union. Please contact your Komatsu
distributor if you need a manual in another language.
© 2016 Komatsu Hanomag GmbH

All Rights Reserved
Printed in Europe 02-2016
Foreword
1. Foreword
WA80M-7, WA100M-7 – VENAM03001 1-1

1.1 Foreword Foreword
1.1 Foreword
This manual provides rules and guidelines to help you use this
machine safely and effectively. The precautions in this manual
must be followed at all times during the operation and mainte-
nance of the machine. The majority of accidents are caused by a
failure to follow fundamental safety rules for the operation and
maintenance of machines. Accidents can be prevented by know-
ing beforehand the conditions that may create hazards during
operation or maintenance.
WARNING
 Operators and maintenance personnel must always do as fol-
lows before beginning operation or maintenance.
 Be sure to read and understand this manual thoroughly

before operating the machine or performing maintenance.
 Read the safety messages given in this manual and the

safety labels affixed to the machine thoroughly and be sure
that you understand them fully.
 Keep this manual at the storage location for the Operation

and Maintenance Manual given below.
 Have all personnel read the manual periodically. If this man-

ual is lost or has become so dirty as to be illegible, immedi-
ately request a replacement manual from Komatsu or your
Komatsu distributor.
 If you sell the machine, be sure to hand over this manual to

the new owners together with the machine.
 Komatsu delivers machines that comply with all applicable

regulations and standards of the country to which it has been
shipped. If this machine was purchased in another country,
safety devices and specifications may not be compliant with
the requirements applicable in the country of use. If there is
any question about whether your product complies with the
applicable standards and regulations of your country, consult
Komatsu or your Komatsu distributor before operating the
machine.
1-2 WA80M-7, WA100M-7 – VENAM03001

Foreword 1.1 Foreword
The operating manual is to be considered part of the machine and

should be stored in the lid of the hinged panel in the left side of
the operator's cab.
Any safety-relevant modification to the machine by the owner

voids the manufacturer's declaration of conformity.
Our continuous efforts to improve the machine's design may

result in minor changes to the machine.
The introduction of these improvements however does not con-

stitute an obligation on our part to implement the same changes
in machines already delivered and operating. Minor changes due
to improvements are not covered by this manual.
WA80M-7, WA100M-7 – VENAM03001 1-3

1.1 Foreword Foreword
EU Directives
Machines delivered by Komatsu are compliant with the Machine
Directive 2006/42/EEC and its amendments. If the machine is
used in another country, it is possible that certain safety devices
and specifications may not be compliant with the requirements
applicable in the country of use. For example, warning beacons
may be used in some countries while being prohibited in others.
If there is any question about whether your product complies with

the applicable standards and regulations of your country, consult
your Komatsu distributor before operating the machine.
Notes on subsequent installation of electrical and electronic

equipment and components
Electrical and electronic equipment and/or components installed

after delivery emit electromagnetic radiation which may possibly
influence the function of the electronic components and assem-
blies of the machine. This may affect the safety of the machine or
endanger persons. For this reason, please ensure that the follow-
ing safety instructions are observed.
If you are installing electrical or electronic equipment and/or com-

ponents in the machine and connect them to the vehicle's electri-
cal system, you are obliged to have the installation verified for not
interfering with vehicle's electronic system or other components.
In particular, please ensure that any subsequently installed elec-
trical and electronic components comply with the EMC Directive
2004/108/EC in its currently valid version and that they have CE
marks.
The following requirements also have to be met for subsequent

installation of mobile communication systems (e.g. radio, tele-
phone):
 Only equipment approved by national legislation (e.g. BZT

approval for Germany) may be installed.
 The unit must be fixed in position.
 Portable or mobile units may only be used inside the vehicles

if they are connected to a fixed outside antenna.
 The transmitter unit must be spatially separated from the

vehicle’s electronic system.
 Ensure that the antenna is installed properly with a good

earthing connection between the antenna and the vehicle
earth.
Also observe installation instructions by Komatsu or the manufac-

turer for wiring, installation and maximum permitted power con-
sumption.
1-4 WA80M-7, WA100M-7 – VENAM03001

Foreword 1.2 Safety information
1.2 Safety information

In order to ensure the safe operation of the machine, this manual
contains safety instructions, and there are safety labels affixed to
the machine. They are intended to inform the operator of situa-
tions that may pose an injury hazard and to point out ways to
avoid such situations.
1.2.1 Signal words

The following signal words are used to inform you that there is a
potentially hazardous situation that may lead to personal injury or
damage.
In this manual, the following signal words are used to express the
potential level of hazard.
DANGER
Indicates an imminently hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which, if not avoided,
could result in death or serious injury.
ATTENTION
Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. This word is also used to
indicate unsafe practices that may cause property damage.
Example of safety message using a signal word.
WARNING
 Engage the work equipment lock lever before leaving the
operator's cab.
 Accidentally touching the control levers when they are not

locked may result in serious injury or death.
Other signal words
In addition to the above, the following signal words are used to

provide useful information or indicate precautions that should be
followed to protect the machine.
WA80M-7, WA100M-7 – VENAM03001 1-5

1.2 Safety information Foreword
NOTICE
This word is used to indicate precautions that must be taken to
avoid actions which could shorten the life of the machine.
REMARK
This word is used for information that is useful to know.
1.2.2 Safety labels

Safety labels are affixed to the machine to inform the operating or
maintenance personnel immediately of hazards in the operation
or maintenance of the machine.
For details see “Safety labels (2-2)”.
Safety labels using pictograms
Safety pictograms use a picture to express a hazard level that

corresponds to the signal word. The pictures used are intended
to help the operating and maintenance personnel understand the
level and type of hazard at all times. Safety pictograms show the
type of hazardous condition at the top or on the left side, and the
method of avoiding the hazardous condition at the bottom or on
the right side. In addition, the type of hazardous condition is dis-
played inside a triangle, and the method of avoiding the hazard-
ous condition is shown inside a circle.
Komatsu cannot predict every circumstance that might involve a

potential hazard in operation and maintenance. Therefore, the
safety messages in this manual and on the machine may not Part no.
include all possible safety precautions. GK032002
If any procedures or actions not specifically recommended or

allowed in this manual are used, it is your responsibility to take
the necessary steps to ensure safety.
Never perform any type of work or use the machine in any way
that is expressly prohibited in this manual.
The explanations, values, and illustrations in this manual were

prepared based on the latest information available at the time.
Continuous improvements to the machine's design may result in
minor changes to the machine that may not be reflected in this
manual. Consult Komatsu or your Komatsu distributor for the lat-
est information available on your machine or for questions
regarding the information in this manual.
1-6 WA80M-7, WA100M-7 – VENAM03001

Foreword 1.3 Introduction
1.3 Introduction
This loader is an independently powered machine moving on
wheels. Using the equipment (e.g., a bucket or fork) installed to
its front, the loader can be used to load or dig material while mov-
ing forwards.
This Komatsu machine is designed to be used mainly for the fol-

lowing work:
 Digging
 Smoothing
 Pushing
 Loading
1.3.1 Intended use

If you use the machine for any other purpose than those specified
above, we will not accept any responsibility for its safety. Any con-
siderations regarding safety will 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 func-
tions explicitly prohibited in these operating instructions.
The transport of persons in the work equipment is strictly forbid-

den!
For details of the operating procedure, see chapter “Working with

the wheel loader (3-78)”.
WA80M-7, WA100M-7 – VENAM03001 1-7

1.3 Introduction Foreword
1.3.2. Breaking in the machine

Every machine has been thoroughly tested and set up before
shipping. However, a new machine needs to be handled carefully
during the first 100 hours of service.
If the machine is worked excessively hard during the breaking-in

period, this will cause premature deterioration of performance
and shorten the machine's service life. A new machine needs to
be broken in and serviced carefully.
Particularly observe the following points:
 Let the engine run at idle for 5 minutes after starting.
 Avoid operation with heavy loads or at high engine speeds.
 Avoid sudden starts and stops, hard acceleration and sudden

steering movements, except in emergencies.
The precautions for operation and maintenance in this manual as

well as the safety information apply only as long as the product is
used according to the specified intended use. If the machine is
used for any purpose not listed in this manual, Komatsu cannot
accept any responsibility for safety. In such cases, any safety
considerations are the sole responsibility of the operator.
Never perform any type of work or use the machine in any way
that is expressly prohibited in this manual.
1-8 WA80M-7, WA100M-7 – VENAM03001

Foreword 1.4 Key data of the machine
1.4 Key data of the machine
1.4.1 Product identification number (PIN)/Machine serial no. plate and its
position
Position of the serial no. plate (1)
1
Serial number stamp (2)
The plate is on the right side of the machine's front frame.
The design of the serial no. plate differs depending on the country.
1.4.2 Engine serial no. plate

Engine serial no. plate
WA80M-7, WA100M-7 – VENAM03001 1-9

1.4 Key data of the machine Foreword
1.4.3 Axle serial no. plate

Axle serial no. plate (1)
Rear axle: Left 1
Front axle: Right
1.4.4 Transmission serial no. plate

Transmission serial no. plate (1)
1.4.5 ROPS/FOPS cab serial no. plate

ROPS/FOPS cab serial no. plate
In the cab beneath the operator's seat.
1-10 WA80M-7, WA100M-7 – VENAM03001

Foreword 1.4 Key data of the machine
1.4.6 Operator's seat serial no. plate

Operator's seat serial no. plate
Under the bellows at the front of the seat, or on the rear lower
frame (arrow mark).
GJ2K4590
1.4.7 Serial number and distributor
Machine serial number
Engine serial number
Product identification number (PIN)
Komatsu Hanomag GmbH

Manufacturer name
Address Hanomag Straße 9
30449 Hanover
Germany
Dealer name
Address
Service personnel
Phone/fax
WA80M-7, WA100M-7 – VENAM03001 1-11

1.4 Key data of the machine Foreword
1.4.8 Declaration of Conformity

The manufacturer:
Komatsu Hanomag GmbH
Hanomag Straße 9
30449 Hanover
Germany
declares that this machine:
WA80M-7*
WA100M-7*
is in conformity with the applicable provisions of the following EU

Directives:
Machinery Directive 2006/42/EC

2004/108/EC until 19 April 2016
Electro Magnetic Compatibility Directive
2014/30/EU after 20 April 2016
Outdoor Noise Directive 2000/14/EC amended 2005/88/EC
Radio Equipment and Telecommunications Terminal
1999/5/EC until 12 June 2016
Equipment Directive
Radio Equipment Directive 2014/53/EU after 13 June 2016
* Explanation of machine category
Machine category Stand for:
WA Wheel loader
1-12 WA80M-7, WA100M-7 – VENAM03001

Foreword 1.5 Table of contents
1.5 Table of contents
1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
EU Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.2.1 Signal words. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.2 Safety labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.3.1 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.4 Key data of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.4.1 Product identification number (PIN)/Machine serial no. plate and its position . . . . . . . . 1-9
1.4.2 Engine serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.4.3 Axle serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.4 Transmission serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.5 ROPS/FOPS cab serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.4.6 Operator's seat serial no. plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4.7 Serial number and distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.4.8 Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.5 Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.6 Dimensions, weights, and operating data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.7 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1.7.1 Equipment – part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.7.2 Equipment – part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Safety labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Position of the safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3 Precautions during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

2.3.1 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2.3.3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.3.4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.4 Precautions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2.5 Precautions when handling tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.1 General view of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.2 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
WA80M-7, WA100M-7 – VENAM03001 1-13

1.5 Table of contents Foreword
General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.1.3 Machine monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.1.4 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2 Descriptions of the individual elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3.2.1 Machine monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Caution lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Pilot lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3.2.2 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3.2.3 Control levers and pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3.2.4 Steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.2.5 Tow hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.2.6 Trailer tow hitch (only WA100M-7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
3.2.7 Power outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.2.8 Door unlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.2.9 Back-up alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.2.10 Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
3.2.11 Slow-blow fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3.2.12 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
3.2.13 Setting the heating and ventilation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
3.2.14 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
3.3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49

3.3.1 Checks before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Checks before starting the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52
Adjustments before starting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
3.3.2 Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Ambient temperature for operation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Checks after starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3.3.3 Driving the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Limiting the maximum speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3.3.4 Changing direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3.3.5 Turning and steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3.3.6 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Engaging the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Disengaging the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
Braking with the service brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
If the service brake fails. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
Braking on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.3.7 Stopping and parking the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
3.3.8 Operating the work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
Multi-function lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
3.3.9 Return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
3.3.10 Working with the wheel loader. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Saving the tyres. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78
Engaging the 100% differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
1-14 WA80M-7, WA100M-7 – VENAM03001

Digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Excavating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Working with the forklift attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3.3.11 Operating precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Permissible water depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Working on snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Dumping on steep slopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Working near high-voltage cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Working on road shoulders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Working on loose ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
If the service brake fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
Precautions for driving uphill or downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Precautions when driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
3.3.12 Adjusting the work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Selecting the work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Attaching the work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
Removing the work equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
Removing the multi-purpose bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
Bucket level indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.3.13 Switching off the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.3.14 Checks after switching off the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.3.15 Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.3.16 Handling tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Precautions when handling tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Tyre pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Standard tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-97
3.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99

3.4.1 Transporting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Ensure steady positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
3.4.2 Loading the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Loading the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Securing the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Unloading the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
3.4.3 Lifting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
3.5 Operation in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106

3.5.1 Precautions for operation in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-106
3.5.2 Precautions after work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.5.3 After the cold weather period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.6 Long-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108

3.6.1 Before storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3.6.2 During storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3.6.3 After storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
3.7 Machines equipped with KOMTRAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-110

3.7.1 Basic precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
WA80M-7, WA100M-7 – VENAM03001 1-15

3.8 Reading error code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-112

3.8.1 Adjusting the monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
4. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Towing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Starting the engine with booster cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3 In case of insufficient brake power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.3.1 Checking the service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.2 Checking the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.4 Emergency steering properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.5 Emergency lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6 Other troubles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.6.1 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.6.2 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.6.3 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.6.4 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.6.5 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.6.6 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.6.7 Operator's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
5. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Maintenance guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.1.1 Tipping up the operator's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.1.2 Tipping down the operator's cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.2 Basic maintenance guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

5.2.1 Fuel, coolant and lubricant specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Storing oil and fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Biodegradable hydraulic oil and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.2.2 Outlines of the electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.3 Wear parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

5.3.1 Wear parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.4 Fuel, lubricants, and coolants; quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5.4.1 Lubrication table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.4.2 Recommended brands, recommended quality for products other than Komatsu genuine oil
5-22
5.5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5.5.1 List of required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.6 Periodic replacement of safety-critical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
1-16 WA80M-7, WA100M-7 – VENAM03001

5.7 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.8 Maintenance procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

5.8.1 Checks before starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.8.2 Corrective maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Air conditioner – checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Window washer fluid level – checking, adding fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Battery – charging the built-in battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Air grille – cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Radiator fins – cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Cooling system – cleaning internal area of the cooling system . . . . . . . . . . . . . . . . . . 5-32
Air cleaner – checking, cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Air cleaner – renewing, renewing safety filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.8.3 Maintenance after the first 50 service hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Hydraulic system – change filter insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Wheel nuts – checking and retightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Rear axle – lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5.8.4 Maintenance after the first 500 service hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Front and rear axle – change oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Transfer case – change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
5.8.5 Maintenance every 10 service hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Articulated steering – lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Check coolant level – add coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Water separator – draining water and dirt accumulations . . . . . . . . . . . . . . . . . . . . . . 5-43
Check engine oil level – add engine oil (WA80M-7). . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5.8.6 Maintenance every 50 service hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Work equipment – lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Central lubrication system – checking, replenishing grease . . . . . . . . . . . . . . . . . . . . 5-46
Check engine oil level – add engine oil (WA100M-7). . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5.8.7 Maintenance every 250 service hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Service brake – check the brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Steering cylinder – lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Rear axle – lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Wheel nuts – checking and retightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5.8.8 Maintenance every 500 service hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Manual pump – check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Service brake – check brake pads and brake disc, check oil level . . . . . . . . . . . . . . . 5-52
Engine oil – changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Oil filter cartridge – renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
Heating/air conditioner – clean/renew filter cloth, clean condenser . . . . . . . . . . . . . . . 5-55
Pressure accumulator for multi-function lever – checking gas pressure . . . . . . . . . . . 5-56
E.C.S.S. pressure accumulator – check gas pressure. . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Front and rear axle – check oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Transfer case – check oil level, add oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
Fuel prefilter – changing filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59
5.8.9 Maintenance every 1000 service hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Alternator V-belt – checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60
Service brake – checking, changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
System pressures – check and adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Hydraulic system – renewing filter insert, renewing venting filters . . . . . . . . . . . . . . . . 5-62
WA80M-7, WA100M-7 – VENAM03001 1-17

Fuel filter – change filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

Fuel system – bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64
5.8.10 Maintenance every 1500 service hours. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Front and rear axle – change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Transfer case – change oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Valve clearance – checking and setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Water pump – checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Alternator and starter – checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Fuel pump – checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Hydraulic system – change hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69
CCV filter – renewing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
Fuel and coolant hoses – checking, replacing/renewing if required . . . . . . . . . . . . . . . 5-73
Water pump – checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Checking the clamp of the high-pressure line is firmly seated and checking for
embrittlement of the rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Checking for missing fuel spray prevention cap and checking for embrittlement of the
rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Clamps of the high-pressure line – renewing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Fuel spray prevention cap – renewing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
6. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.1 WA80M-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.2 WA100M-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Noise emission levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3 Vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.4 Limit values for slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
7. Special equipment, attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 E.C.S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.1 Design and functional principle of the E.C.S.S.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.1.2 Precautions when 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 pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.2 Bucket position indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 Central lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.3.1 Changing the lubrication intervals and duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.2 Operating the central lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.3.3 Display and operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
1-18 WA80M-7, WA100M-7 – VENAM03001

Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Three-digit LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
8. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.1 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
9. Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
WA80M-7, WA100M-7 – VENAM03001 1-19

1.6 Dimensions, weights, and operating data Foreword
1.6 Dimensions, weights, and operating data
a
d
c
f H
b
E
D F
e B
C A
G0070228A
WA80M-7
1316
270
5144
k
l
h
m
n
g
G0070229A
1-20 WA80M-7, WA100M-7 – VENAM03001

Foreword 1.6 Dimensions, weights, and operating data
Dimensions, operating data with bucket WA80M-7 WA100M-7

Tyres 405/70R18 455/70R20
Bucket 420-70-32250 42W-70-32400
Bucket capacity according to ISO 7546 m³ 1.00 1.25
Material density t/m³ 1,8 1,8
Bucket weight without teeth kg 401 415
Stat. tipping load, straight kg 4595 5900
Stat. tipping load at 40° angle kg 3899 5030
Breakout force, hydraulic kN 37 74,2
Lifting force, hydraulic, on the ground kN 51 69,8
Operating weight (w/o counterweight) kg 5690 6950
Turning radius, outer edge of tyre mm 3875 4210
Turning radius, bucket corner mm 4290 4730
a Reach at 45° (without wear blades) mm 995 845
b Dumping height at 45° (without wear blades) mm 2425 2730
c Height, bucket pivot point mm 3225 3525
d Height, top edge of bucket mm 4190 4515
e Digging depth mm 90 130
f Max. loading height at 45° mm 2910 3185
A Overall length, bucket on the ground mm 5640 6000
B Wheelbase mm 2260 2400
C Bucket width mm 1915 2200
D Width over tyres mm 1880 2080
Track width, front mm 1470 1635
E
Track width, back mm 1435 1635
Ground clearance (axle/transfer case) mm 340 388
F
Ground clearance (cardan shaft) mm 446 501
H Overall height mm 2721 2885
Dimensions, operating data with fork
Fork length mm 1200 1200
g Max. reach on the ground mm 845 850
h Max. reach mm 1400 1380
j Max. reach at max. stacking height mm 700 565
k Max. height, fork carriage mm 3670 4000
l Height, fork pivot mm 3230 3525
m Max. stacking height mm 3065 3319
n Tine height at max. reach mm 1470 1539
Max. tipping load, fully extended kg 3523 4437
Max. tipping load, at angle kg 3000 3784
Max. tipping load, fully extended acc. to EN 474-3, 80% kg 2400 3027
Max. tipping load, fully extended acc. to EN 474-3, 60% kg 1800 2270
Operating weight with tines kg 5483 6840
WA80M-7, WA100M-7 – VENAM03001 1-21

1.7 Equipment Foreword
1.7 Equipment
1.7.1 Equipment – part 1
Equipment
1 2 3 4 5
Hydraulic Weight
Type Part no. Volume, m³
pressure, bar kg
42U-70-32260 1.0 401
42U-70-32250 1.0 422
WA80M-7 42U-70-22120 1.25 336
42U-70-22411 1.3 370
42U-70-32401 0.8 250 597
42W-7032260 1.05 695

Bucket
42W-70-32100 1.25 390
42W-70-32400 1.25 415
WA100M-7 42W-70-22080 1.6 461
42W-70-22110 1.8 496
42W-70-32310 1.4 452
42W-70-32300 1.4 427
1-22 WA80M-7, WA100M-7 – VENAM03001

Foreword 1.7 Equipment
1.7.2 Equipment – part 2
Equipment
1 2 3 4 5
Payload,
Payload,
fork carriage
fork carriage Weight
Type Part no. with additional
STD kg
CTW
kg/pair
kg/pair
42T-70-22052 2400 215
WA80M-7 42U-70-22181 2400 222

Fork carriage
42T-70-32301 2400 230
WA100M-7 42W-70-22040 2950 3200 304
STD Standard machine version

CTW Machine with counterweight
WA80M-7, WA100M-7 – VENAM03001 1-23

1.7 Equipment Foreword
1-24 WA80M-7, WA100M-7 – VENAM03001

Safety
2. Safety
WARNING
Please read and make sure that you fully understand the precautions described in
this manual and the safety labels on the machine. When operating or servicing the
machine, always follow these precautions strictly.
WA80M-7, WA100M-7 – VENAM03001 2-1

2.1 Safety labels Safety
2.1 Safety labels

The following warning signs and safety labels are used for this
machine.
 Ensure that the labels are applied correctly and that you
understand the content fully.
 In order to ensure that the content of the labels can be read

properly, ensure that they are in the right location, and keep
them clean at all times. When you clean them, do not use
organic solvents or petrol, as this could lead to the label dis-
solving.
 If the labels are damaged, lost or cannot be read properly,

replace them with new ones. For details of the part numbers
for the labels, see this manual or the labels themselves, and
submit an order with your Komatsu distributor.
 There are also other labels, in addition to the warning signs

and safety labels. Treat these labels in the same way.
Position of the safety labels
18 1, 2, 19 3 22 4 5 21 7
8 14 9,13 15 16 12 10,11 20 17 8
2-2 WA80M-7, WA100M-7 – VENAM03001

Safety 2.1 Safety labels
1. Caution before operating (09651-A0481)
Warning!
Read this manual before carrying out commissioning, main-

tenance, disassembly, setup and transport.
2. Caution when leaving the operator's seat (09654-C0481)
This symbol highlights the danger of unexpected movement

of the stopped machine.
Lower the work equipment to the ground, activate the locking

switch for the work equipment and take the starting switch key
with you before leaving the machine.
3. Caution
Work equipment lock (42W-93-42071)
G0010021
WA80M-7, WA100M-7 – VENAM03001 2-3

4. Caution: do not walk beneath the work equipment (09807-

C1201)
This symbol highlights the risk of crushing if the work equip-

ment falls.
Stay away from the raised work equipment.
5. Caution: explosion (09659-A057B) or (09659-A0641)
There is a risk of explosion that could cause injury.
Do not dismantle the pressure accumulator, make any holes

in it, carry out any welding, make cuts, roll it or put in near a
flame.
6. Caution: when engine is running (09667-A0800)
This symbol highlights the risk posed by rotating parts such

as a belt drive.
Switch the engine off before carrying out inspection or main-

tenance work.
7. Caution: risk of burning from coolant (09653-A0481)
This sign warns of the risk of burning posed by spraying hot

water or oil if the radiator cap or the hydraulic tank lid on the
hot radiator or hydraulic tank is removed.
Always allow the radiator or hydraulic tank to cool down

before opening.
2-4 WA80M-7, WA100M-7 – VENAM03001

8. Stay clear (09806-C1201)
This symbol highlights the risk of being run over by the

machine.
Keep a safe distance from the vehicle while it is moving.
9. Lifting the machine (42W-93-H42010)
10. Lifting position mark/transport lock (42W-93-42000)
11. Warning to stay away from moving parts (09162-C0881)
This sign warns of the risk of being crushed between the mov-
ing parts of the vehicle.
Stay away from the vehicle while it is moving.
WA80M-7, WA100M-7 – VENAM03001 2-5

12. (Safety notice for steering lock (09161-C0881)
This sign warns of the risk of being crushed between the mov-
ing parts of the vehicle.
Secure the machine with the steering lock to prevent it from

moving during maintenance and transport.
13. Caution when handling the battery cable (09808-A1681
This symbol highlights the risk of electrocution while handling

power cables.
Read the manual to ensure safe and correct handling.
14. Prohibition of short circuit starts (09842-A0481)
Do not start the engine before sitting in the operator's seat.
Do not try to start the engine by short circuiting the engine

starter circuit. Doing so can lead to serious injury or fire.
15. Caution when handling the battery (09664-62A11)
This symbol highlights a risk posed by the battery.
Read the manual to ensure safe and correct handling.
2-6 WA80M-7, WA100M-7 – VENAM03001

16. Battery main switch (421-93-H2150)
17. Caution when modifying the roll-over protection system

(09620-A2001, 09620-A3001)
Modifications to roll-over or falling object protection systems

(ROPS or FOPS) can hinder the protective effect and may not
be compliant with standards. Seek advice from your Komatsu
distributor before carrying out any changes.
The protective effect of the ROPS and FOPS reduces follow-
ing damage to the structure or rolling over something.
In such a case, seek advice from your Komatsu distributor.
Always buckle up while moving.
18. Caution: explosion area (09845-00480)
This machine is equipped with a KOMTRAX or, if an optional

modem is fitted, a VHMS two-way radio device.
Keep away from explosion areas. If the machine must be

operated within 12 m of a blast zone or an active blasting
machine, the wiring harness must be disconnected from the
KOMTRAX/VHMS module.
Failure to comply with this can lead to serious or even fatal 09845-00480
injuries.
19. Take care in the vicinity of electrical cables (09801-C0481)
This symbol indicates the danger of an electric shock if the

machine is moved too close to power lines. Keep a safe dis-
tance away from power lines.
WA80M-7, WA100M-7 – VENAM03001 2-7

20. Precautionary measures when topping up brake fluid (09811-

C088B)
Read the operating instructions for information about correct

and safe handling.
09811-C088B
21. (Caution: shared line with high-pressure (6271-81-2980)
Do not open the high-pressure fuel system when the engine

is running. Engine operation causes high fuel pressure.
High-pressure fuel spray can lead to serious or even fatal

injuries.
22. Emergency exit (20Y-00-K2220)
2-8 WA80M-7, WA100M-7 – VENAM03001

Safety 2.2 General precautions
2.2 General precautions

Safety rules
 Only trained and authorised personnel may operate and

maintain the machine.
 Follow all safety rules, precautions and instructions when

operating or performing maintenance on the machine.
 If you are under the influence of alcohol or medication, your

ability to safely operate or repair your machine may be
severely impaired, endangering yourself and everyone else
on your jobsite.
 When working with another operator or with a person on

worksite traffic duty, be sure that all personnel understand all
hand signals that are to be used.
Getting to know the machine
Please read this manual carefully before operating the machine.

If you do not understand any part of the content of this manual,
let the person in charge explain the matter to you.
If abnormalities are found
If you detect any abnormality in the machine during operation or

maintenance (noise, vibration, smell, incorrect gauges, smoke,
oil leakage, etc., or any abnormal display on the warning devices
or monitor), report to the person in charge and have the neces-
sary action taken. Do not operate the machine until the abnormal-
ity has been corrected.
Clothing and personal safety equipment
 Do not wear loose clothing or accessories. There is a hazard

that they may catch on control levers or other protruding
parts.
 If you have long hair and it hangs out from your hard hat, there
is a hazard that it may get caught up in the machine. Tie your
hair up.
 Always wear a hard hat and safety shoes. If the nature of the
work requires it, wear safety goggles, mask, gloves, hearing
protection, or a safety belt when operating or maintaining the
machine.
 Check that all safety equipment functions properly before

using it.
WA80M-7, WA100M-7 – VENAM03001 2-9

2.2 General precautions Safety
Fire extinguisher and first aid kit
 A functional fire extinguisher has to be available and within

reach.
 If, in the course of certain operations, there is danger of fire,

fire extinguishers must be made available as a precaution.
Familiarise yourself with the use of the fire extinguishers.
 Inform yourself on how to proceed in the event of a fire.
 The first-aid kit can be stored under the right armrest.
 Make sure that you know all telephone numbers of the per-
sons that you need to contact in case of an emergency.
Safety features
 Be sure that all guards and covers are in their proper position.
Ensure that guards and covers are repaired immediately if
they are damaged.
 Understand the method of use of safety features and use

them properly.
 Never remove any safety features. Always keep them in good

operating condition.
Keeping the machine clean
 If water enters the electrical system, there is a hazard that it

will cause unexpected and erratic machine behaviour during
operation. Do not use water or steam to wash the electrical
system (sensors, connectors).
 If inspection and maintenance is carried out when the

machine is still dirty with mud or oil, there is a hazard that you
will slip and fall, or that dirt or mud will get into your eyes.
Always keep the machine clean.
GK032034
2-10 WA80M-7, WA100M-7 – VENAM03001

In the operator's cab
 When entering the operator's cab, always remove all mud

and oil from your shoes.
Operating pedals with mud or oil on one's shoes carries the

risk of slipping from the pedal, which may cause serious acci-
dents.
 Do not leave parts or tools lying around the operator's cab.
 Do not stick suction pads to the window glass. Suction pads

act as a lens and may cause fires.
 Do not use cellular telephones inside the operator's cab when

driving or operating the machine.
 Never bring any dangerous objects such as flammable or

explosive items into the operator's cab.
Before leaving the machine
1. Lower the work equipment to the ground.
2. Switch off the engine.
3. Push the multi-function lever forward to position “S”.

The remaining hydraulic pressure is released by doing this.
4. Engage the work equipment lock lever.
5. Apply the parking brake.
6. Remove the starting key before leaving the operator's cab. G0010009
Store the starting key in a safe place.
7. Close the cab door.
Mounting and dismounting
 Never jump on or off the machine. Never get on or off a mov-

ing machine.
 If the machine starts to move when there is no operator on the

machine, do not jump on to the machine and try to stop it.
 Always use handles and steps when getting on or off the

machine. Do not hold on to control levers.
 To ensure a safe hold, always ensure that either one hand is

on a handle and both feet are on the steps or that one foot is
on the steps and both hands are on the handles.
WA80M-7, WA100M-7 – VENAM03001 2-11

Protection against injuries
 If the clearance at the articulating portion changes, it can lead

to serious personal injury.
Do not allow anyone to come inside the articulation range.
 Never enter or put your hand, arm, or any part of your body
in the movable portion between the work equipment and
machine or between the cylinder and the work equipment. If
someone operates the control levers by mistake, the gap
between the work equipment and machine and between the
cylinder and work equipment will change, and you, your hand,
or arm can be caught which can lead to serious injuries.
If you have enter to an area between moving parts of the

machine, always ensure that the work equipment is locked
and cannot move.
Prevention of burns
 Hot coolant
To prevent burns from hot water or steam spurting out when

checking or draining the coolant, wait for the water to cool to
a temperature where it is possible to touch the radiator cap
by hand before starting the operation. Even when the coolant
has cooled down, loosen the cap slowly to relieve the pres-
sure inside the radiator before removing the cap.
GK032042
 Hot oil
To prevent burns when checking or draining the oil, wait for

the oil to cool to a temperature where it is possible to touch
the plug by hand before starting the operation. Even when the
oil has cooled down, loosen the plug slowly to relieve the
internal pressure before removing the plug entirely.
 Hot parts GK032043
In order to avoid burns during inspection and maintenance,

wait until all parts that can get hot have cooled down.
2-12 WA80M-7, WA100M-7 – VENAM03001

Fire prevention
 Fire caused by fuel or oil
Fuel, oil, antifreeze, and window washer liquid are particularly

flammable and can be hazardous. To prevent fire, always
observe the following:
 Do not smoke or use any flame near fuel or oil.
 Switch off the engine before refuelling.
 Do not leave the machine while adding fuel or oil. GK032044
 Tighten all fuel and oil caps securely.
 Do not spill fuel on overheated surfaces or on parts of the

electrical system.
 Use well-ventilated areas for adding or storing oil and

fuel.
 Store oil and fuel in a designated location and prevent

access by unauthorised persons.
GK032045
 After adding fuel or oil, wipe up any spilled fuel or oil.
 When carrying out grinding or welding work on the chas-

sis, move any flammable materials to a safe place before
starting.
 When washing parts with oil, use a non-flammable oil.

Diesel oil and gasoline are flammable. Do not use them.
 Put greasy rags and other flammable materials into a safe

container to maintain safety at the work place.
 Do not weld or use a cutting torch to cut any pipes or

tubes that contain flammable liquids.
 Fire caused by accumulation of combustible material
Remove any dry leaves, wood chips, pieces of paper, dust, or

any other flammable materials accumulated or stuck in the
area of the engine, the exhaust manifold, the muffler, the bat-
tery, or at the underbody.
WA80M-7, WA100M-7 – VENAM03001 2-13

 Cable fires
Short circuits in the electrical system can cause fire.
 Always keep the electric wiring connections clean and

securely fastened.
 Check the wiring every day for looseness or damage.

Tighten any loose connectors or wiring clamps. Repair or
replace any damaged wiring.
 Fire in the hydraulic system
Check that all the hose and tube clamps, guards, and pads
are securely fixed in position.
If they are loose, they may vibrate during operation and rub
against other parts. This may lead to damage to the hoses,
and cause high-pressure oil to spurt out, leading to fire dam-
age or serious injury.
 Explosion caused by lighting equipment
When checking fuel, oil, battery electrolyte, window washer

fluid, or coolant, always use lighting with anti-explosion spec-
ifications. If other lighting equipment is used, there is a danger
of explosions that may cause serious injuries.
When taking the electrical power for the lighting from the
machine itself, follow the instructions in this manual.
Procedure in case of fire
In case of fire, escape from the machine as follows.
 Turn the starting switch to the 'A' (OFF) position to stop the
engine. A B
 Use the handrails and steps to get off the machine.

C
Window washer liquid
 Use an ethanol-based window washer fluid.
 Do not use methanol-based liquid because it may cause irri- G0070421A

tation of the eyes.
2-14 WA80M-7, WA100M-7 – VENAM03001

ROPS (roll-over protection system)
 The roll-over protection system (ROPS) protects the operator

and absorbs load and impact energy if the machine should
roll over.
 The ROPS is integrated into the cab. The machine may not
be operated without this roll-over protection system.
 The ROPS meets the regulations of all EU member states.

Damage or unauthorised modification or repair of the ROPS
affect its stability. 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 oper-

ator wears the seat belt correctly. Always wear the seat belt
when operating the machine.
FOPS
(Attachment for protection against falling objects)
 The FOPS is integrated into the cab.
 If working on sites where there is a risk of falling boulders or

other objects, work only with machines equipped with a
FOPS. Damage or unauthorised modification or repair of the
FOPS affect its stability. In this case the system must be
replaced because its proper function cannot be guaranteed
any more.
Precautions for attachments, options
 Installing optional parts or attachments may lead to problems

with safety or legal restrictions. Please consult your Komatsu
distributor for advice.
 Komatsu does not accept any liability for injuries, accidents

or damage resulting from the use of non-approved attach-
ments.
 When installing and using optional attachments, read the

instruction manual for the attachment and the general infor-
mation on attachments in this manual.
WA80M-7, WA100M-7 – VENAM03001 2-15

Unauthorised modification
 If this machine is modified without permission from Komatsu,

there is danger that safety problems may occur, which can
lead to serious personal injuries. Modifications may have an
adverse effect on charactersistics such as machine perfor-
mance or visibility.
 Before making a modification, consult your Komatsu distribu-

tor.
 Komatsu does not accept any liability for injuries, accidents

or damages resulting from non-approved modifications.
Worksite safety
 Before starting operations, thoroughly check the work area

for dangerous working conditions.
 Inspect the surface of the soil in the working area and deter-
mine the optimum and safest procedure.
 When carrying out operations near combustible materials

such as thatched roofs, dry leaves or dry grass, there is a haz-
ard of fire. Take this into consideration when operating the
machine.
 Determine the required safety measures against dangers on

public roads in co-operation with the owners, users, and
responsible authorities.
 If there are underground water pipes, gas pipes, or conduits

for high voltage cables on site, contact the responsible utility
company to determine the routing of the lines. Ensure that
these facilities are not damaged.
 When working in water or crossing sand banks, first check the

bottom surface, as well as the depth and current of the water.
Ensure that the permitted water depth is not exceeded.
 Secure the jobsite to prevent unauthorised access.
2-16 WA80M-7, WA100M-7 – VENAM03001

Working on loose ground
 Avoid travelling or operating the machine too close to the

edge of cliffs, overhangs and deep ditches. The ground may
be weak in such areas. If the ground collapses under the
weight or vibration of the machine, there is a hazard that the
machine may fall or tip over. Remember that the soil is weak
in these areas after heavy rain, blasting, or earthquakes.
 When working on slopes or near excavated ditches, there is

a hazard that the weight or vibration of the machine will cause
the soil to collapse. Before starting operations, take neces-
sary steps to ensure that the ground is safe to prevent the
machine from rolling over or falling.
Working near high-voltage cables
Do not travel or operate the machine near electric cables. There

is a hazard of electric shock, which may cause serious injury or
property damage. On jobsites that require the machine to work
close to electric cables, always proceed as follows.
 Before starting work near electric cables, inform the local

power company about the work to be performed, and ask
them to take the necessary action.
 Even approaching high-voltage cables may cause an electric

shock that possibly results in severe burns or even death. Safety dis-
Always maintain the safety distance (see the table on the Nominal voltage
tance
right) between the machine and the electric cable. Consult
with the local power company about safe operating proce- up to 1000 V 1m
dures before starting operations. over 1 kV up to 110 kV 3m
 To prepare for any possible emergencies, wear rubber shoes over 110 kV up to 220 kV 4m
and gloves. Place a rubber sheet on top of the seat and be
over 220 kV up to 380 kV 5m
careful not to touch the chassis with any exposed part of your
body. in case of unknown nominal voltage 5m
 Use a signalman to give warning if the machine approaches

too close to the electric cables.
 When carrying out operations near high voltage cables, do

not let anyone come close to the machine.
 To prevent electric shock, the operator must not leave the

operator's cab when the machine comes too close to or even
touches an electric cable, until the electricity has been turned
off.
Also, do not let any person approach the machine.
WA80M-7, WA100M-7 – VENAM03001 2-17

Ensuring good visibility
If it is impossible to determine the condition of the working area

and detect obstacles due to low visibility, there is a hazard of dam-
age to the machine as well as severe injury. Before starting to
drive, sound the horn to warn people in the area. When operating
or travelling in places with poor visibility, always observe the fol-
lowing items strictly:
 Clean the windows and headlights to ensure optimum visibil-

ity.
 Adjust the mirrors so that the rear of the machine can be seen
clearly from the operator's seat. Keep the mirrors clean.
 Ensure that the entire lighting system is in perfect working

order and adjusted as specified in the applicable regulations.
 If the visibility cannot be sufficiently assured, position a sig-

nalman if necessary. Operators should pay careful attention
to the signs and follow the instructions from the signalman.
 Only one signalman should give signals.
 When working in dark places, turn on the machine's work

lights, and set up additional lighting in the work area if neces-
sary.
 Stop operations if the visibility is poor, such as in mist, snow,

rain, or dust.
 Immediately replace broken windows.
Precautions related to exhaust gas
 Engine exhaust gas includes substances that may harm your

health or even cause death. Ensure good ventilation when
starting the engine or operating the machine.
 If it is necessary to start the engine or run the machine inside

a building or underground, where the ventilation is poor, take
steps to remove the exhaust gas and bring in ample fresh air.
2-18 WA80M-7, WA100M-7 – VENAM03001

Gas, dust and flammable vapours
Do not operate combustion engines in environments that may

contain flammable gases or vapours. These gases, dusts or
vapours could ignite or be drawn in by the intake system, which
could cause the engine speed to increase or the maximum engine
speed to be exceeded. This may cause fire, explosion, or serious
property damage. It might also become impossible to switch off
the engine.
Signals and signs from the signalman
 Set up signs to warn of slopes and soft ground. If the visibility

is not good, position a signalman if necessary. Operators
should pay careful attention to the signs and follow the
instructions from the signalman.
 Only one signalman should give signals.
 Make sure that all workers understand the meaning of all sig-
nals and signs before starting work.
Emergency exit
The door on the right side of the operator's cab can be used as
an emergency exit in case of danger.
WA80M-7, WA100M-7 – VENAM03001 2-19

Protection against asbestos dust
Asbestos dust in the air can cause lung cancer if it is inhaled.

There is a hazard of inhaling asbestos dust when working on
demolition sites or when handling industrial wastes.
Always observe the following points:
 Spray water to minimise dust build-up when cleaning. Never

use compressed air for cleaning.
 In case of danger from asbestos dust in the air, always oper-

ate the machine from a downwind position. All workers must
use an approved respirator.
 Do not allow other persons to approach during the operation.
 Always observe the rules and regulations for the work site
and environmental standards.
 The machine does not contain any asbestos. There is how-

ever a danger that imitation parts may contain asbestos.
Therefore, always use Komatsu genuine parts.
2-20 WA80M-7, WA100M-7 – VENAM03001

Safety 2.3 Precautions during operation
2.3 Precautions during operation
2.3.1 Starting the engine

If there is a warning tag hanging from the work equipment control
lever, do not start the engine or touch the levers.
Checks before starting the engine
Carry out the following checks before starting the engine at the
beginning of the day's work.
 Remove all dirt from the surface of the window glass to

ensure a good view.
 Before getting on the machine, check again that there is no

one in the surrounding area and that there are no obstacles
blocking the machine.
 When starting the engine, sound the horn as a warning.
 Always sit in the operator's seat when starting or operating

the machine.
 The operator must be the only person in the cab or on the

machine.
 If the machine is equipped with a back-up warning signal,

ensure that the signal is fully functional.
 Check if the articulated steering is unlocked before operating

the machine (right side: 1).
 Only operate the machine with the seat belt fastened.
WA80M-7, WA100M-7 – VENAM03001 2-21

2.3 Precautions during operation Safety
Precautions in cold areas
 Allow the machine to warm up for a maximum of 20 minutes.

If the machine is not thoroughly warmed up before the control
levers are operated, the reaction of the machine will be slow,
which can lead to unexpected accidents.
 If the battery electrolyte is frozen, do not charge the battery

or start the engine with a different power source. There is a
hazard of the battery ingniting or exploding.
Before charging or starting the engine, allow the battery fluid

to thaw slowly and ensure that no electrolyte escapes.
2.3.2 Operation
Checks before operation
 Wear seat belt.
 Check the driving controls, the steering, the brake system,

and the work equipment control system.
 Check for any abnormality in the sound of the machine, vibra-

tion, heat, smell, and check the gauges. Check that there is
no leakage of oil or fuel.
 If any abnormality is found, carry out repairs immediately.
Precautions when travelling in forward or reverse
 Before travelling, check again that there is no one in the sur-

rounding area, and that there are no obstacles blocking the
machine.
 Before travelling, sound the horn to warn people in the area.
 Always sit in the operator's seat when operating the machine.
 Do not allow anyone apart from the operator to ride on the

machine.
 Check that the back-up alarm (alarm buzzer when machine

travels in reverse) works properly.
 Always lock the door and windows of the operator's cab in

position (open or closed).
 When travelling or carrying out operations, always keep a

safe distance from people, structures, or other machines to
avoid coming into contact with them.
2-22 WA80M-7, WA100M-7 – VENAM03001

 Set the bucket to the carrying position for travelling. Observe

the carrying position indicator.
 Drive slowly on uneven surfaces and avoid sudden steering.
 If the engine fails while you are driving, you can still steer the
machine. More force is however necessary for this.
 In case of engine failure, immediately drive to the side of the

road, switch on the warning lights and secure the machine.
 Always obey the traffic regulations when travelling on public

roads.
 Do not exceed the maximum permitted load or performance

of the machine.
WA80M-7, WA100M-7 – VENAM03001 2-23

 When operating in tunnels, under bridges, under electric

wires, or in other places of limited height, be extremely careful
to prevent the work equipment from hitting objects.
 To avoid accidents and collisions with other objects, the

machine must always be operated at a speed where safety is
guaranteed. This is particularly important for work in confined
spaces, indoors, and on sites with other machines.
Driving on slopes
 Keep sufficient distance to ridges or steep slopes. The

machine may tip over or slip when operated too close to steep
slopes, ridges or embankments. The limit values are listed in
chapter “Limit values for slopes (6-6)”.
 To keep the centre of gravity low, keep the bucket close to the
ground (approx. 20–30 cm) when driving near slopes, ridges
or embankments. In case of an emergency, quickly lower the
bucket to the ground to stabilise the machine.
 Do not turn or traverse on slopes. Only execute these

manoeuvres on level ground.
 If it is necessary to drive on slopes, avoid driving on grass,

fallen leaves, or steel plates. The machine may slip on these
surfaces when traversing across the slope. Drive very slowly
and carefully.
 When driving downslope, use the braking power of the engine

and drive slowly.
 If the engine fails when driving on a slope, immediately oper-

ate the service brake to stop the machine. Then apply the
parking brake. Lower the working equipment.
 When driving on a slope with a load, drive
 uphill: forwards
 downhill: backwards
Impermissible work
 It is dangerous to use the bucket or lift arm for crane work.

Therefore, do not carry out work of this kind.
 No people on the attachments
 Never allow people to travel on the work equipment or

other attachments. There is a risk that they will fall and be
seriously injured.
 Never use the machine to lift people.
2-24 WA80M-7, WA100M-7 – VENAM03001

Emergency lowering
When the engine is not running, the work equipment can still be
lowered with the multi-function lever.
If the hose break safety device is installed, the machine is

equipped with a pressure accumulator, so that the work unit can
be lowered by means of the multi-function lever when the diesel
engine is off.
NOTICE
The work equipment cannot be lowered if it is locked with the work
equipment lock lever. G0010009
1. Make sure that no one is standing under the machine.

WA80M-7
2. Slowly press the multi-function lever into the “S” position. The
work equipment is lowered.
WA100M-7
G0080301
WA80M-7, WA100M-7 – VENAM03001 2-25

While loading
 When heaping up dikes, making landfills or when dumping

soil over a steep edge, proceed as follows:
1. First dump a load in front of the edge.
2. Push the first load over the edge with a second load.
 When the soil is pushed over a steep edge, or when the

machine reaches the tip of the slope, the load will decrease
suddenly. In this case, the machine's ground speed may
increase suddenly. Therefore, drive especially slow and care-
ful in such places.
 Perform loading work with the rear of the machine turned into
the wind if possible to protect yourself against dust and pre-
vent visual obstructions.
 Avoid sudden starts, turns or stops if the bucket is fully

loaded.
Braking
 Only use the brake pedal for braking and not as a footrest.
 Use the braking force of the engine when driving downhill.

Use the brake pedal in addition when necessary.
2-26 WA80M-7, WA100M-7 – VENAM03001

Working on snow
 Snow-covered or frozen ground is slippery. Drive and work

very carefully and do not operate the levers abruptly. Even a
slight slope may cause the machine to slip.
 For this reason, be particularly careful when driving on

slopes. Frozen ground may become soft when thawing, and
this may cause the machine to tip over.
 If the machine enters deep snow, there is a hazard that it may

tip over or become buried in the snow. Be careful not to leave
the road or become trapped in a snow drift.
 When clearing snow, the road shoulder and objects placed

beside the road are buried in the snow and cannot be seen.
There is a hazard of the machine tipping over or hitting cov-
ered objects, so work carefully.
 When travelling on snow-covered roads, always fit tyre

chains.
 When driving on snow-covered slopes, never apply the foot

brake suddenly. Reduce the speed and use the engine as a
brake while applying the foot brake intermittently (depress the
brake intermittently several times). If necessary, lower the
bucket to the ground to stop the machine.
 Avoid driving or operating the machine too close to the edges

of cliffs, overhangs, or deep ditches.
 If the ground sags in such places, the machine may tip over,
fall down, or roll over, causing severe injuries.
 Take into account that the soil is wet and soft after heavy rain-
fall, or very loose after blasting.
WA80M-7, WA100M-7 – VENAM03001 2-27

Working with the forklift attachment
 Check the tines of the fork for visible damages every day
before starting the machine (e.g., bends, cracks, heavy
wear).
The locking mechanism that prevents the tines from being

pulled out or sliding must be free of defects. Never work with
a damaged forklift attachment.
 Verify that the forklift attachment is properly locked after

mounting it to the quick coupler.
 Verify that the gap between the tines is sufficiently large.
 Never exceed the specified maximum load of the forklift

attachment. It depends on the ground conditions and the lift-
ing height. The values specified in chapter “Equipment 19.685 in
(1-22)” apply to the most unfavourable lifting position with the (500 mm)
boom in a horizontal position.
19.685 in
The load's centre of gravity is 500 mm from the fork's back (500 mm)
and the tines (see drawing).
 Do not load several palettes simultaneously.

75_156
If, as an exception and on the explicit instructions of the

responsible superior, it is necessary to transport several
stacked palettes, be sure to verify that the stacking devices of
all palettes are free of defects.
The overall height of the palette stack must not exceed 2 m.
 Ensure that the length of the tines is appropriate to the length

of the load. Approach the load so that it contacts the fork's
back.
 If carrying a load that obstructs the view, drive in a direction

where you have full visibility, i.e. in reverse, if necessary. If
this is not possible, use a signalman to clear the path and sig-
nal where to drive.
In this case, drive at walking pace with extreme caution.
 Lower the boom into the carrying position for carrying work
(see picture).
You may only lift above the stack when lowering or raising the
load.
 Always drive slowly with loads (speed range 1).
 The load should always be facing uphill when driving on

slopes.
 The boom executes a semicircular movement during the lift-

ing process.
Raise the boom to the desired unloading height shortly before

reaching the location of unloading. (danger of tilting)
 Lower the forklift attachment onto the ground before leaving

the cab.
2-28 WA80M-7, WA100M-7 – VENAM03001

Parking the machine
 Park the machine, if possible, on level ground.
 Apply the parking brake.
 Lower the work equipment (1) to the ground.
 Set the direction selector switch to NEUTRAL.
 If it is necessary to park the machine on a slope, position the

machine with the work equipment facing downhill.
 Block the wheels with wheel chocks (2) to prevent the

machine from rolling away.
 When parking the machine on public roads, ensure that it

does not obstruct traffic.
 Put up signal lamps and required warning signs to ensure that

passing traffic can clearly see the machine.
 Adhere to all regulations on parked vehicles and securing

building sites.
 Lower the work unit entirely to the ground before leaving the
cab.
 Engage the work equipment lock lever.
 Switch off the engine.
 Lock all points that can be locked and store the key in a safe
place.
2.3.3 Transport
Loading and unloading the machine
For details see “Transport (3-99)”.
Towing
For details see “Towing the machine (4-2)”.
WA80M-7, WA100M-7 – VENAM03001 2-29

2.3.4 Battery
Battery main switch
 Turn the battery main switch OFF.
In the case of the following events, follow the switch-off pro-

cedure described below.
Turn the starting switch to the OFF position. Only switch the
battery main switch off once the green pilot lamp on the relay
box has gone out. Remove the key to the battery main switch
before:
 storing the machine for one or more months
 repairing electrical systems
 carrying out electric welding
 handling the battery
 replacing the main fuses
Handling batteries
Battery electrolyte contains sulphuric acid.
 When handling batteries, always wear protective goggles.
 If battery acid gets into your eyes, it may cause blindness.

If acid gets into your eyes, flush them immediately with large
amount of water and seek medical attention. Flush the eyes
until a doctor arrives or you have reached a hospital.
 If sulphuric acid touches your skin or clothing, it causes chem-

ical burns. Immediately rinse the area that came in contact
with the sulphuric acid with water.
 When working in the battery range, acid can adhere to hands

unnoticed. For this reason, never touch your eyes when work-
ing with batteries. Always wash hands after working.
 Batteries create hydrogen gas. Hydrogen gas is extremely

explosive and can ignite with the smallest sparks.
 Never disconnect the battery when the engine is running.
2-30 WA80M-7, WA100M-7 – VENAM03001

 Before connecting two machines with booster cables:
 Turn the starting switch of the faulty machine to the OFF

position.
 Only switch the battery main switch of the faulty machine

off once the green pilot lamp on the relay box has gone
out.
 Switch the starting switch of the functioning machine off.
There is a risk that the faulty machine will move when the
power is connected.
 Avoid short circuits with the battery poles or the battery termi-
nals by accidentally touching them with metal objects, e.g.
tools.
 Always disconnect the negative (-) terminal (ground side) first

when removing the battery; when installing the battery, con-
nect the positive (+) terminal first, and connect the ground
last.
 Attach the battery terminals securely. Loose battery terminals

can cause sparks and lead to an explosion. Make sure that
the cover for the positive (+) terminal is mounted at all times.
 Tighten the battery caps securely.
 Remove the negative (-) terminal from the battery during

repair work of the electric connections or during electric weld-
ing, to disrupt the electricity flow.
Starting the engine with booster cables
For details see “Starting the engine with booster cables (4-7)”.
WA80M-7, WA100M-7 – VENAM03001 2-31

2.4 Precautions for maintenance Safety
2.4 Precautions for maintenance

Personnel
You may only execute maintenance or repair work on the

machine if you are a trained specialist or have been carefully
instructed by a specialist.
Warning tag
Do not start the engine, or touch and operate the work equipment
control element while performing service or maintenance. This
could lead to accidents that can cause serious injuries.
Always attach the warning tag to the work equipment control lever
or on the multi-function lever to alert others that you are perform-
ing service or maintenance on the machine. Attach additional
warning tags around the machine if necessary.
NOTICE
These tags are available from your Komatsu distributor.
Tools
You may only use tools suited for the respective task. Using dam-
aged, low quality, faulty, makeshift tools or improper use of the
tools could cause serious personal injury.
2-32 WA80M-7, WA100M-7 – VENAM03001

Safety 2.4 Precautions for maintenance
Safety relevant parts
The quality of the components can be susceptible to regular wear

and tear. Therefore replace safety relevant components on a reg-
ular basis with new parts, irrelevant of the fact if they are func-
tional or not.
Safety relevant parts include:
 Fuel system:
 Fuel hose
 Fuel spill hose
 Tank cap
 Hydraulic system:
 all hydraulic hoses
Replace or repair safety-critical parts if any defect is found, even

when they have not reached the time specified interval. Hydraulic
hoses have to be replaced every 2 years.
In order to ensure safe assembly and operation of the machine,

it is recommended that you use Komatsu genuine parts.
For details see “Periodic replacement of safety-critical parts

(5-24)”.
Keeping the worksite clean
Do not leave tools lying around the worksite. Remove grease, oil
and other substances that may cause a slip hazard. Always keep
the worksite tidy and clean to ensure safe completion of work. If
the worksite is not kept tidy and clean there is a risk of tripping,
falling or slipping, which can lead to injury.
WA80M-7, WA100M-7 – VENAM03001 2-33

Before executing the inspection and maintenance
Choose a location where there is no risk of landslide, rockfall or

flood.
Before performing inspection and maintenance tasks, park the

machine on solid, level ground. Lower the work unit. If your
machine is equipped with E.C.S.S., you have to switch off the
E.C.S.S.. Switch off the engine and secure the machine.
If the engine has to remain on during maintenance, e.g. during

pressure inspection of the hydraulic system, proceed with
extreme caution. Only perform this work in pairs after defining
unmistakable signals.
One person has to remain on the operator's seat to immediately

shut down the engine when necessary. Only operate the operat-
ing level after consulting the second person.
The person performing the maintenance has to be careful not to

touch or get caught in moving parts.
Ensure steady positioning
When disassembling or assembling the machine for maintenance

or repair, ensure at each stage that the machine is in a steady
position. Failure to comply with this can lead to injury or death.
Guards
The area around the engine contains guards to protect persons

from moving parts. These guards can only be removed by
Komatsu customer service technicians, unless specific instruc-
tions are provided in this manual.
2-34 WA80M-7, WA100M-7 – VENAM03001

Securing the articulated steering
1. Park the machine in a straight line.
2. On the left side:
Loosen the spring pin and remove bolt (1).
3. On the right side:
Insert the bolt (2) and secure it with the locking bolt.
1
WA80M-7, WA100M-7 – VENAM03001 2-35

Working under the raised boom
WARNING
Danger of injury! The raised boom may suddenly fall! For safety
reasons, a raised boom must be secured against dropping before
you pass or stand under it.
1. The boom must be secured against moving if any work is to

be carried out under it when it is in a raised position. For this
purpose you should use a supporting prop (1), which is to be
positioned below the boom. 1
2. Park the machine on level, solid ground.
4. Place wheel chocks in front of the wheels to prevent the

machine from rolling away.
GK032080
5. Secure the articulated steering with the locking bolt.
6. Lift the arm far enough to allow the supporting prop to be

placed beneath the boom.
8. With the engine switched off, lower the boom slowly until it
rests safely on the supporting prop.
9. Position the direction selector switch to “N”.

WA80M-7
WA100M-7
G0080301
2-36 WA80M-7, WA100M-7 – VENAM03001

Tipping up the operator's cab
For details see “Tipping up the operator's cab (5-3)”.
Two people for maintenance work when the engine is run-

ning
In order to avoid injury, do not carry out maintenance while the

engine is running. If maintenance must be carried out while the
engine is running, the work must be carried out by at least two
workers, observing the following.
 One worker must always sit in the operator's seat and be

ready to stop the engine at any time. The workers must
always maintain contact with each other.
 When working near the fan, fan belt or other rotating parts,
there is a risk of being caught in the device. Ensure that you
do not go too close to them.
 Never allow tools or other items to fall into the fan or onto the
fan belt or stick tools or other items into other rotating parts.
There is a risk that they will come into contact with the rotating ,&
parts and break or be flung back out.
 Lower the work equipment to the ground.

WA80M-7
 Do not touch the control lever or steering wheel. If it is neces-
sary to use the control lever or steering wheel, always give a
signal to your colleagues so that they can get into a safe posi-
tion.
WA100M-7
G0080301
WA80M-7, WA100M-7 – VENAM03001 2-37

Attachments
Place attachments that have been removed from the machine in

a stable condition so that they do not fall.
ATTENTION
Caution – Danger of injury!
Working beneath the machine
 Always lower all movable work equipment to the ground or to

the lower position before performing maintenance or repair
work under the machine.
 Block the wheels with a wheel chock.
 Never work under a machine that has not been sufficiently

secured.
Keeping the machine clean
 Always keep the machine clean and tidy.
 Oils, grease and tools or parts laying around are dangerous

because they are a potential source for slipping or tripping.
 Do not use water or steam to clean sensors, plugs and the

interior of the cab. If water gets into the electrical system,
there is a hazard that it will cause malfunctions or misopera-
tion and lead to accidents.
Special operations
Always wear appropriate protective clothing and protective gog-

gles when sanding, welding, using the sledge hammer or per-
forming similar work.
2-38 WA80M-7, WA100M-7 – VENAM03001

Adding fuel or oil
 Spilled fuel or oil is a source for potential slipping and a fire

hazard. Therefore immediately remove all spilled sub-
stances.
 Use well ventilated areas for adding fuel and oil.
 Close the filling places after adding.
 Never use fuel to rinse or clean parts.
 Do not let oil or fuel seep into the ground or water. Dispose of
meeting environmental standards.
 If the machine is equipped with a fuel strainer in the tank filler

port, it may not be removed when adding fuel.
Coolant
 The machine is equipped with an aluminium radiator. There-

fore only use coolants with the prescribed mixing ratio.
 Careful, antifreeze is extremely flammable.
 Switch off the engine and wait until the coolant system has
cooled down before inspecting the coolant level. Then inspect
the coolant level in the expansion tank.
 Remove the lid slowly so that the pressure can be released.
 Add water into the expansion tank if necessary.
WA80M-7, WA100M-7 – VENAM03001 2-39

Application of lighting
When checking fuel, oil, coolant or battery electrolyte, always use

lighting with anti-explosion specifications.
High-pressure hoses
 You may not bend high-pressure hoses or hit them with hard
objects. Do not use piping or hoses with tears or bends,
because they may burst during operation.
 Replace loose or damaged fuel or oil hoses immediately.

Leaking fuel or oil is a potential slipping hazard and is flam-
mable.
 Replace hoses every 2 years at the latest.
Handling high pressure oil
 Always keep in mind that the hydraulic circuits are under high
pressure.
 Do not add or remove oil and perform maintenance or inspec-

tion work, before the work equipments has been completely
lowered and the system is depressurised.
 If oil escapes under high pressure, there is a danger of oil

entering the skin or eyes. Therefore always wear safety gog-
gles and thick gloves and use a piece of cardboard or wood
to search for oil leakages.
 If you are hit by a stream of high pressure oil, immediately

consult a doctor for medical attention and explain the incident.
2-40 WA80M-7, WA100M-7 – VENAM03001

Handling the pressure accumulator
WARNING
Danger of injury! Pressure accumulators are filled with highly
pressurised nitrogen. Do not open or damage the pressure accu-
mulator.
 Immediately consult a Komatsu distributor if you find malfunc-

tions or defects on the pressure accumulator.
 Only persons with the authorisation for dealing with high-

pressure gas may fill or refill gas.
 Do not disassemble the accumulator.
 Do not bring it near flame or dispose of it in fire.
 Do not make holes in it, weld it, or use a cutting torch.

GK032078
 Do not hit or roll the accumulator. Do not subject it to any
impact.
 Before the maintenance technician extracts the pressure

accumulator, the hydraulic system has to be depressurised.
Fan and belt
 Always keep sufficient distance to revolving parts and ensure

that nothing can get caught in it.
 Parts that get caught in the fan or belt can be cut off or flung
away.
 Do not wear loose clothing, scarves or similar clothing or

open, long hair that could get caught.
Salvage
 Never pour old oil into sewers or in rivers, etc.
 Always put oil drained from your machine in containers.

Never let the oil spill on the ground.
 Obey applicable laws and regulations when disposing of

harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
WA80M-7, WA100M-7 – VENAM03001 2-41

Sources of chemical hazards
If there is a risk posed by contact with hazardous chemicals when

carrying out maintenance or disassembly work, corresponding
precautions must be taken.
If in doubt, please consult your Komatsu distributor for informa-

tion.
Waste material
Avoid any kind of environmental pollution when disposing of

waste.
 Always put oil drained from your machine in containers.

Never pour the oil directly onto the ground or into drains, riv-
ers, lakes or seas.
 Obey applicable laws and regulations when disposing of

harmful objects such as oil, fuel, coolant, solvent, filters, and
batteries.
Maintaining the air conditioner
 If refrigerant from the air conditioner comes into contact with

the eyes or skin, that can lead to loss of sight or frostbite.
 Never touch the refrigerant.
Pressurised air
 Flying objects can cause serious injury or material damage

when carrying out cleaning work using pressurised air.
 Always wear protective goggles, a dust mask, gloves and

other safety equipment when cleaning parts or the radiator
with pressurised air.
End of service life
Ask your Komatsu distributor about safe disassembly of the

machine at the end of its service life.
2-42 WA80M-7, WA100M-7 – VENAM03001

Safety 2.5 Precautions when handling tyres
2.5 Precautions when handling tyres

Handling tyres
For details see “Handling tyres (3-96)”.
If tyres or rims are handled incorrectly, there is danger that the

tyre may explode or be damaged, or that the rim may fly off and
cause serious injury or death.
To maintain safety, always proceed as follows.
 Maintenance, disassembly, repair, and assembly of the tyres

and rims requires special equipment and special technology.
Ask your Komatsu distributor to carry out these operations.
 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 if 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 tyre pressure and permitted speed given in this
manual correspond to the manufacturers' values and refer to
standard usage. In case of special usage, please refer to your
Komatsu distributor or the tyre manufacturer.
WA80M-7, WA100M-7 – VENAM03001 2-43

2.5 Precautions when handling tyres Safety
Precautions when storing tyres
Tyres for construction equipment are extremely heavy and may

cause serious injuries.
 In general, tyres must be stored in a protected room that can-

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

70° (2) against a solid stopper and secure them with wheel
chocks (1) so that they 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.
Tyres for construction machines are very heavy and may
cause serious injuries.
2-44 WA80M-7, WA100M-7 – VENAM03001

Operation
3. Operation
WA80M-7, WA100M-7 – VENAM03001 3-1

3.1 General view Operation
3.1 General view
3.1.1 General view of the machine
5 6 7
2
13
1
10
11
12
14
3-2 WA80M-7, WA100M-7 – VENAM03001

Operation 3.1 General view
1. Bucket
2. Tipping lever
3. Front wheel
4. Bucket cylinder
5. Front work lights
6. ROPS cab
7. Warning beacon
8. Rear wheel
9. Turn signals
10. Headlights
11. Boom
12. Lift cylinder
13. Rear work lights
14. Tail lights, turn signals
WA80M-7, WA100M-7 – VENAM03001 3-3

3.1.2 Controls
General view
WA80M-7
WA100M-7
6 7 8
5
G0080301
10
11
12
13
1
2
14
16 15
4 3
G0010060
3-4 WA80M-7, WA100M-7 – VENAM03001

1. Accelerator pedal
2. Brake pedal
3. Parking brake
4. Steering column adjustment lever
5. Monitor
6. Turn signal lever
7. Headlight switch
8. Horn
9. Work equipment lock lever
10. Multi-function lever
11. Special equipment control lever

12. Starting switch
13. Cigarette lighter
14. Car radio (option)
15. Speed regulator (option)
16. Engine shutdown secondary switch
WA80M-7, WA100M-7 – VENAM03001 3-5

3.1.3 Machine monitor
1 2 3 4 5 6 7 8 9 10 11 12 13
G0010011E
20 19 18 17 16 15 14
3-6 WA80M-7, WA100M-7 – VENAM03001

1. Back-up light pilot lamp
2. Speed range 2 pilot lamp

3. Battery charge circuit caution lamp
4. Intake air pre-heater pilot lamp
5. Parking brake caution lamp
6. High-beam pilot lamp
7. Direction selector switch pilot lamps
8. Turn signal pilot lamp

9. Seat belt caution lamp
10. E.C.S.S. pilot lamp
11. Rear window defroster pilot lamp

12. Trailer turn signal pilot lamp
13. Engine oil pressure caution lamp
14. Coolant temperature gauge
15. Save button
16. Read out engine fault button
17. Programming button
18. Service meter
19. Speedometer
20. Fuel gauge
WA80M-7, WA100M-7 – VENAM03001 3-7

3.1.4 Switches
20
7
19
6 8 12 G0010005
5 9 18 21
4 11
10 17
1
23
2 24
3 25
22 26
27
16
14 15
13
28
31
G0010061
30 29
G0070417
3-8 WA80M-7, WA100M-7 – VENAM03001

1. Hazard warning light switch with pilot lamp
2. Light switch
3. Rear window wiper and washer switch
5. Button for reading out the engine controller errors

6. Save button
7. Work light switch
8. Rear window defroster switch
9. Warning beacon switch (option)
10. Turn indicator lever
11. Windshield wiper and washer switch
12. Horn button
13. Fan reversal switch
14. Switch for quick coupler

15. Sweeper switch
16. Back-up light switch
17. Blower switch

18. Temperature switch
19. Air conditioner switch (option)
20. 100% differential lock switch
21. Speed range 2 switch
22. Switch 3rd control circuit
23. Direction selector switch
24. E.C.S.S. switch with pilot lamp (option)*
25. Auto-inch (option)
26. Starting switch

28. Speed control (option)
29. Battery main switch
30. Cab light switch
(*) E.C.S.S.: (Electrically Controlled Suspension System)
WA80M-7, WA100M-7 – VENAM03001 3-9

3.2 Descriptions of the individual elements Operation
3.2 Descriptions of the individual elements
3.2.1 Machine monitor
A A C A C A A A A C A A A C
C B C G0010011E
G0010063A
The machine monitor consists of:
A Pilot lamps
B Gauges
C Caution lamps
All elements needed for the efficient operation of the machine are
explained below.
Pilot lamps
This group includes the pilot lamps for high beam, glow plugs,
turn indicators, direction selector switch, E.C.S.S. (optional).
3-10 WA80M-7, WA100M-7 – VENAM03001

Operation 3.2 Descriptions of the individual elements
Gauges
This group includes the fuel gauge, the service meter, the coolant
temperature gauge, and the speedometer.
Caution lamps
This group includes caution lamps for battery charge circuit, park-
ing brake, air cleaner, water separator, engine oil pressure, and
seat belt warning.
WA80M-7, WA100M-7 – VENAM03001 3-11

Caution lamps
2 3 4 5
G0010011A
1. Warning symbol display
Water separator caution lamp
Air cleaner caution lamp
Differential lock caution lamp
Engine stop caution lamp
Engine controller error code caution lamp
3-12 WA80M-7, WA100M-7 – VENAM03001

1. Warning symbol display
Water separator caution lamp
The water separator caution lamp lights up when an excessive

amount of water has accumulated in the water separator at the
fuel filter.
If this is the case, you have to drain the water from the water sep-
arator.
For details see “Water separator – draining water and dirt accu-
mulations (3-58)”.
G0070206
Air cleaner caution lamp
This lamp lights up if the air cleaner becomes clogged when the
engine is running.
If this is the case, clean or replace the air cleaner cartridge.
For details see “Air cleaner – renewing, renewing safety filter

(5-39)”.
G0070211
Differential lock caution lamp
This indicator lights up when the differential lock is engaged.
G0010064
Engine stop caution lamp
This indicator lights up when the engine shutdown secondary

switch is switched on or the engine has been stopped due to a
fault.
In this case, you must reset the engine shutdown secondary

switch for shutting off the engine, or read out the error code.
For details see “Reading error code (3-112)”.
G0010065
WA80M-7, WA100M-7 – VENAM03001 3-13

Engine controller error code caution lamp
This indicator lights up if the engine controller has detected a

fault.
In this case, you must read out the error code.
G0010066
Before starting the engine:
This lamp lights up when the starting switch is turned to the 'B'
(ON) position.
With the engine running:
When the engine is running, the alternator generates a voltage to

charge the battery. The lamp goes out. If the battery charge circuit
caution lamp does not go out when the engine is running, there G0070210
is a malfunction.
For details see “Other troubles (4-11)”.

A B
G0070421A
(ON) position with the parking brake engaged.
If the direction selector switch is brought into the forward or

reverse position with the parking brake engaged, an acoustic
warning signal sounds.
G0070207
This lamp lights up if the seat belt is not fastened.
You are at risk while driving: always fasten your seat belt.
3-14 WA80M-7, WA100M-7 – VENAM03001

Before starting the engine:
(ON) position. At the same time, the acoustic warning signal
sounds.
With the engine running:
After starting the engine, the engine oil pressure builds up and the
G0070209
lamp goes out. If the lamp does not go out when the engine is
running, or if it lights up during operation and the acoustic warning
signal sounds, there is a malfunction in the oil pressure circuit.
WA80M-7, WA100M-7 – VENAM03001 3-15

Pilot lamps
1 2 3 4 5 6 7 8 9
G0010011E
11
10
G0010067A

10. Pilot lamp in the E.C.S.S. switch
11. Hazard warning light pilot lamp
3-16 WA80M-7, WA100M-7 – VENAM03001

This indicator lights up if the switch for the back-up light is

switched on.
G0010068

2
When you turn on the ignition, speed range 2 is engaged and the
lamp (1) lights up. As long as lamp (1) is lit, the machine is oper-
ating in speed range 2.
Pressing and releasing button (2) on the multi-function lever once

causes the machine to return to speed range 1, and lamp (1) goes
out.
1
G0010006
G0010007
(ON) position and the pre-heater is in operation.
It goes out when the pre-heating is completed. It is now possible

to start the engine.
G0070215
A B
G0070421A
This lamp lights up when the headlights are at high beam.
The lamp also lights up when the headlights are flashed.
G0070216
WA80M-7, WA100M-7 – VENAM03001 3-17

The direction selector switch pilot lamps indicate the selected

direction of travel:
 Left arrow is lit: machine travelling forward
(direction selector switch in “F” position)

GK100836
 Right arrow is lit: machine travelling in reverse
(direction selector switch in “R” position)
If the direction selector switch is in the neutral position (“N”), both

pilot lamps are unlit.
This lamp flashes when the turn signal is engaged.
REMARK
If the turn indicator circuit is interrupted, the lamp flashes more
quickly.
GK100837
(Option)
The E.C.S.S. indicator in the instrument panel lights up if the

E.C.S.S. is engaged and the machine is travelling at a speed
higher than 5 km/h.
G0070214
This lamp is lit when the rear window defroster is switched on.
GK100839
3-18 WA80M-7, WA100M-7 – VENAM03001

This indicator flashes when towing a trailer if the turn signal is acti-
vated.
If the turn indicator circuit is interrupted, the lamp flashes more

quickly.
GK100837
10. Pilot lamp in the E.C.S.S. switch
(Option)
This lamp in the switch is lit when the E.C.S.S. is active.
NOTICE
The speed range 2 switch must be active.
G0070432
11. Hazard warning light pilot lamp
This lamp flashes when the hazard warning lights are active.
G0070427
WA80M-7, WA100M-7 – VENAM03001 3-19

Gauges
G0010011E
1 2 3
1. Speedometer
3. Service meter
4. Fuel gauge
1. Fuel gauge
Turn the starting switch to the 'B' (ON) position.
The fuel gauge indicates the fuel level.
F = The tank is full

E = The tank at the reserve level
The background light is green if enough fuel is available.

G0010069
The background light is red when the fuel level is low. Refill fuel.
A B
NOTICE
The symbol for the fill level indicator flashes if there is no contact
with the sensor. In this case, contact service. C
G0070421A
3-20 WA80M-7, WA100M-7 – VENAM03001

2. Service meter
The service meter indicates the total service hours. The service
meter counts only the service hours when the engine is running,
whether the machine is actually operating or not. The “hourglass”
symbol is displayed continuously whilst the service meter is
counting.
G0070220
When the starting switch is set to the 'B' (ON) position, the tem-
perature gauge indicates the coolant temperature.
The background light is green if the coolant temperature is nor-

mal.
The background light is red if the coolant temperature is too high.

The acoustic warning signal sounds.
G0010070
NOTICE
The symbol for the coolant temperature flashes if there is no con-
tact with the sensor. In this case, contact service.
4. Speedometer
The speedometer indicates the gound speed.
The background light changes from green to red when the set
maximum speed is exceeded. The acoustic warning signal
sounds.
G0070271
The two buttons are for setting the tyre size and changing the
speedometer display from “km/h” to “mph” and vice versa.
NOTICE
Have your Komatsu distributor adjust these settings!
G0070407
WA80M-7, WA100M-7 – VENAM03001 3-21

3.2.2 Switches
20
7
19
6 8 12 G0010005
5 9 18 21
4 11
10 17
1
23
2 24
3 25
22 26
27
16
14 15
13
28
31
G0010061
30 29
G0070417
3-22 WA80M-7, WA100M-7 – VENAM03001

2. Light switch
5. Button for reading out the engine controller errors

6. Save button
9. Warning beacon switch (option)
10. Turn indicator lever
12. Horn button
14. Switch for quick coupler

15. Sweeper switch
16. Switch for quick coupler Back-up light switch
17. Blower switch

19. Air conditioner switch (option)
20. 100% differential lock switch
21. Speed range 2 switch
24. E.C.S.S. switch with pilot lamp (option)*
25. Auto-inch (option)
26. Starting switch

28. Speed control (option)
(*) E.C.S.S.: (Electrically Controlled Suspension System)
WA80M-7, WA100M-7 – VENAM03001 3-23

Use this switch to turn the turn signal on and off.
NOTICE
Only turn on the hazard warning lights in an emergency.
If the hazard warning lights are on, all flashing lights on the
machine are on. At the same time, the pilot lamp in the hazard
warning light switch and the turn indicator pilot lamp are flashing. G0070427
2. Light switch
2
Use the light switch to turn the main headlights, the side clear-
ance lights, the tail lights and the search lights on and off. 0 1
Position 0 = Lights off
Position 1 =
Parking lights on
Clearance lights and tail lights on.
Position 2 =
Main headlights on
Clearance lights and tail lights are also on. G0010071
Position 3 = Headlights flash

High-beam pilot lamp on 3
Position 2 + 4 = Low beam on
Position 2 + 5 = High beam on
High-beam pilot lamp on 4
Use this switch to turn the rear window wiper and washer on and
off.
 The switch has two positions:
 Position '1' is retained and turns the wiper on or off.
If the switch is held in position '2', the washer stays active as long
as the switch is held. G0070425
3-24 WA80M-7, WA100M-7 – VENAM03001

This switch can be used to set the type and dimension of the
tyres.
5. Engine controller error code button
You can read out the errors in the engine controller using this but-
ton.
G0010066
6. Save button
This button can be used to save the programmed type and dimen-
sion of the tyres.
WARNING
Working lamps may blind incoming traffic! Switch off the working
lamps before travelling on public roads.
Use this switch to turn the work lights on and off.

G0070428
WA80M-7, WA100M-7 – VENAM03001 3-25

Use this switch to turn the rear window defroster on and off.
The pilot lamp on the machine monitor lights up when the rear
window defroster is switched on.
G0070429
9. Warning beacon switch
(Option)
Use this switch to turn the warning beacon on and off.
G0070431
10. Turn signal lever
Use the turn signal lever to turn the turn signal on and off. 1
Position 1 = Left turn signal

Position 2 = Right turn signal

3
Use this switch to turn the windshield wiper and washer on and 0
off.
The switch position can be checked by means of the position of

the mark. 1 4
Item 0 = Window wiper off.

2
Item 1 = Wiper moves at low speed.
Item 2 = Wiper moves at high speed.
Item 3 = Wiper moves intermittently.
Item 4 Cleaning water is sprayed onto the front of
the windscreen
3-26 WA80M-7, WA100M-7 – VENAM03001

12. Horn button
Use the horn button to sound the horn.
NOTICE
Use the fan reversal function only when the engine is idling!
The fan wheel turns in the opposite direction for as long as you
press the fan reversal switch.
Releasing the switch causes the fan to rotate in the usual direc-
tion.
G0010073
14. Electrical quick coupler button
Use this button to unlock the quick coupler.
Pull the button's lock (A) in the direction of the arrow to unlock the
button.
The quick coupler remains unlocked as long as the lamp is lit.

A
Releasing the button locks the quick coupler, and the lamp goes
out.
G0070420
For details see “Control lever for special equipment and additional
function (3-37)”.
15. Sweeper switch
(Option)
Use this switch to turn the sprayer (water supply) on and off.
G0070430
WA80M-7, WA100M-7 – VENAM03001 3-27

16. Back-up light switch
(Option)
Use this switch to switch on the back-up light.
Switching the switch again turns off the back-up light.
NOTICE
The back-up light must be switched off on public roads.
G0070405A
17. Blower switch
Use this rotary switch to control the airflow in several levels.
Position 1 = Blower off

Position 2 = Low airflow
Position 3 = Medium airflow
Position 4 = High airflow
Use this rotary switch to control the power of the heater in levels
from 'cold' (heater off) to 'warm'.
19. Air conditioner switch
(Option)
Use this switch to turn the air conditioning on and off.
3-28 WA80M-7, WA100M-7 – VENAM03001

20. 100 % differential lock switch
Use button (2) to turn the differential lock on and off. As long as
the button is held, the indicator (1) in the middle monitor lights up
and the differentials in the axles are locked 100%.
When button (2) is released, the differentials are unlocked and

lamp (1) goes out.
NOTICE
For details see “Engaging the 100% differential lock (3 79)”.
1
2 G0010005
21. Speed range 2 switch 2

This lamp (1) lights up when button (2) on the multi$function lever
is pressed once and then released.
As long as lamp (1) is lit, the machine is operating in speed

range 2.
Pressing and releasing button (2) again causes the machine to

return to speed range 1, and indicator (1) goes out. 1
G0010006
G0010007
(option WA100M 7)
WARNING
If the work equipment is not locked properly, it may drop suddenly
and cause serious accidents.
This switch makes an electrical proportional regulation of the 3rd G0010008

control circuit possible (e.g. working with a bottom$dump bucket).
You can also use this switch to release and lock the locking bolts
of the quick coupler.
Position 1 = Pressing this button (3) causes the locking

bolts for the work equipment to engage.
Position 0 = Neutral 3
Locking bolts are engaged; this position allows
you to pick up the work equipment
Position 2 = Engage
Work equipment locking bolts extend G0070420
WA80M 7, WA100M 7 – VENAM03001 3 29

Use this switch to change the machine's direction of travel. The

selected direction of travel is displayed on the machine monitor.
Position F = Forward
Position N = Neutral position
Position R = Reverse
NOTICE G0010004
Starting the engine is possible only if the direction selector switch
is in the neutral position 'N'.
24. E.C.S.S. switch with pilot lamp
(Option)
Use this switch to turn on the E.C.C.S.
The lamp in the switch is lit when speed range 2 is active.
 If the machine is travelling at a speed higher than 5 km/h, the

E.C.S.S. is activated automatically and the E.C.S.S. pilot
lamp on the machine monitor lights up.
G0070432
 If the machine is travelling slower than 5 km/h, the E.C.S.S.
circuit is deactivated and the pilot lamp on the machine mon-
itor goes out. The pilot lamp in the E.C.S.S. switch remains
on.
25. Auto-inch
(Option)
When the hydraulic back pressure in the work equipment is too

high while loading, the tractive force of the drive is reduced until
the work equipment can be raised again.
NOTICE
Always turn this switch off when driving on roads.
G0070424
3-30 WA80M-7, WA100M-7 – VENAM03001

26. Starting switch

A B
Use this switch to turn the engine on and off.
 (A) 'OFF' position C

In this position the engine is turned off and it is possible to
remove the key. In the stop position, all functional circuits are
turned off.
 (B) 'ON' position G0070421A

In this position, the pilot lamps are lit and the intake air pre-
heater is active. The functional circuits are turned on. The
ignition key remains in this position while the engine is run-
ning.
 (C) 'START' position
With the switch in this position, the engine starts.
NOTICE
Starting the engine is possible only when the direction selector
switch is in the neutral position, 'N'.
This is used to light cigarettes.
A few seconds after pushing the button in, it will return to its orig-
inal position. Then you may pull it out and light a cigarette.
GK032135
28. Speed regulator
(Option)
The speed regulator is used to adjust the maximum ground speed

of the machine in all gears within a continuous range from slow
(dial at '0') to fast (dial at '10').
Turn the dial to the right to increase the setting. Turn the dial to
the left to decrease the setting. The conditions for use may differ
G0070225
according to the condition of the road surface.
WA80M-7, WA100M-7 – VENAM03001 3-31

Before you switch off the battery main switch, you have to switch
off the starting switch and wait until the green pilot lamp on the
relay box has gone out.
NOTICE
 Put the battery main switch into the ON position unless
 the machine is being stored for one or more months
 electrical systems are being repaired
 electric welding is being carried out
 the battery is being handled
 the main fuses are being replaced
 Never switch off the main switch while the engine is running.
This can lead to damage to electrical systems.
 If the battery switch is switched off, the power supply to all

electrical systems is interrupted and data for the time or
selected station on the radio may be lost.
The battery main switch is used to switch the power supply from
the battery to the electrical systems in the machine on or off. The
location of the switch is shown in the diagram to the right.
Position (O): OFF
The power supply is interrupted. The key can be removed in this

position.
Position (I): ON
The power supply to the switching circuits is created.
Ensure that this position is selected before starting the machine.
3-32 WA80M-7, WA100M-7 – VENAM03001

This button in the middle is used to switch the cab light on and off.
The cab light can also be switched on when the starting switch is
in the 'A' (OFF) position. For this reason, turn off the cab light
before leaving the cab.
G0070417
A B
G0070421A
NOTICE
Only use this switch in emergencies.
This switch is used if the starting switch is off but the engine does
not stop.
1. Lift the cover.
The switch is located beneath the cover.
2. Pull on the switch in position (a) and the engine will stop.
 (a) Engine stopped: If abnormal (switch is pulled up)
The engine cannot be started in this position.
 (b) Normal: If normal (switch is pressed down)
The switch is automatically returned to the normal position (b)

when the cover is closed.
Contact your Komatsu distributor as soon as possible to have the

problem fixed.
WA80M-7, WA100M-7 – VENAM03001 3-33

3.2.3 Control levers and pedals
WA80M-7
WA100M-7
G0080301
5
6
4
3
1 2
G0010060
1. Steering column adjustment
2. Parking brake
3. Brake pedal
6. Accessory control lever (3rd control circuit and electrical quick coupler)
3-34 WA80M-7, WA100M-7 – VENAM03001

1. Steering column adjustment
Use lever (2) to tilt the steering column (1) forward and backward
continuously. The range of adjustment is 125 mm.
For details see “Adjusting the steering column (3-64)”.
2. Parking brake
The brakes start to engage as soon as the parking brake lever is

moved out of its home position. If the starting switch is in the 'B'
(ON) position, the parking brake caution lamp on the machine
monitor lights up. The machine is able to move again when the
parking brake is released.
NOTICE G0010091
The machine will not start with the parking brake engaged. If the
direction selector switch is brought into the forward ('F') or reverse
('R') position with the parking brake engaged, an acoustic warning A B
signal sounds.
G0070421A
3. Brake pedal
ATTENTION
 When travelling downhill for extended periods of time, the ser-
vice brake may overheat and become damaged as a result!
 Keep the engine running when driving downhill. Use the

brake in addition when necessary.
 Accident hazard through non-intended use of brake – do not

G0010090
use the brake pedal as a footrest.
The brake is actuated with a combined inching and brake pedal.

Inching provides an additional braking effect in the hydrostatic
traction drive.
WA80M-7, WA100M-7 – VENAM03001 3-35

The accelerator pedal controls the engine speed.
G0010090
The multi-function lever controls the work equipment. The multi-

function lever has 6 positions to control the work equipment as
follows:
G0010009
The multi-function lever locks in this position. The floating position
â
is used for levelling (drawing off).
SW Floating position
In this switching position, the work equipment lowers under its own
weight and moves freely due to external force.
ç
This switch position lowers the boom. When the engine is not run-
S Lower ning, you can lower the work unit by setting the multi-function lever
to this position (in emergencies).
0 Hold
å The boom is held in position.
H Lift
ã The boom is raised.
E Tilt
ä This position causes the bucket to tilt.
A Dump
à This position causes the bucket to dump.
3-36 WA80M-7, WA100M-7 – VENAM03001

6. Control lever for special equipment and additional

function
The control lever for special equipment has three positions whose
functions depend on the type of special equipment used.
Standard bucket, bucket for light materials, or forklift imple-

ment
Position 1 = Pressing this button (4) causes the locking

bolts for the work equipment to retract. G0010048
Position 0 = Neutral
Locking bolts are retracted; this position allows
you to pick up the work equipment.
Position 2 = Work equipment locking bolts extend
4
Multi-purpose bucket
Position 1 = Open multi-purpose bucket

Position 2 = Close multi-purpose bucket G0070420
Sweeper, snowblower
Position 1 = Work equipment rotates backwards

Position 2 = Work equipment rotates forward
Position 3 = Work equipment rotates forward continuously
(lever is retained)
 Move the control lever to position '3' for continuous operation.

The control lever remains in this position.
 This electrical detent function only works when the starting

switch is on.
NOTICE
Do not move the special equipment control lever to positions '1',
'2' or '3' with no additional equipment attached. This would cause
the work equipment to operate against overpressure and heat the
oil unnecessarily, possibly damaging the hydraulic components in
the long term.
WA80M-7, WA100M-7 – VENAM03001 3-37


WA80M-7
The work equipment lock lever secures the work equipment
against unintended use. Use this lock lever to lock the work
equipment before driving on roads and prior to maintenance
work.
WA100M-7
G0080301
3-38 WA80M-7, WA100M-7 – VENAM03001

3.2.4 Steering lock

The steering lock provides a rigid connection between the front
and rear frame to prevent the steering from articulating. Lock the
articulated steering before lifting the machine and prior to repair
and maintenance work.
1. Park the machine in a straight line.
2. On the left side:

1
Loosen the spring pin and remove bolt (1).
3. On the right side:
Insert the bolt (2) and secure it with the locking bolt.
3.2.5 Tow hitch

Use the tow hitch e.g. for towing another machine.
Always secure the bolt of the tow hitch with the locking pin
attached to the chain.
WA80M-7, WA100M-7 – VENAM03001 3-39

3.2.6 Trailer tow hitch (only WA100M-7)

(Option
WARNING
Danger of accidents! The driving behaviour and stability change
when towing a trailer. Comply with the attachment regulations.
Before using a trailer, obtain instruction from your Komatsu
dealer.
You can tow a trailer using the Rockinger Varioblock trailer tow
hitch. An electric connection with 13 pins is available.
Maximum drawbar load 200 kg
Maximum trailer load 3500 kg
Maximum speed 30 km/h
Check the lighting system after connecting the trailer tow hitch.
Secure the trailer using the securing cable.
 Ball-type hitch G0010075
3-40 WA80M-7, WA100M-7 – VENAM03001

 Automatic hitch
G00100501
G00100500
WA80M-7, WA100M-7 – VENAM03001 3-41

3.2.7 Power outlet
ATTENTION
 Danger of accidents!
Electrical devices may interfere with the on-board electronics.
 Never connect electrical devices other than the reading light

to the power outlet.
Use the power outlet to connect a reading light.
G0010079
3.2.8 Door unlocking

The cab doors are equipped with detents that engage when the
door is fully opened to prevent the door from slamming shut when
the machine is moving. To close the door again, it is necessary to
pull the release (1) back or press the release (2).
1 2
3.2.9 Back-up alarm

The back-up alarm sounds when the direction selector lever is in
the reverse position.
3-42 WA80M-7, WA100M-7 – VENAM03001

3.2.10 Fuses
ATTENTION
 Turning fuses off while the ignition is on may cause damage
to components of the electrical system.
 Switch the starting switch to the OFF position before replac-

ing fuses; only switch the battery main switch off once the
green pilot lamp on the relay box has gone out. Remove the
key to the battery main switch.
 Fuses with improper ratings may cause cable fires or blow

again immediately.
 Always replace defective fuses with fuses of the same rating.
The fuses protect the electrical system. Replace defective, cor-

roded, or loose fuses.
The fuses can be seen when the panel on the right side of the cab
is opened.
WA80M-7, WA100M-7 – VENAM03001 3-43

Fuse allocation
G0010012
3-44 WA80M-7, WA100M-7 – VENAM03001

No. Fuse rating Circuit name
F1.1 10 A Starting switch, KOMTRAX, battery relay

F1.2 10 A KOMTRAX
F1.3 10 A Connection socket, optional cigarette lighter
F1.4 10 A Radio, interior lighting
F1.5 10 A Turn signal, hazard warning light
F1.6 10 A Switch, windshield wiper, horn
F1.7 10 A Brake lights
F1.8 20 A Blower switch, heater blower, air conditioner switch/relay, compressor
F2.1 10 A Rear window defroster switch
F2.2 10 A Forward/backward valve, speed range, stopwatch, back-up alarm relay, speed range relay
F2.3 10 A Turn indicator
F2.4 10 A Monitor, fan drive, engine starter relay
F2.5 10 A Monitor
F2.6 20 A Working lamps
F2.7 10 A Left-side clearance lamp, license plate lighting, attachment clearance lamp
F2.8 10 A Right-side clearance lamp
F3.1 10 A High beam
F3.2 10 A Low beam
F3.3 10 A Solenoid switch, return to dig
F3.4 10 A Auto-inch, ECSS, hose break safety device
F3.5 25 A Relay and engine capacitor
F3.6 10 A Radio
F3.7 10 A Warning beacon
F3.8 10 A Light switch, head lamp switch, left-side clearance lamp
F4.1 10 A Back-up light, reverse gear light, back-up alarm
F4.2 10 A Rear window wiper
F4.3 10 A Seat heater, air suspension
F4.4 10 A Quick-changer, window wiper, proportional controller, 3rd control circuit switch
F4.5 10 A Speed control
F4.6 10 A Central lubrication system
F4.7 10 A 4th control circuit
F4.8 10 A Option (max.)
F5 250 A Engine air pre-heater
F6 100 A Battery relay
F7 30 A Engine controller
F8 5A Engine controller
WA80M-7, WA100M-7 – VENAM03001 3-45

3.2.11 Slow-blow fuses

If the power supply fails, one of the slow-blow fuses might be
blown. Check the electrical system and replace defective fuses.
The fuse box is located in the battery compartment.
1. Starter motor relay 70 A 1

2. Battery fuse 100 A
3. Intake air pre-heater relay 200 A 5 2
4. Intake air pre-heater fuse 250 A
5. Battery relay 120 A
6. Engine controller fuse 30 A
7. Engine controller fuse 5A
8. Pilot lamp, controller 7 6
4 250A
G0010080A
3.2.12 Relays
1. A450 option Immobiliser

2. K56.1 Relay (headlight)
3. K56.2 Relay (high beam)
4. K67 Turn indicator
5. K158.2 Relay (KOMTRAX)
6. K167 Relay 0.8 SEC.
7. K209 option Return to dig
8. K235 Relay (speed range)
9. K296 option Relay (air conditioner)
10. K314 option 650 Hz switch or 400 Hz switch
11. K373.1 Relay (parking brake)
12. K373.2 Relay (parking brake)
13. K376 option Relay (differential)
14. K385 Relay (back-up alarm)
15. K411 option Relay (hose break safety device)
16. K464 option Relay (4th control circuit)
17. KOP3 option Relay (option)
18. V118 Diode
3-46 WA80M-7, WA100M-7 – VENAM03001

3.2.13 Setting the heating and ventilation system
Adjusting the ventilation system
When the ventilation system is on, air is blown into the cab. If the
cab door is closed, this results in a slight overpressure. This pre-
vents dust from entering the cab.
The air is distributed by means of the air outlet nozzles (a).

a a
 You can open and close all air outlet nozzles (a) individually.
 The airflow may be directed with the diffuser discs.
 The upper, round air outlet nozzles can be directed at the a a

windscreen and at the side windows.
a = Air outlet nozzles

b = Air intake nozzles
a a
b G0010035
Adjusting the heating system
NOTICE
The heating capacity depends on the coolant temperature of the
engine. Full heating capacity is only achieved when the engine
has warmed up.
1 Rotary fan switch

2 Rotary temperature switch 2
1
To achieve the maximum heating effect inside the cabin, open all
air outlet nozzles (a), set rotary switch 2 to maximum heating
power, and set the fan to its highest speed with rotary switch 1.
To achieve a comfortable temperature, open all air outlet nozzles

(a), set rotary switch 2 to a comfortable temperature, and set the
fan to a low airflow rate.
To cool down the cab, open all air outlet nozzles. Then set rotary
switch 2 to 'cold', and set the fan to the highest speed.
WA80M-7, WA100M-7 – VENAM03001 3-47

3.2.14 Air conditioner

(Option)
NOTICE
Only use the air conditioner when the engine is running. Let the
air conditioner run for about 10 minutes every month to prevent
the compressor shaft seal from drying out.
Do not let the air conditioner run for an extended period of time at
low engine speeds to prevent the battery from discharging.
Keep the cab doors and windows closed when the engine is run-
ning.
If the machine was exposed to strong sunlight for an extended

period of time, it is recommended to air the cab thoroughly when a a
starting the machine and turning on the air conditioner.
Turning on the air conditioner

a a
a = Air outlet nozzles
b = Air intake nozzles
1. Turn the fan switch (1) to position '4'.
2. Turn the temperature control switch (2) to 'cold'. a a

3. Activate the air conditioner switch (3). b G0010035
The air conditioner is now on. This setting achieves the great-
est cooling effect, especially if the engine is running at high
speed.
4. Turn the fan switch (1) back one position when the desired
temperature has been reached.
5. Use the temperature dial for further adjustment.

3
6. The air is distributed by means of air outlet nozzles (a).
2
1
 You can open and close all air outlet nozzles (a) individu-
ally.
 The airflow may be directed with the diffuser discs.
 The air outlet nozzles (a) can be directed at the wind-

screen and at the side windows.
3-48 WA80M-7, WA100M-7 – VENAM03001

Operation 3.3 Operation
3.3 Operation
3.3.1 Checks before starting
Visual inspection
WARNING
Danger of fire! Leaking oil or fuel or accumulations of combustible
material may ignite when making contact with hot components
such as the exhaust pipe! Check oil and fuel lines for leakage
before starting. Repair leaks immediately. Stow combustible
materials safely.
Before starting the engine
Check the area around the machine for loose nuts and bolts.
Check for leaking oil, fuel, or coolant. Check the condition of the
work equipment and the hydraulic system. Also check for loose
cables and accumulations of dirt. Repair any defects and remove
accumulations of dirt.
Before starting to work
Perform the following tasks daily:
1. Check work equipment
Check the work equipment, cylinders, linkage, and hoses for

tears, excessive wear, and looseness. Repair defects.
2. Remove dust and dirt
Check the engine and radiator area for accumulations of dirt

or dust. Also check the areas around the battery and around
hot components like the exhaust pipe for accumulations of
combustible material. Completely remove dust and dirt.
3. Check engine area for water or oil leaks
Check that the engine does not leak oil and verify that the
coolant and fuel systems do not leak.
Repair defects.
WA80M-7, WA100M-7 – VENAM03001 3-49

3.3 Operation Operation
4. Check transmission, axles, the hydraulic tank, hoses,

and connections
Check transmission, axles, the hydraulic tank, hoses, and

connections for oil leakage. Repair defects.
5. Check brake lines
Check the brake lines for oil leakage. Repair defects.
6. Check wheels
Check the tyres for cracks, damages, and wear. Check wheel
rims and retaining rings for cracks and damages. Retighten
loose wheel nuts. Repair defects. Replace missing valve cov-
ers.
7. Check handrails
Check the handrails for damages and loose screws. Repair

damages and retighten loose screws.
8. Check gauges and indicators
Check all gauges and indicators for damages and loose

screws. Replace defective parts. Remove dirt from surfaces.
9. Check air cleaner
Check the mounting screws of the air cleaner. Retighten

loose screws.
10. Check battery terminals
Retighten the battery terminals.
11. Check the seat belt
The seat belt must be replaced after heavy strain such as

hard deceleration or the machine rolling over.
Check the belt, the belt lock, and the mounting points.
Replace the seat belt if the belt, its lock, or the mounting
points are damaged.
Check the fixing screws of the mounting points for firm seat.
3-50 WA80M-7, WA100M-7 – VENAM03001

12. Check ROPS
Check for loose or damaged screws. Have any screws

retightened or replaced by a Komatsu distributor. Always
retighten loose screws to the specified torque. Always
replace damaged screws with original parts.
13. Check cab windows
Clean cab windows before beginning to work.
WA80M-7, WA100M-7 – VENAM03001 3-51

Checks before starting the engine
Check coolant level – add coolant
ATTENTION
 An improper coolant mixing ratio cause damage to the alu-
minium radiator. The proportion of coolant must always be
between 30% and 60%.
 Danger of fire! Coolant may ignite when making contact with

the hot engine.
 Wait until the engine has cooled down before adding coolant.
1. Open the bonnet.
2. Check that the coolant level in the expansion tank is between

the FULL and LOW marks.
Add coolant if the coolant level is below LOW.
3. Remove the lid of the expansion tank.
4. Add coolant until the FULL mark is reached.
5. Firmly tighten the lid after adding coolant.
6. If the expansion tank becomes empty again after a short

period of time, immediately have the cooling system checked
for leaks and repaired at a workshop.
3-52 WA80M-7, WA100M-7 – VENAM03001

Radiator – clean radiator fins
The radiator fins have to be checked daily and cleaned if neces-

sary.
1. Stop the vehicle.
2. Lower the work equipment.
3. Set the direction selector switch to the neutral position 'N' and
apply the parking brake.
4. Press and hold the fan reversal switch (1).
NOTICE
The fan reversal function is only allowed to be operated at idling
speed!
5. Press the accelerator pedal fully down for 30 s. The engine is

running at its max. speed.
6. Release the accelerator pedal. The engine is running at idle

speed.
7. Release the fan reversal switch (1).
8. Turn off the engine and visually check the radiator fins for dirt.
9. If the radiator fins are still dirty, use compressed air or a water 1
jet to clean them.
G0010073
NOTICE
Do not hold the compressed-air or water nozzle too close to the
radiator fins. Do not use a brush for cleaning, as it may damage
the radiator fins.
WA80M-7, WA100M-7 – VENAM03001 3-53

Removable fan grille
WARNING
 Danger of accidents! Switch off the engine before installing or
removing the fan grille.
 Never use the machine without the fan grille installed. 1
A fold-down fan grille is installed with the large-mesh radiator.

This can be tipped back together with the fan for easier cleaning
of the radiator fins.
1. Unscrew the four screws (1) and remove the radiator guard.
2. Unscrew both screws (2) to flip out the fan grille (approx. 45°)
and clean the radiator fins.
3. Reinstall the fan grille after cleaning. 2
Torque (2) = 40 Nm
4. Install the radiator guard.
V-belt – check condition
Check the v-belt of the alternator and the air conditioner (optional)
for cracks.
 If a vertical crack (2) is apparent which intersects with a hori-

zontal crack (1).
 If a part of the belt is broken (3).
There is no need for a renewal if only a horizontal crack (4) is

detected.
3-54 WA80M-7, WA100M-7 – VENAM03001

Check engine oil level – add engine oil
NOTICE
Wait for at least 5 minutes after switching off the engine before
checking the engine oil level. The machine must be on level
ground.
1. Pull out the dipstick (1) and wipe off the oil with a clean cloth.
WA80M-7
2. Fully insert the dipstick and pull out again after a moment. The
oil level must be between the (H) and (L) marks on the dip-
stick.
3. If the oil level is below the (L) mark, add engine oil through
2 1
the oil filler neck (2). See chapter “Fuel, lubricants, and cool-
ants; quantities (5-16)” for recommended oils.
NOTICE
Do not pour an excessive amount of oil into the oil filler neck!
WA100M-7
4. Wait for three minutes and check the oil level again. Drain
some oil if the oil level is above the (H) mark. For details see
“Draining engine oil (3-56)”.
2 1
5. Close the oil filler neck (2).
WA80M-7, WA100M-7 – VENAM03001 3-55

Draining engine oil
If too much oil was added, the excessive oil must be drained. Pro-
vide a sufficiently large oil tray.
1. Place the tray underneath the drain screw (arrow).
2. Remove the cap (1) of the drain valve.
3. Screw a drain hose (2) onto the drain valve. This opens the
drain valve.
4. Drain excessive oil.

G0010083
5. Unscrew the drain hose (2) from the drain valve. This closes
the drain valve.
6. Check the oil level again.
7. Reinstall the cap (1) on the drain valve.
3-56 WA80M-7, WA100M-7 – VENAM03001

Check the fuel level – add fuel
WARNING
 Danger of fire! Spilled fuel may ignite!
 Immediately remove any spilled fuel.
1. Turn the starting switch to the 'B' (ON) position.

A B
G0070421A
2. Check the fuel level at the fuel gauge.
F = Fuel tank full

E = Fuel tank empty
3. Turn the starting switch to the 'A' (OFF) position.
G0010069
4. Add fuel as required.
5. Close the filler neck after refueling.
G0010083
WA80M-7, WA100M-7 – VENAM03001 3-57

Water separator – draining water and dirt accumulations
1. Keep a container ready for collecting the fluid from the water
separator. WA80M-7 2
2. Unscrew the valve (1) at the bottom of the water separator by

2 rotations.
3. Drain off water and dirt until pure fuel flows out.
3
4. Retighten the valve (1) again by turning clockwise.
ATTENTION 1
Do not over-tighten the valve, as this might damage the thread.
NOTICE WA100M-7
It is recommended to fill the filter with fuel after draining to prevent
problems when starting the engine.
5. Loosen the bleed screw (1) on the injection pump.
6. Work the pump button (2) on the fuel filter until there are no 3
more bubbles in the fuel flowing from the bleed screw.
7. Retighten the bleed screw (1). 2
3-58 WA80M-7, WA100M-7 – VENAM03001

Check gauges and indicators
Turn the starting switch to the 'B' (ON) position.

A B
The fuel level and coolant temperature LCDs as well as all cau-
tion and pilot lamp LEDs light up for 2 seconds, and the acoustic C
warning signal sounds.
 The fuel level (1) and the coolant temperature (2) are dis-
played.
G0070421A
 The parking brake caution lamp (4) lights if the parking brake
is engaged. 6 5 4 3
 The caution lamps for battery charge circuit (6) and engine oil
pressure (3) are lit.
 The intake air pre-heater pilot lamp (5) is lit if the intake air
pre-heater is active.
NOTICE G0010011
1 2
Contact your Komatsu distributor if one of the pilot lamps does not
light up.
Do not use only the gauges and indicators for the checks before
starting; also be sure to perfom the tasks specified for regular
maintenance.
Check electrical connections
ATTENTION
Fire hazard! Combustible material (leaves, twigs, grass, etc.) in
the electrical system may ignite.
Remove combustible material from the electrical system.
NOTICE
Contact your Komatsu distributor if a fuse blows or if there are
signs to indicate a short circuit in the electrical system.
Periodically check the terminals for firm seat and retighten loose
terminals.
WA80M-7, WA100M-7 – VENAM03001 3-59

Heating/air conditioner – check airflow

A B
G0070421A
2. Open all air outlet nozzles (a).

a a
3. Turn on the fan.
4. Check if there is enough air flowing from the air outlet nozzles
to the left and to the right of the steering column.
a a
5. If the airflow is insufficient, the filter cloth in the heater/air con-
ditioner may be clogged and should be cleaned or replaced.
If the cooling performance of the air conditioner is too low,
check whether the condenser is dirty.
For details see “Heating/air conditioner – clean/renew filter

cloth, clean condenser (5-55)”. a a
b G0010035
Other maintenance tasks to perform before starting.
 Check lights for function, dirt, and damages.
 Check horn and back-up alarm.
 Check steering play and function.
 Check rear-view mirrors for function, dirt, and damages.
3-60 WA80M-7, WA100M-7 – VENAM03001

Adjustments before starting
Adjusting the operator's seat
Readjust the operator's seat whenever changing operators.

Before starting to work, verify that the seat is adjusted to allow you
to fully press down the brake pedal with your back touching the
backrest.
Proceed as follows to adjust the seat:
Model: ISRI
1. Weight adjustment
Turn the knob (1) to adjust the suspension system to the oper-
ator's weight.
2. Horizontal adjustment
To adjust the horizontal seat position, raise lever (2) and push
the operator's seat forward or back. The seat locks in position
when the lever is released.
3/4.Vertical and angle adjustment

1
The height and angle of the operator's seat can be adjusted 4
(with spring support) with levers (3) and (4). Use lever (3) to
adjust the front section of the seat and lever (4) for the rear 3
section.
2
Height adjustment
Equally adjust the front and rear sections of the seat.
To do so, pull up and hold lever (3). At the same time, take
the weight off the front part of the seat upholstery to raise the
front of the seat. Apply weight to the front of the seat to lower
it. Release the lever when reaching the desired height. The
seat will lock in this position.
Then pull up and hold lever (4). At the same time, take the
weight off the rear part of the seat upholstery to raise the rear
of the seat. Apply weight to the rear of the seat to lower it.
Release lever (4) when reaching the desired height. The seat
will lock in this position.
Angle adjustment
Adjust the front and rear of the seat differently.
Proceed as described in the above chapter.
WA80M-7, WA100M-7 – VENAM03001 3-61

5. Adjusting the backrest
To adjust the backrest, apply a light load to it and pull and hold
lever (5).
Take load off the backrest to tilt it forward. Press the backrest
to the rear to tilt it backward.
Release lever (5) when the backrest has reached the desired
position.
The backrest will lock in this position.

5
3-62 WA80M-7, WA100M-7 – VENAM03001

Model: GRAMMER
1. Weight adjustment
The seat should be adjusted for the operator's weight by turn-

ing the weight adjustment lever (1) with the seat empty. The
set weight can be seen on the display.
2. Horizontal adjustment
To adjust the horizontal seat position, raise lever (2) and push
the operator's seat forward or back. The seat locks in position
when the lever is released.
3. Adjusting the height
The seat hight can be set to several different positions.
Raise the seat to the desired height until you can hear it click-
ing into place. If the seat is raised above the upper stop, it
drops back down to the lowest position. 1 70kg 2
4. Adjusting the backrest
To adjust the backrest, apply a light load to it and pull and hold
lever (3).
Take load off the backrest to tilt it forward. Press the backrest
to the rear to tilt it backward. 3
Release lever (3) when the backrest has reached the desired
position.
The backrest will lock in this position.
5. Adjusting the headrest
Move the headrest up or down.
WA80M-7, WA100M-7 – VENAM03001 3-63

Adjusting the steering column
WARNING
 Adjusting the steering column while driving may cause seri-
ous accidents.
 Stop the machine before adjusting the steering column.
Use this lever to adjust the steering column (1) angle. (Range of
adjustment: 125 mm)
Proceed as follows:
1. Release the lock lever (2).
2. Adjust the steering column angle so you can use the steering
wheel when sitting comfortably while at the same time having
a good view of the work equipment. Hold the steering wheel
in this position.
3. Lock the steering column in this position by applying the lock

lever again.
Adjusting the armrest
Proceed as follows to adjust the armrest:
1. Loosen the screw (1).
2. Extend or retract the armrest so you can easily access the

multi-function lever.
3. Retighten the screw. 1
Adjusting the rear-view mirrors
Sit in the operator's seat and adjust the rear-view mirrors as

desired. You should be able to observe the following traffic with-
out having to lean forward or backward.
3-64 WA80M-7, WA100M-7 – VENAM03001

Fastening the seat belt
WARNING
 Danger of injury! A seat belt that has been damaged,
stretched in an accident, or whose mounting points or screws
have not been fastened correctly does not provide adequate
protection in case of an accident.
 Replace the seat belt if it is damaged or the machine has

been involved in an accident. Check the condition of the
mounting points and screws before fastening the seat belt.
 Not wearing the safety belt when involved in an accident may

cause severe injuries.
 Fasten the safety belt before starting to work, and do not take
it off while working. Fasten the belt so that it is not twisted and
fits snugly.
The machine is equipped with a seat belt that retracts automati-

cally. Automatically retracting seat belts offer full freedom of
movement when pulled slowly but block immediately if the vehicle
decelerates or accelerates suddenly, travels downhill, or turns.
Fastening the seat belt
1. Sit in the operator's seat.
2. Pull out the seat belt slowly and continuously.
3. Insert the tongue into the lock until the lock engages.
The caution lamp in the instrument panel goes out when the
belt engages.
4. Pull the belt to check that the tongue is locked properly. The
caution lamp in the instrument panel goes out when the belt
engages.
NOTICE
The belt cannot be pulled out unless it is completely wound up.
Taking off the seat belt
Press the orange button to open the seat belt lock, and allow the
belt to wind up.
WA80M-7, WA100M-7 – VENAM03001 3-65

3.3.2 Starting the engine

2. Set the direction selector switch to the neutral position 'N'.
NOTICE
Starting the engine is possible only when the direction selector
switch is in the neutral position 'N'.
G0010091
WARNING
 Do not start the engine before sitting in the operator's seat.
 Never attempt to start the engine by hot-wiring the ignition cir-

cuit. This may cause severe injuries or fires.
 Check that there are no persons or obstacles in the surround-

ing area. Sound the horn and start the engine.
 Exhaust gas is toxic. When starting the engine in confined

spaces, be particularly careful to ensure good ventilation.
G0010004

A B
The fuel level and coolant temperature LCDs as well as all
caution and pilot lamp LED light up for 2 seconds, and the C
acousting warning signal sounds.
 The fuel level (1) and the coolant temperature (2) are dis-
played.
G0070421A
 The parking brake caution lamp (4) lights if the parking
brake is engaged. 6 5 4 3
 The caution lamps for battery charge circuit (6) and

engine oil pressure (3) are lit.
 The intake air pre-heater pilot lamp (5) is lit if the intake
air pre-heater is active.
The start-up time of the intake air pre-heater depends on the

G0010011
coolant temperature. The lower the coolant temperature, the 1 2
longer is the pre-heating period.
4. Slightly depress the accelerator pedal.
5. When the intake air pre-heater pilot lamp (5) goes out you
may turn the ignition key to 'START' to start the engine.
3-66 WA80M-7, WA100M-7 – VENAM03001

NOTICE
Do not keep the starting motor rotating for more than 15 seconds.
If the engine does not start during this time, wait for at least two
minutes before trying again. Turn the starting switch to the 'A'
(OFF) position for this time.
6. Release the starting switch as soon as the engine starts. It

automatically returns to its operating position 'B' (ON).
7.
WARNING
 Danger of accidents! Automatic starting up of the machine is
possible at a coolant temperature of less than 20 °C if the
parking brake has been released and the direction selector
switch is set to 'F' or 'R'.
 Always set the direction selector switch to the neutral position

'N' and apply the parking brake before starting the engine.
When the engine is started and the coolant temperature is below

20 °C, the engine speed is automatically brought up to 1100 rpm G0010004
to warm up the engine. As soon as the coolant temperature
reaches 30 °C, the warm-up is ended automatically (engine
speed: 900 rpm).
1100
If the travel direction is set to 'F' or 'R', the increased engine speed
Engine speed (rpm)
can cause the machine to start moving on its own, even though
the accelerator pedal has not been pressed. To avoid this, always
set the direction selector switch to the neutral position 'N' and 900
apply the parking brake before getting out of the operator's cab.
0 20 30
NOTICE
Water temperature (°C) G0010096
For details see “Operation in cold weather (3-106)”.
Do not let the engine run for more than 20 minutes at idling speed,
to avoid the CCV filter clogging up.
Ambient temperature for operation and storage

The recommended ambient temperature for operation and stor-
age is between -20 °C and +45 °C.
For ambient temperatures under 0 °C see “Operation in cold

weather (3-106)”.
WA80M-7, WA100M-7 – VENAM03001 3-67

Checks after starting the engine
NOTICE
 Do not rev up or load the engine suddenly before it has
warmed up.
 Do not run the engine unnecessarily at low or high idle speed.

If it is necessary to run the engine at idle for an extended
period, load the engine from time to time or let it run at
medium speed.
 Confirm that the engine is running smoothly during the checks

after starting.
Do not start working immediately after starting the engine. Per-

form the following preparations and checks first:
1. Slightly depress the accelerator pedal and let the engine run
at medium speed and no load.
 Verify the proper functioning of all hydraulic cylinders with

the multi-function lever.
 Verify the proper functioning of the steering.
 To warm up the hydraulic oil, repeatedly tip the multi-func- G0010009

tion lever for the work equipment from the '0' (HOLD)
position to the 'E' (TILT) position and back at short inter-
vals. The multi-function lever should not be in the tilt posi-
tion for more than 10 seconds at a time.
 Then check the hydraulic system for leakage.
NOTICE
These checks also provide for a quicker warming-up of the
hydraulic oil.
1 G0010011
2. During the checks, observe all gauges and caution lamps and
immediately repair any faults.
3. Check that the exhaust colour is normal and that the exhaust
pipe does not vibrate or sound abnormally. Repair any
defects.
4. Do not work under full load before reaching the operating

temperature. The coolant temperature gauge (1) must be in
the green.
3-68 WA80M-7, WA100M-7 – VENAM03001

3.3.3 Driving the machine
Starting
ATTENTION
Carelessly starting from a stop may cause accidents! Before
starting to drive, ensure that there are no persons in the area sur-
rounding the machine, and sound the horn.
1. Start the engine as described in chapter “Starting the engine

(3-66)”.
2. Raise the work equipment to the carrying position.

WA80M-7
4. Depress and hold the brake pedal.
WA100M-7
G0080301
5. Release the parking brake.
The parking brake caution lamp goes out.
G0010091
WA80M-7, WA100M-7 – VENAM03001 3-69

6. Set the direction selector switch to the desired direction.
NOTICE
If the direction selector switch is set to the forward or reverse posi-
tion while the parking brake is engaged, an acoustic warning sig-
nal sounds. G0010004
7. Release the brake pedal and simultaneously depress the

accelerator pedal to start the machine.
Limiting the maximum speed

The speed regulator is used to adjust the maximum ground speed
of the machine in a continuous range from slow (dial at '0') to fast 2
(dial at '10').
1
1. Stop the machine.
2. Initially set the speed regulator to the lowest speed. To do so,

turn the speed regulator (1) all the way to the left stop ('0' posi-
tion).
3. Depress the accelerator pedal. The machine stays stationary.

G0070225
4. Slowly turn the speed regulator to the right to increase the
speed to the desired speed.
5. The machine slowly starts moving and accelerates to the

speed that matches the setting on the speed regulator.
6. Lock the speed regulator against being adjusted unintention-

ally by moving the locking device (2) all the way to the right
stop.
NOTICE
Depending on the road surface, identical speed regulator settings
may result in different speeds.
3-70 WA80M-7, WA100M-7 – VENAM03001

Starting on an incline
ATTENTION
Carelessly starting from a stop may cause accidents! Before
starting to drive, ensure that there are no persons in the area sur-
rounding the machine, and sound the horn.
1. Start the engine as described in chapter “Starting the engine

(3-66)”.
2. Apply the parking brake. The parking brake caution lamp

lights up.
3. Depress the brake pedal.
4. Release the parking brake.
5. Set the direction selector switch to the desired direction.
6. Depress the accelerator pedal and slowly release the brake

pedal simultaneously to start the machine.
G0010004
WA80M-7, WA100M-7 – VENAM03001 3-71

3.3.4 Changing direction
WARNING
 Carelessly changing direction may cause severe accidents!
 Before changing direction from forward to reverse or vice

versa, check that there are no persons or obstacles in the new
direction of travel.
NOTICE
 Suddenly reversing the direction when driving at high speeds
may damage the engine.
 Decelerate before reversing. The speed should not exceed

15 km/h.
Use the direction selector switch to switch between forward and

reverse. The machine may still be coasting when the direction is
reversed.
Driving in reverse
G0010004
 The back-up lights light up and the back-up alarm sounds
when the direction selector lever is set to the reverse position.
(Option)
 The machine can travel as fast in reverse as forward.
 Look to the rear of the machine when driving in reverse; do

not just orient yourself with the rear-view mirrors.
 Before travelling, sound the horn to warn people in the area.
3-72 WA80M-7, WA100M-7 – VENAM03001

3.3.5 Turning and steering
WARNING
 Carelessly changing direction may cause severe accidents!
 Suddenly turning at high speeds may cause the machine to

tip over.
 If the engine stops while driving, the power steering becomes

inactive. Steering the machine requires a significantly higher
effort in this case.
Turning on slopes, ridges, or embankments
Keep sufficient distance to ridges or steep slopes. The machine

may fall over or slip when operated too close to steep slopes,
ridges or embankments. The limit values are listed in chapter
“Limit values for slopes (6-6)”.
Do not turn or traverse on slopes. Only execute these manoeu-

vres on level ground. If it is necessary to drive on slopes, avoid
driving on grass, fallen leaves, or steel plates. The machine may
slip on these surfaces when traversing across the slope. Drive
very slowly and carefully.
To keep the centre of gravity low, keep the bucket close to the
ground (approx. 20 – 30 cm) when driving on slopes, ridges or
embankments. In case of an emergency, quickly lower the bucket
on the floor to stabilise the machine.
WA80M-7, WA100M-7 – VENAM03001 3-73

3.3.6 Brakes
Use the service brake (1) to decelerate the machine when driving.
After stopping, secure the machine with the parking brake (2).
1
3
G0010090
Engaging the parking brake

1. Press the lock button.
2. Pull up the parking brake lever.
3. Release the lock button. The parking brake pilot lamp lights
up.
Disengaging the parking brake

1. Slightly pull up the parking brake lever.
2. Press the lock button.
3. Lower the parking brake lever.
4. Release the lock button. The parking brake pilot lamp goes
out.
Braking with the service brake

If the deceleration by releasing the accelerator pedal is insuffi-
cient, use the service brake to further decelerate the machine.
To do so, depress the brake pedal.
The service brake (1) may also be used to adapt the ground
speed to the actual driving and working conditions, irrespective of
the accelerator pedal position (3). (This is called inching.)
If you need to fully depress the accelerator pedal to use the full
engine power for the work equipment, you may still use the brake
pedal to lower the ground speed or stop the machine.
3-74 WA80M-7, WA100M-7 – VENAM03001

If the service brake fails

If the machine does not stop even when the brake pedal is fully
depressed, you must use the parking brake.
Stop driving and immediately have the machine inspected by the

responsible Komatsu distributor.
Braking on slopes
ATTENTION
 When travelling downhill for extended periods of time, the ser-
vice brake may overheat and become damaged!
 Keep the engine running when driving downhill. Use the

brake in addition, when necessary.
 Accident hazard through non-intended use of brake – do not

use the brake pedal as a footrest.
If the service brake is used excessively when driving downhill, it

may overheat and become damaged.
Prevent this by driving downhill slowly and using the braking force
of the engine.
NOTICE
An alarm buzzer sounds if the maximum permitted travel speed
is exceeded by 10%.
WA80M-7, WA100M-7 – VENAM03001 3-75

3.3.7 Stopping and parking the machine

Avoid sudden stops. Proceed as follows to stop the machine:
1. Release the accelerator pedal and depress the brake pedal.
WARNING
 Inadvertently operating the multi-function lever or moving the
G0010004
work equipment may cause accidents!
 Engage the work equipment lock lever before leaving the

operator's cab.

WA80M-7
WA100M-7
G0080301
Parking the machine on a slope
 Park the machine, if possible, on level ground.
 If it is necessary to park the machine on a slope, position the

machine with the work equipment facing downhill.
 Lower the work equipment (1) to the ground.
 Block one wheel with the chock (2).
3-76 WA80M-7, WA100M-7 – VENAM03001

3.3.8 Operating the work equipment
Multi-function lever
The multi-function lever controls the work equipment. The multi-
function lever has 6 positions to control the work equipment as
follows:
G0010009
The multi-function lever locks in this position. The floating position
â
is used for levelling (drawing off).
SW Floating position
In this switching position, the work equipment lowers under its own
weight and moves freely due to external force.
ç
This switch position lowers the boom. When the engine is not run-
S Lower ning, you can lower the work unit by setting the multi-function lever
to this position (in emergencies).
0 Hold
å The boom is held in position.
H Lift
ã The boom is raised.
E Tilt
ä This position causes the bucket to tilt.
A Dump
à This position causes the bucket to dump.
WA80M-7, WA100M-7 – VENAM03001 3-77

3.3.9 Return to dig

1. Lower the bucket to the ground, adjust the desired digging
angle, and set the multi-function lever to HOLD. 1 4
2. Engage the work equipment lock lever and stop the engine.
2
3. Loosen the 2 bolts (1) and adjust the bracket of the proximity
switch (4) so that the rearward end of the rod (2) is in line with
the centre of the sensing surface of the proximity switch (3).
Tighten the screws to lock the bracket in position.
Set the gap between the rod (2) and the sensing surface of
the proximity switch (3) to between 3 and 5 mm.
4. After adjusting, start the engine and raise the boom. Set the 3
bucket control lever to DUMP and then to TILT BACK. The
control lever should lock in a detent.
Check that the lever automatically returns to HOLD when the

bucket has reached the desired digging angle.
3
–
5
mm
3.3.10 Working with the wheel loader
Saving the tyres

When digging in piles of soil or blasted rock, the tyres may
become cut by slipping. This reduces the service life of the tyres.
Use the following guidelines to prevent tyre slip:
 Keep the ground in the working are level, and remove any
fallen rocks.
 Always drive into the stockpile in a straight line. This yields

the greatest digging force and lowest tyre wear.
 Drive slowly when clearing away stockpiled material or load-

ing blasted rock (speed range 1).
 When digging, raise the bucket when entering the stockpile.

This increases the load on the front wheels, prevents the front
wheels from slipping, and reduces tyre wear.
 Lower the bucket to the ground slowly. If the bucket hits the
ground, the front tyres will come off the ground, and the tyres
will slip.
 To prevent the front wheels from slipping, they should press

into the ground as much as possible. Therefore, slightly raise
the bucket as soon as it enters the stockpile.
3-78 WA80M-7, WA100M-7 – VENAM03001

Engaging the 100% differential lock
WARNING
Be sure to disable it when turning on solid ground.
On soft, slippery ground, traction can be improved by engaging it.
To engage the differential lock, press and hold button (2) on the 1
multi-function lever. 2 G0010005
The differential lock may only be switched on when the machine

is stopped.
When the differential lock is engaged, pilot lamp (1) on the instru-
ment panel is lit.
If only one wheel of an axle is turning when starting from a stop,

stop and correct the steering until the lock engages properly.
To disengage the differential lock, release button (2) on the multi-

function lever.
The differential lock can be disengaged while driving.
WA80M-7, WA100M-7 – VENAM03001 3-79

Loading
ATTENTION
 Danger of accidents! Carrying a load with the bucket raised
high may cause the machine to tip over.
 When carrying a load, lower the bucket to lower the centre of

gravity.
The loading procedure for wheel loaders is based on the following

cycle:
Digging or excavating  Carrying  Dumping
The individual steps in the cycle are presented in the following

sections.
Digging
ATTENTION
 Digging with the steering hinge at an angle may damage the
articulated steering and the cardan shaft.
 Always drive the machine into the material in a straight line.
Observe the instructions in section “Saving the tyres (3-78)” when

digging. Proceed as follows when digging:
1. Drive the machine into the stockpiled soil in a straight line.
2. While driving forward, quickly lower the bucket to a height of

about 30 cm off the ground and hold it in this position.
NOTICE
If the bucket hits the ground, the front tyres will come off the
ground, and the tyres will slip.
3. Next, lower the bucket to the ground slowly.
4. Inch the machine with the service brake while keeping the
accelerator pedal depressed.
5. Depress the accelerator pedal and dig the bucket into the
material. For digging loose material, hold the bucket's cutting
edge level when pushing into the material.
3-80 WA80M-7, WA100M-7 – VENAM03001

For loading blasted rock, tilt the bucket slightly downwards.
When digging blasted rock, take care that no rocks slip under-
neath the bucket. Otherwise the front wheels may lose con-
tact with the ground, causing tyre slip and increased tyre
wear.
Always keep the load at the centre of the bucket. An uneven

load distribution may impair the machine's balance.
6. Raise the boom while entering the material to prevent the

bucket from entering too deeply. Raising the boom provides
a sufficient amount of traction.
7. Tilt the bucket.
8. If the bucket is too full, quickly tilt, dump, and lower the bucket
to reduce the load and prevent the load from spilling while car-
rying.
WA80M-7, WA100M-7 – VENAM03001 3-81

Excavating
When excavating, be careful not to load the bucket unevenly
since an uneven load distribution may impair the machine's bal-
ance.
1. Drive the machine to the excavating location in a straight line.
2. Inch the machine with the service brake while keeping the
accelerator pedal depressed.
3. Slightly tilt the bucket downwards.
4. While driving forward, move the multi-function lever for the

boom slightly towards LOWER in order to remove only a thin
layer from the surface.
5. Slightly wiggle the multi-function lever for the boom up and

down to reduce the resistance when driving the machine for-
ward.
When digging, check that the digging force does not act une-
venly on the bucket.
3-82 WA80M-7, WA100M-7 – VENAM03001

Levelling
The purpose of levelling is to create an even surface. Use a
straight-edge bucket without teeth. Levelling includes two steps:
filling in and drawing off.
Filling in
It is possible that holes in the ground in front of the machine need

to be filled with soil. Proceed as follows:
NOTICE
For filling, tilt the bucket by a maximum of 15°.
Scoop soil into the bucket. Drive the machine slowly forward while
spreading soil from the bucket little by little. If there are particularly
large holes to be filled in, also place some soil in front of the
bucket to be spread while driving forwards.
Dragging
After filling in the holes, you may level the ground.
ATTENTION
 Danger of accidents! Carelessly driving in reverse may cause
severe accidents!
 Check that there are no persons behind the machine before

starting to drive in reverse. Use the horn to warn persons who
are in your way.
Slightly angle the bucket downwards. Drive in reverse while drag-

ging the bucket over the ground.
To make the ground particularly level, lower the boom in the float-
ing position. Slowly drive in reverse while dragging the smooth
underside of the bucket over the ground.
Scraping
Scraping is a special form of levelling. It is used to remove the

topmost soil layer.
Always drive in the lower speed range when scraping.
NOTICE
Scraping with the bucket in the dumping position damages the
bucket and the teeth. Align the bottom of the bucket level with the
ground when scraping.
WA80M-7, WA100M-7 – VENAM03001 3-83

Carrying
Check that the carrying route is in good condition and that there
are no persons in the way. Remove fallen rocks from the working
area. Keep the bucket tilted in. Lower the boom to the carrying
position.
For details see “Saving the tyres (3-78)”.
NOTICE
Set the work equipment to the carrying position before moving it
to the tilting stop.
Loading
Always select the loading method with the lowest turning and driv-
ing effort in order to work as efficiently as possible.
WARNING
Danger of accidents! Suddenly turning or decelerating with a
raised load may result in the load falling from the bucket and
causing accidents. Turn slowly and decelerate cautiously with a
raised load.
ATTENTION
Driving into a stockpile or a pile of rocks at a high speed may dam-
age the bucket or the machine. Drive slowly when pushing the
bucket into a stockpile or a pile of rocks.
Avoid shaking the bucket excessively. Work in a way to save the

tyres (see section “Saving the tyres (3-78)”).
Cross-loading
Position the machine at right angles to the stockpile. Back the

machine up in a straight line after filling the bucket. Then wait for
the dump lorry to move between the stockpile and the machine.
Drive forward towards the dump lorry and unload the material.
This is the fastest loading method and reduces cycle times con-
siderably.
3-84 WA80M-7, WA100M-7 – VENAM03001

V-shape loading
Position the dump lorry so that the machine's direction of

approach to the stockpile is at an angle of about 60° with the
direction of approach to the dump lorry. Load the bucket and
shake it. This distributes the load in the bucket properly and pre-
vents it from falling out to the rear. Back the machine up from the
stockpile and direct the machine towards the dump lorry. Raise
the bucket to its maximum height. Drive forward towards the
dump lorry and unload the material.
The smaller the turning angle of the machine, the more efficiently
you are working.
Stockpiling
When stockpiling material, do not set the bucket to the maximum

dump or tilt position but rather to the required levelling angle. The
rear counterweight should not touch the ground.
Working with the forklift attachment

Working with a forklift attachment on a wheel loader is different
both from working with a bucket and working with a forklift. There-
fore, observe the following points as well as the instructions in 19.685 in
chapter “General precautions (2-9)”. (500 mm)
 Do not pick up loads that are so high as to block the operator's

19.685 in
view of the route.
(500 mm)
 Hold the tines of the forklift attachment horizontally when
picking up a load.
75_156
 While driving, carry the load as close to the ground as possi-
ble in order to have a good view of the route.
 Always drive slowly with loads (speed range 1).
 The boom executes a semicircular movement during the lift-

ing process. Raise the boom to the desired unloading height
shortly before reaching the location of unloading. This pre-
vents the load from becoming damaged while lifting.
 Keep the forklift attachment horizontal when stacking, if pos-

sible.
WA80M-7, WA100M-7 – VENAM03001 3-85

Picking up the load
1. Approach the load slowly.
WARNING
Danger of accidents! If the load is not in the centre of gravity, the
stability of the machine will be negatively affected. Drive the fork-
lift attachment under the load until the load contacts the back of
the forklift attachment.
2. Drive the forklift attachment under the load so the load con-
tacts the back of the forklift attachment.
3. Slightly tilt the forklift attachment to prevent the load from slip-
ping off.
4. Lower the boom to the carrying position.
5. Raise the load to the proper height a short time before reach-
ing the unloading location. Raise the load a little higher than
necessary.
6. Set the load down slowly and from above onto the unloading
location.
7. Slowly lower the boom until it is possible to pull the tines out
from under the load.
8. Check that there are no persons standing behind the

machine, and back up from the unloading location.
3-86 WA80M-7, WA100M-7 – VENAM03001

3.3.11 Operating precautions
Permissible water depth

When working in water or on muddy ground, the water level must
be below the underside of the axle housing. After finishing oper-
ation, wash the machine and check the lubrication points.
Working on snow
Follow the instructions in section “Working on snow (2-27)”.
Dumping on steep slopes

Follow the instructions in section “While loading (2-26)”.
Working near high-voltage cables

Follow the instructions in section “Working near high-voltage
cables (2-17)”.
Working on road shoulders

Follow the instructions in section “Driving on slopes (2-24)”.

Follow the instructions in section “Working on loose ground
(2-27)”.
If the service brake fails

If the machine does not stop even when the brake pedal is fully
depressed, you must use the parking brake.
WA80M-7, WA100M-7 – VENAM03001 3-87

Precautions for driving uphill or downhill
Turning on slopes, ridges, or embankments
Follow the instructions in section “Turning and steering (3-73)”.
Braking on slopes
Follow the instructions in section “Braking on slopes (3-75)”.
Precautions when driving

The tyres will become very hot if the machine is driven at high
speeds for an extended period of time with improper tyre pres-
sure. This is to be avoided, as it causes premature tyre wear.
Observe the following points when it is necessary to drive the
machine over a long distance:
 Perform all checks before starting. For details see “Operation

(3-49)”.
 Fasten any manual tools before starting to drive.
 The required tyre pressure, the ground speed, and the type
of tyre vary depending on the road conditions. Contact your
Komatsu distributor or your tyre distributor for related infor-
mation.
 See table “Tyres and tyre pressure” in chapter “Tyre pressure

(3-96)” for the proper tyre pressure.
 Check the tyre pressure before starting to drive, when the

tyres are cold.
 Lower the work equipment to the carrying position and tilt it

back fully.
 Always drive with the bucket or forklift attachment empty.
 Observe applicable traffic rules and drive carefully. Check

that the work lights and the warning beacon are off when driv-
ing on roads.
 Take a 30-minute break after each hour of driving. Check the

tyres and any parts exposed to high stress by road travel for
proper function and damages.
3-88 WA80M-7, WA100M-7 – VENAM03001

3.3.12 Adjusting the work equipment
Selecting the work equipment

See chapter “Equipment (1-22)” for approved work equipment.
Attaching the work equipment

1. Start the engine.
2. Unlock the quick coupler by setting the special equipment

control lever to position '1' while pressing and holding button
(4).
G0010048 4
G0070420
3. Slightly raise the boom by setting the multi-function lever to

position 'H'.
4. Slightly tilt the quick coupler forward. Push the multi-function

lever to position 'A' to do so.
G0010009
5. Drive the machine towards the work equipment until the quick
coupler (a) is underneath the mounting hooks of the work
equipment. Then raise the boom until the work equipment is a
suspended from the quick coupler.
7 5 _ 2 8 0A
WA80M-7, WA100M-7 – VENAM03001 3-89

6. Push the multi-function lever into position 'E' to tilt back the
quick coupler until the stops of the work equipment contact
the quick coupler.
7. Lock the quick coupler by setting the special equipment con-

trol lever to position '2'.
The locking bolts (b) must be visible.
WARNING
G0010009
8. Check the work equipment for proper attachment by tilting a

and dumping.
7 5 _ 2 8 0A
G0010048
3-90 WA80M-7, WA100M-7 – VENAM03001

Attaching the multi-purpose bucket
Perform the following additional steps for attaching a multi-pur-

pose bucket.
10. Set the special equipment control lever to position '1'.
G0010048
11. Connect the hydraulic lines of the multi-purpose bucket to

quick couplers (5) and (6). 5 6
Now the multi-purpose bucket can be operated with the spe-

cial equipment control lever.
Position 1 = Open multi-purpose bucket

Position 2 = Close multi-purpose bucket
WARNING
13. Check the multi-purpose bucket for proper attachment by tilt-

ing and dumping.
WA80M-7, WA100M-7 – VENAM03001 3-91

Removing the work equipment

1. Set the work equipment down on level ground.

(4).
G0010048 4
G0070420
3. Use the multi-function lever to set the quick coupler to the

dump position 'A', until the quick coupler disengages from the
mounting hooks of the work equipment.

machine, and back up the machine from the work equipment.
G0010009
3-92 WA80M-7, WA100M-7 – VENAM03001

Removing the multi-purpose bucket

1. Set the multi-purpose bucket down on level ground.
3. Set the special equipment control lever to position '1' first and
then to position '2' to relieve the pressure in the hydraulic
lines.
4. Disconnect the hydraulic lines of the multi-purpose bucket

from the quick couplers.

G0010048 4
(4). G0070420
7. Use the multi-function lever to set the quick coupler to posi-

tion 'A' until the quick coupler disengages from the mounting
hooks of the multi-purpose bucket.

machine, and back up the machine from the multi-purpose
bucket.
G0010009
Bucket level indicator

The bucket level indicators consist of markings on the upper edge
on both sides of the bucket. They are parallel with the cutting
edge.
The level indicators inform the operator of the position of the cut-
ting edge when the operator is sitting in the operator's seat.
WA80M-7, WA100M-7 – VENAM03001 3-93

3.3.13 Switching off the engine
NOTICE
Turning the engine off immediately after working at heavy load
without letting it cool down first may significantly reduce the
engine's service life. Do not switch off the engine suddenly unless
in an emergency.
1. Check the engine temperature at the coolant temperature

gauge (1).
2. If the engine overheats, run it without load at a medium speed

for 5 minutes before switching it off, so that the engine can
cool down.
3. Lower the working equipment.
4. Turn the starting switch to the 'A' (OFF) position to stop the
G0010011
engine. 1
5. Remove the key from the starting switch.

A B
G0070421A
3.3.14 Checks after switching off the engine

1. Walk around the machine and check the work equipment, the
chassis, and the undercarriage. Also check for oil and water
leakage. Immediately repair any defects.
2. Fill the fuel tank.
3. Remove combustible material from the engine area, as it is a

fire hazard.
4. Remove coarse dirt from the undercarriage.
3-94 WA80M-7, WA100M-7 – VENAM03001

3.3.15 Locking
Lock at the following locations:
3
1 Engine bonnet
2 Cab door
1
3 Battery box
NOTICE
The ignition key fits all locks.
2
WA80M-7, WA100M-7 – VENAM03001 3-95

3.3.16 Handling tyres
Precautions when handling tyres

For safety reasons, replace any tyres with one or more of the fol-
Tread
lowing defects:
Belt
 The bead wire is bent or broken. Sidewall
 Excessive wear, and the carcass ply (excepting the breaker)

is exposed.
 The carcass damage exceeds 1/3 of the tyre width.

Bead
 The tyre layers are separated from each other.
Carcass
 Radial cracks extending into the carcass.
 Warping or damage rendering the tyre unsuitable for use.
Tyre pressure
Check the tyre pressure before starting to work, when the tyres
are cold.
To prevent the tyre from slipping off the rim, make sure the tyre
pressure does not drop below 2 bar.
If the tyre inflation pressure is too low, there will be overload; if it

is too high, it will cause tyre cuts and shock burst.
As a general principle for visual inspections, the deflection ratio

of the front tyre (deflection/free height) should be as follows:
Deflection ratio = (H – h)/H x 100
H = unloaded tyre
h = loaded tyre
For carrying normal loads (horizontal boom position): a

pprox. 15–25%.
When digging (rear wheels off the ground): approx.

25–35%. GK032224
When checking the tyre pressure, also check for cracks, peeling,
and abnormal wear. Remove nails, chunks of metal, and other
foreign particles from the tyres.
Remove fallen rocks from the working area. Clearing the work-
space prolongs the service life of the tyres and increases the prof-
itability of the machine.
3-96 WA80M-7, WA100M-7 – VENAM03001

Standard tyres
Air pressure (min. 2 bar)
Machine Manufacturer Tyre size Front axle Rear axle
bar psi bar psi
12,5-20 NB38 TBL, tread 1500/1465 -

BARUM 4 58 3.5 51
11*20
405/70 R18 SPT9, tread 1470/1435 -

DUNLOP 3 44 2.5 36
13*18
335/80 R20 SPT9, tread 1500/1465 -

DUNLOP 3.75 54 2.75 40
11*20
365/80 R20 SPT9, tread 1500/1465 -

DUNLOP 3 44 2.5 36
11*20
405/70 R20 SPT9, tread 1441/1406 -

DUNLOP 2.5 36 2.5 36
13*20
365/70 R18 SPT9, tread 1520/1485 -

DUNLOP 3.75 54 3 44
11*18
375/75 R20 XZSL, tread 1450/1415 -

WA80M-7 MICHELIN 2.4 35 2 29
11*20
340/80 R20 XMCL TL, tread 1500/1465 -

MICHELIN 2.8 41 2.4 35
11*20
335/80 R20 XZSL, tread 1500/1465 -

MICHELIN 2.8 41 2 29
11*20
380/75 R20 XMCL, tread 1450/1415 -
11*20
400/70 R20 XMCL, tread 1441/1406 -
13*20
335/80 R20,TL,MPT 70E, tread 1500/

CONTINENTAL 3.75 54 3.5 51
1465 -11*20
365/80 R20, TL,MPT 70E, tread 1500/

CONTINENTAL 3.5 51 3 44
1465 -11*20
WA80M-7, WA100M-7 – VENAM03001 3-97

Air pressure (min. 2 bar)
Machine Manufacturer Tyre size Front axle Rear axle
bar psi bar psi
BARUM 405/70-24 NB38, tread 1745 -13*24 3 44 2.75 40
DUNLOP 405/70 R20 SPT9, tread 1715 -13*20 3 44 2.6 38
DUNLOP 405/70 R24 SPT9, tread 1745 – 13*24 3 44 2.75 40
DUNLOP 455/70 R20 SPT9, tread 1635 – 14*20 2.75 40 2.2 32
DUNLOP 455/70 R24 SPT9, tread 1690 – 14*24 2.5 36 2 29
455/70 R20 SPT9, tread 1635 – 14*20,

WA100M-7 DUNLOP 2.75 40 2.2 32
with lifting device
MICHELIN 405/70 R20 XZSL, tread 1715 – 13*20 3 44 2.5 36
MICHELIN 425/75 R20 XZSL, tread 1715 – 13*20 2.5 36 2 29
MICHELIN 420/75 R20 XMCL, tread 1715 – 13*20 3 44 2.4 35

CONTINENTAL 405/70 R20 MPT, tread 1715 – 13*20 3 44 2.4 35
CONTINENTAL 455/70 R24 MPT, tread 1690 – 14*24 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 distributor.
The service life and performance of the tyres is depends critically

on the proper pressure. Proper pressure protects the tyres
against damage. Do not deflate the tyres if the pressure increases
due to high temperature. Check and adjust the tyre pressure
before starting to work, when the tyres are cold.
Under extreme operating conditions (e.g. load and carry opera-

tion), have the tyre pressure specified on location by the tyre
manufacturer or an authorised representative.
Increase the tyre pressure if the deflection ratio is too great.
3-98 WA80M-7, WA100M-7 – VENAM03001

Operation 3.4 Transport
3.4 Transport
Observe all applicable laws and regulations when transporting
the machine. Be careful to ensure safety.
3.4.1 Transporting procedure

As a basic rule, always transport the machine on a trailer.
Select a trailer that is suitable for the weight and dimensions

specified in “Technical data (6-2)”.
Note that the specifications for the weights and dimensions for
transport vary according to the type of tyre and the type of bucket.
Ensure steady positioning

See “Ensure steady positioning (2-34)”.
3.4.2 Loading the machine
WARNING
 When loading or unloading the machine, run the engine at low
speed. Drive and work slowly.
 Park the trailer on firm and level ground for loading and
unloading the machine. Keep a sufficient distance from the
road shoulder.
 Use ramps of ample width, length, thickness, and strength.

Install the ramps with an inclination of less than 15°. When
using an embankment, compact the soil thoroughly and make
sure that the slope face does not collapse.
 Remove the mud stuck to the undercarriage to prevent the

machine from slipping to the side on the ramps. In addition,
remove any water, snow, ice, grease, or oil from the ramps.
 Never use the steering on the ramps. There is a risk that the
machine may tip over. If it is necessary to change direction,
return to the ground surface or the trailer platform, correct the
direction, and start again.
 The position of the centre of gravity of the machine will

change suddenly at the transition between the ramp and the
trailer. There is risk of the machine losing its balance. Always
drive slowly over this point.
When loading or unloading, always use ramps or a platform. Pro-

ceed as follows:
WA80M-7, WA100M-7 – VENAM03001 3-99

3.4 Transport Operation
Loading the machine

1. Load or unload the machine only on firm, level ground.
Maintain a safe distance from the road shoulder or slopes.
2. Apply the parking brake of the trailer and block the wheels
with chocks to ensure that the trailer does not move.
Then fix the ramps in line with the centres of the trailer and
the machine.
Ramp
Check that both sides are of equal height.
Wheel chocks
The ramp's angle of inclination must not exceed 15°. Block
max. 15°
Distance
Set the distance between the ramps to match the centre of between ramps
the tyres. GK032225
If the ramp sags noticeably, reinforce it with blocks or similar.
3. Determine the direction of the ramp, then slowly load the

machine.
4. Load the machine correctly in the specified position on the

trailer.
Securing the machine
DANGER
If the machine is not properly secured, it may slide or fall off the
transport vehicle and cause severe accidents. Always secure the
machine with ropes and wheel chocks or wedges to prevent it
from sliding or falling off.
Secure the machine to the trailer as follows.
G0010004
3-100 WA80M-7, WA100M-7 – VENAM03001


WA80M-7
WA100M-7
G0080301
5. Lock the articulated steering with the locking bolt (right side:
1).
For details see “Securing the articulated steering (2-35)”.
ATTENTION
 Incorrectly attached ropes may damage the machine! Attach
the hooks of the fastening ropes to the marked attachment
points only.
 Check the attachment points of the machine and the trans-

porter for possible damage before and after loading, particu-
larly when transporting frequently.
6. Put wheel chocks in front of and behind the wheels. Secure

the machine with chains or wire ropes to prevent it from mov-
ing during transport.
Be especially careful to ensure that the machine cannot slip

sideways.
To avoid damaging the machine, only fasten the hooks of the

fastening ropes to the marked attachment points on the
machine as shown in the diagram on the right.
Chains or ropes must not contact other components.
Always retract the car radio antenna fully. G0070240
WA80M-7, WA100M-7 – VENAM03001 3-101

Unloading the machine

1. Load or unload the machine only on firm, level ground.
Maintain a safe distance from the road shoulder or slopes.
2. Apply the parking brake of the trailer and block the wheels
with chocks to ensure that the trailer does not move.
Then fix the ramps in line with the centres of the trailer and
the machine.
Ramp
Check that both sides are of equal height.
Wheel chocks
The ramp's angle of inclination must not exceed 15°. Block
max. 15°
Distance
Set the distance between the ramps to match the centre of between ramps
the tyres. GK032225
If the ramp sags noticeably, reinforce it with blocks or similar.
3. Remove the chains and wire ropes fastening the machine.
4. Remove the locking bolt (right side: 1).
Warm the engine up fully.

1

WA80M-7
7. Depress the brake pedal and release the parking brake.
Keep the right brake pedal depressed.
8. Determine the direction of the ramp, then slowly unload the

machine.
WA100M-7
G0080301
3-102 WA80M-7, WA100M-7 – VENAM03001

3.4.3 Lifting the machine
WARNING
 Lifting operations using a crane must be carried out by a qual-
ified operator.
 Use a suitable lifting traverse. Use suitable lifting traverses to

ensure that the maximum diagonal pull of 10° is not
exceeded.
 Lifting traverse, slings and attachment points must be

inspected regularly and before operation for: cracks, defor-
mations, wear and excessive corrosion.
 The lifting point of the traverse must lie above the center of
gravity.
 Never lift the machine with any worker on it.
 Keep the machine horizontal when lifting it.
 Lock the articulated steering before lifting the machine.
 Danger of injury! Objects placed on the machine may drop

when the machine is lifted. Remove all loose objects from the
machine before lifting it.
ATTENTION
 Incorrectly attached ropes may damage the machine! Attach
the hooks to the marked attachment points only.
 Check the attachment points before and after lifting, particu-

larly when transporting frequently.
 When the machine is raised, check that there is no oil leakage

from the hydraulic circuits.
NOTICE
This lifting procedure applies to machines with standard specifi-
cations. The method of lifting differs according to the attachments
and options actually installed. In such cases, please contact your
Komatsu distributor for information.
For details on the weight please see “Technical data (6-2)”.
WA80M-7, WA100M-7 – VENAM03001 3-103

Standard machines
max.10 max.10
max.10
G0010055
Attach the lifting hooks to the four points on the machine as

shown in the diagram above.
The slings (ropes, chains or similar) may only be used at a max-

imum angle of 10° (see illustration above) and must not touch any
part of the machine aside from the attachment points.
Lift the machine at these 4 points exclusively. There is a high risk

of the machine losing its balance.
GK032227
3-104 WA80M-7, WA100M-7 – VENAM03001

Rim with lifting fixture (option WA100M-7)
max.10 max.10
350 G
1200 1200
2400
G0070241A
NOTICE
 Rim with lifting fixture may only be used with “Dunlop 455/70
R20 SPT9” tyres.
 Only Komatsu replacement parts may be used. Original parts

may not be modified.
Attachment points and rims must be examined by an expert, reg-

ularly (at least yearly) and in case of an accident or unusual event,
for:
 Bolt (A) and nut are tight

Use thread locker
Torque = 400 Nm
 Deformation, wear, damage and excessive corrosion
 The lifting eyes must turn easily and be oriented as shown in

A
the illustration.
The lifting point of the traverse must lie over the center of gravity
(G). G0070241B
The slings (ropes, chains or similar) may only be used at a max-

imum angle of 10° (see illustration above) and must not touch any
part of the machine aside from the attachment points.
The attachment points must not be rotated when carrying a load.
Lift the machine at these 4 points exclusively. There is a high risk

of the machine losing its balance.
WA80M-7, WA100M-7 – VENAM03001 3-105

3.5 Operation in cold weather Operation
3.5 Operation in cold weather
3.5.1 Precautions for operation in cold weather

At low temperatures, it may become difficult to start the engine,
and the coolant may freeze. Use the following precautions:
 Change to low-viscosity oil for all components.
 Use winter fuel.
For details see “Fuel, lubricants, and coolants; quantities

(5-16)”.
 Fill the windshield washer system with antifreeze.
 Check the coolant.
WARNING
 Antifreeze is toxic. Be careful to avoid contact with eyes or
skin. If antifreeze should contact your eyes or skin, wash it off
with a large amount of fresh water and see a doctor at once.
 When changing the coolant or when handling coolant con-

taining antifreeze that has been drained while repairing the
radiator, please contact your Komatsu distributor. Antifreeze
is toxic. Prevent it from leaking into drainage ditches or spill-
ing on the ground.
 Antifreeze is flammable. Keep away from open fire. Do not

smoke when handling antifreeze.
NOTICE
 Please use the original Komatsu antifreeze, Supercoolant
(AF-NAC). We recommend using Komatsu genuine Super-
coolant exclusively.
 Do not mix antifreeze agents of different brands.
For details see “Coolant (5-12)” and “Cooling system – clean-

ing internal area of the cooling system (5-32)”.
3-106 WA80M-7, WA100M-7 – VENAM03001

Operation 3.5 Operation in cold weather
3.5.2 Precautions after work

To prevent mud, water, or the undercarriage from freezing and
making it impossible for the machine to move on the following
morning, always observe the following precautions:
 Remove mud and water from the machine body. In particular,

wipe the hydraulic cylinder rods clean to prevent mud and dirt
on the rod surface from entering through the seal with the
water.
 Park the machine on solid, dry ground.
If this is impossible, park the machine on wooden boards.
The boards prevent the wheels from freezing to the ground

so the machine will be able to move the next morning.
 Open the drain valve and drain any water collected in the fuel
system to prevent it from freezing solid.
 Completely fill the fuel tank to prevent moisture from con-

densing inside the tank due to falling ambient temperatures.
3.5.3 After the cold weather period

When season changes and the weather becomes warmer, do as
follows:
Change the fuel. Replace the oil for all components with oil of the
specified viscosity.
For details see “Fuel, lubricants, and coolants; quantities (5-16)”.
WA80M-7, WA100M-7 – VENAM03001 3-107

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

For keeping the machine in long-term storage (more than one
month), proceed as follows:
 Clean and dry all parts and store the machine indoors. If the
machine has to be stored outdoors, park it on level ground
and cover with a tarp.
 Fill the fuel tank to prevent moisture from accumulating.
 Lubricate the machine and change the oil before storage.
 Coat the exposed portion of the hydraulic cylinder rod with

grease.
 Switch off the engine and starting switch.
Only switch the battery main switch off once the green pilot
lamp on the relay box has gone out.
Remove the key to the battery main switch. Keep the battery
covered in storage.
 Lock all control levers with the lock levers.
 To prevent corrosion, fill the cooling system with original

Komatsu Supercoolant (AF-NAC). Check that the mixing ratio
is 30% at least.
3.6.2 During storage
WARNING
Risk of poisoning when engine is running indoors! Open doors
and windows before starting the engine indoors.
 During storage, always operate the machine once a month so

that the oil film renews on moving parts and on the surface of
components. Also charge the battery.
 Wipe off all the grease from the hydraulic cylinder rod before
operating the work equipment.
 If the machine is equipped with an air conditioner, operate it

for 3 to 5 minutes once a month to lubricate the compressor.
Have the engine run at low idle during this operation. Check
the refrigerant level twice a year.
 If the machine is equipped with a central lubrication system,

intermediate lubrication must be carried out every month.
3-108 WA80M-7, WA100M-7 – VENAM03001

Operation 3.6 Long-term storage
3.6.3 After storage
NOTICE
If a machine has to be used although the monthly corrosion pro-
tection measures have not been carried out, please contact your
Proceed as follows before using a machine after long-term stor-

age:
 Wipe the grease from the hydraulic piston rods.
 Refill oil and grease at all lubrication points.
 When a machine is stored for a long period, moisture from the

ambient air will enter the oil. Check the oil for accumulation of
water before and after starting the engine. If there is water in
the oil, change the oil.
 For lubricating the machine, see chapter “Maintenance

schedule (5-25)”.
WA80M-7, WA100M-7 – VENAM03001 3-109

3.7 Machines equipped with KOMTRAX Operation
3.7 Machines equipped with KOMTRAX

KOMTRAX is a machine management system that uses wireless
communications.
KOMTRAX is a wireless device operating at radio frequencies. It

requires approval and needs to conform to the laws of the country
or territory where the machine equipped with KOMTRAX is used.
Always contact your Komatsu distributor before selling or export-
ing any machine equipped with KOMTRAX.
When selling or exporting the machine, or in other cases when

your Komatsu distributor considers it necessary, it may be that the
KOMTRAX unit needs to be removed or rendered inoperable.
If these precautions are not followed, neither Komatsu nor your

Komatsu distributor will be liable for any resulting problems or
losses.
3.7.1 Basic precautions
WARNING
 Never disassemble, repair, modify, or move the communica-
tions terminal, the antenna, or the cables. Non-compliance
may cause failure or fire at the KOMTRAX unit or at the
machine itself. (KOMTRAX may be installed and removed by
your Komatsu distributor.)
 Prevent cables and wires from snagging. Do not damage or

pull cables by force. Short circuits or disconnected wires may
cause failure or fire at the KOMTRAX unit or at the machine
itself.
 For anyone wearing a pacemaker, make sure that the com-

munications antenna is at least 22 cm from the pacemaker.
The radio waves may have an adverse effect on the operation
of the pacemaker.
NOTICE
 Even when the key in the starting switch of machine equipped
with the the KOMTRAX system is in the (OFF) position, a
small amount of electric power is consumed. If the machine
is being stored for one or more months, follow the instructions
under “Long-term storage (3-108)”.
 Please contact your Komatsu distributor before installing a

top guard or any other attachment that covers the cab roof.
 Be careful to prevent water from spilling on the communica-

tions terminal or the wiring.
REMARK
KOMTRAX uses wireless communications, so it cannot be used
inside tunnels, underground, inside buildings, or in mountainous
areas without radio reception. Even when the machine is outside,
it may not be usable in areas with limited radio reception or out-
3-110 WA80M-7, WA100M-7 – VENAM03001

Operation 3.7 Machines equipped with KOMTRAX
side the wireless communication service area.

The KOMTRAX communications terminal does not need inspec-
tion or maintenance. Consult your Komatsu distributor in case of
anomalies.
WA80M-7, WA100M-7 – VENAM03001 3-111

3.8 Reading error code Operation
3.8 Reading error code
G0010011E
1 2 3
If there is a malfunction on the machine, one of the following error

codes appears in the middle monitor area.
 Stop the work.
 Check the indicator and proceed as follows.
NOTICE
Contact your Komatsu distributor to arrange a repair. G0010011D
1. Stop the engine if an error code appears.
Error code
“STOP”
“WARNING”

A B
3. Press the middle button (2) and hold it for 5 seconds.
The background lighting starts to flash. All error codes are dis-
C
played after a short time.
G0070421
3-112 WA80M-7, WA100M-7 – VENAM03001

Operation 3.8 Reading error code
4. When the background lighting stops flashing, the “START”

key appears in the middle monitor area.
Press the “START” key and the error code is displayed.
5. Contact your Komatsu distributor and tell them what the error
code is.
START
G0010043
3.8.1 Adjusting the monitor

The two keys are for setting the tyre size and changing the speed-
ometer display from “km/h” to “mph” and vice versa.
Have your Komatsu distributor adjust these settings!
G0010011
WA80M-7, WA100M-7 – VENAM03001 3-113

3.8 Reading error code Operation
3-114 WA80M-7, WA100M-7 – VENAM03001

Troubleshooting
4. Troubleshooting
WA80M-7, WA100M-7 – VENAM03001 4-1

4.1 Towing the machine Troubleshooting
4.1 Towing the machine
WARNING
Towing with a too light tractor can cause accidents! For towing
purposes, use a machine that is at least as heavy as the machine
you intend to tow. Check the attachment points before and after
towing for possible damage.
ATTENTION
The hydrostatic drive could be damaged during the towing pro-
cess! Do not start the machine by towing it. The engine cannot be
started by towing, but the drive can be damaged.
To avoid damage to the hydrostatic drive the machine may not be

towed further than 0.1 km. The towing speed may not exceed
2 km/h.
Before you are permitted to tow a machine that is equipped with

a hydrostatic drive, you have to establish a short-circuit connec-
tion between the high-pressure side and the low-pressure side of
the variable displacement pump.
For towing purposes, use a machine that is at least as heavy as

the machine you intend to tow. Always connect the machines with
a suitable towing device.
ATTENTION
Connecting towing equipment to the wrong point on a machine
may damage the machine. Use the intended towing points for the
connection of the towing device.
On the front frame, the towing device has to be fastened to the

marked towing eye. On the rear frame, the towing device can be
fastened to the towing pin.
Trailer tow hitch option
Attach the towing device to the trailer tow hitch.
 Ball-type hitch
4-2 WA80M-7, WA100M-7 – VENAM03001

Troubleshooting 4.1 Towing the machine
 Automatic hitch
G00100500
Before towing:
1. Set the direction selector switch to “N”.
G0010004
2. Tip up the operator's cab.

Version A
3. Remove the protective caps from the valves.
NOTICE
Observe the types of the valves: Version A or B
Version A is for 20 km/h
Version B is for 30 km/h 1
G0010093
Version B
G0010094
WA80M-7, WA100M-7 – VENAM03001 4-3

Version A
 Hold the valve (1) with a wrench.

3
 Loosen the lock nut (2) and screw in the threaded pin (3) 2
clockwise by means of an Allen key until it is level with the top
of the lock nut (4).
 Retighten the lock nut (2). Perform this task on both valves. 1
Version B

2
 Loosen the lock nut (2) and screw out the threaded pin (3) 3
counter-clockwise by means of an Allen key by 2 rotations.
4. Tip down the operator's cab.
For details see “Tipping down the operator's cab (5-5)”.
4-4 WA80M-7, WA100M-7 – VENAM03001

Troubleshooting 4.1 Towing the machine
After towing:
1. Tip up the operator's cab.
NOTICE
Observe the types of the valves: Version A or B
Version A

3
 Loosen the lock nut (2) and screw out the threaded pin (3) 2
counter-clockwise by means of an Allen key all the way.
 Retighten the lock nut (2). Perform this task on both valves.
1
Version B

2
 Loosen the lock nut (2) and screw the threaded pin (3) clock- 3
wise by means of an Allen key back in all the way.
2. Put the protective caps on the valves.
3. Tip down the operator's cab.
For details see “Tipping down the operator's cab (5-5)”.
WA80M-7, WA100M-7 – VENAM03001 4-5

NOTICE
When the engine is not running, the power steering is inactive.
Steering the machine requires a significantly higher effort in this
case.
If lifting the rear axle of the machine with a crane lorry, the
machine can be towed over longer distances at speeds higher
than 2 km/h. However, remove the cardan shaft of the front axle
first. Furthermore, secure the articulated steering with the safety
bar as during the transport of the machine on a trailer or a railway
carriage.
Towing a machine with defective brakes
WARNING
If the machine to be towed has defective brakes, it may collide
with the towing machine! Always use two machines to tow a
machine with defective brakes. Connect the three machines with
appropriate towing devices.
If you intend to tow a machine with defective brakes or the

machine has to be towed downhill, you need two machines for the
towing process.
Connect the machine to be towed to a larger machine that has

sufficient traction power and braking power. Connect a second
machine to the end of the machine to be towed. This avoids that
the machine to be towed gets out of control.
The towing process can be performed under various circum-

stances, so that it is not possible to define the necessary require-
ments in advance.
Towing on even, level surfaces requires a low traction power

while towing on slopes and on uneven surface requires high trac-
tion power.
Contact your Komatsu distributor for further information on towing

a machine.
4-6 WA80M-7, WA100M-7 – VENAM03001

Troubleshooting 4.2 Starting the engine with booster cables
4.2 Starting the engine with booster cables

To start the engine with booster cables, proceed as follows:
Precautions for connecting and disconnecting the booster

cables
WARNING
 Never touch the positive (+) terminal with the negative (-) ter-
WRONG
minal when connecting the cables.
 Always wear protective goggles when starting the engine with

booster cables.
 Ensure that the operational and the defective machine are not
touching each another. This avoids spark formation near the
battery that can ignite the escaping hydrogen gas and lead to
severe injuries or damages.
 Ensure that no errors occur during the connection of the

jumper cables. The last connection is made to the engine
block of the defective machine; spark formation occurs here.
Therefore perform the connection at a spot that is as far away
as possible from the battery.
 Be careful when disconnecting the cable from the started

machine. Ensure that the cable ends do not come in contact
with one another or the machine to avoid a hydrogen explo-
sion.
NOTICE
 The cross section of the jumper cable and the cable terminals
have to be selected according to the battery size.
 The batteries of the operational and defective machine must

have the same capacity.
 Inspect the cables and cable terminals for damages or corro-

sion.
 Ensure that the cables and cable terminals are securely fas-
tened.
 For machines with battery main switch
When you connect one machine to another machine to start

it with booster cables, turn off the battery main switch of the
defective machine and pull out the key for the battery main
switch to prevent damage to the electrical systems of the
machine.
WA80M-7, WA100M-7 – VENAM03001 4-7

4.2 Starting the engine with booster cables Troubleshooting
Connection of the booster cable
Before connecting two machines with booster cables:

A
 Turn the starting switch of the faulty machine to the OFF 2 1
position.
 Only switch the battery main switch of the faulty machine (S)
off once the green pilot lamp on the relay box has gone 3
out. battery battery
loaded B discharged
 Switch the starting switch of the functioning machine off.
4
Frame of the
Connect the booster cable as follows in the sequence of the num- discharged battery GK100876A
bers in the illustration.
1. Connect a terminal of the booster cable (A) to the positive ter-

minal (+) of the defective machine.
2. Connect the other terminal of the booster cable (A) to the pos-
itive terminal (+) of the operational machine.
3. Connect a terminal of the booster cable (B) to the negative

terminal (-) of the operational machine.
4. Turn on the battery main switch (S) of the defective machine.

Finally connect the other terminal of the booster cable (B) to
the frame of the defective vehicle.
5. Let the engine run at high speed.
Starting the engine
ATTENTION
Ensure that the cable terminals are securely fastened to the bat-
tery terminals.
1. Turn the starting switch of the defective machine to START

and start the engine. If the engine does not start during the
first attempt, wait at least two minutes until repeating the pro-
cess.
Disconnecting the booster cables
When the engine has started, remove the booster cables in the
opposite order of connecting. A
3 4
1. Disconnect the terminals of the booster cable (B) from the
frame of the defective machine.
2. Disconnect the other terminal of the booster cable (B) from 2

the negative terminal (-) of the operational machine. battery battery
loaded discharged
3. Disconnect the terminal of the booster cable (A) from the pos- B
itive terminal (+) of the operational machine. 1
Frame of the
discharged battery GK100876A
4. Disconnect the other terminal of the booster cable (A) from
the positive terminal (+) of the defective machine.
4-8 WA80M-7, WA100M-7 – VENAM03001

Troubleshooting 4.3 In case of insufficient brake power
4.3 In case of insufficient brake power
4.3.1 Checking the service brake

Drive the machine at a speed of 20 km/h on an even and dry road,
and check if the braking distance is less than 5 m.
NOTICE
All repairs of the brake system have to be performed by a
Komatsu workshop.
4.3.2 Checking the parking brake

1. Start the engine, align the machine forward and drive the
1
machine up a 25% slope with an empty bucket.
2. Stop the machine with the service brake and hold the service
brake.
3. Lower the work equipment (carrying position).
4. Set the direction selector switch (1) into the neutral position
“N”.
5. Turn off the engine. G0010004
6. Engage the parking brake (2) and slowly release the brake
pedal. 2 1
The machine must remain steady.
NOTICE
All repairs of the brake system have to be performed by
a Komatsu workshop.
WA80M-7, WA100M-7 – VENAM03001 4-9

4.4 Emergency steering properties Troubleshooting
4.4 Emergency steering properties

If the engine fails while you are driving, you can still steer the
machine. However, you need to manually apply more power.
In case of engine failure, immediately drive to the side of the road,

switch on the warning lights and secure the machine.
4.5 Emergency lowering

When the engine is not running, the work equipment can still be
lowered with the multi-function lever (emergency lowering).
If the hose break safety device is installed, the machine is

equipped with a pressure accumulator, so that the work unit can
be lowered by means of the multi-function lever when the diesel
engine is off.
NOTICE
If you have locked the work hydraulics (multi-function lever) by
WA80M-7
means of the lock lever, you cannot lower the work unit.
WA100M-7
G0080301
1. Make sure that no one is standing under the machine.
2. Push the multi-function lever slowly to the position “S”.
The work equipment is lowered.
G0010009
4-10 WA80M-7, WA100M-7 – VENAM03001

Troubleshooting 4.6 Other troubles
4.6 Other troubles
4.6.1 Electrical system

If errors or causes of errors occur that are not listed here, have
the repair performed by your Komatsu distributor.
ELECTRIC SYSTEM
Fault Cause Remedy
Battery charge circuit caution lamp:

The battery charge circuit caution lamp
does not light up after the engine has Electrical connection is not Check loose terminals, disconnections
been switched off and the starting functioning and cables *)
switch has been set to the operating
position, 'ON'.
Electrical connection is not Check loose terminals, disconnections

functioning and cables *)
Battery charge circuit caution lamp:
The battery charge circuit caution lamp Check the function of the alternator;
Alternator is not functioning
does not go out when the engine is replace defective alternator *)
running
Drive belts of the alternator
Tension drive belt
are not tensioned properly.
Alternator creates abnormal noises Defective alternator Renew alternator *)
Electrical connection is not Check loose terminals, disconnections

functioning and cables *)
Battery main switch is in OFF

Turn the switch to the ON position.
position.
Starter motor does not turn
Charge battery
Insufficient battery charge
Check the function of the battery;
replace the battery if it is defective *)
Pinion of starter motor repeatedly shifts Insufficient battery charge Charge battery
in and out Defective starter motor Replace starter motor *)
Insufficient battery charge Charge battery

Starter motor turns engine sluggishly
Defective starter motor Replace starter motor *)
Starter motor disengages before Insufficient battery charge Charge battery

engine starts Defective starter motor Replace starter motor *)
*) These tasks should be performed by the distributor.
WA80M-7, WA100M-7 – VENAM03001 4-11

4.6 Other troubles Troubleshooting
4.6.2 Engine
ENGINE
Fault Cause Remedy
Oil level in the engine is too low Add engine oil
Engine oil filter (filter cartridge) Replace engine oil filter (filter car-
clogged tridge)
Check lines and hoses (visual

Lines or hoses of the engine lubrica- inspection: discharge of oil)
Engine oil pressure caution lamp:
tion damaged Replace defective lines and
The engine oil pressure caution
hoses *)
lamp lights up and the acoustic
warning signal sounds while the Check line and hose connections
engine is running Line or hose connections of the (visual inspection: discharge of oil)
engine lubrication defective Repair leaky line and hose
connections *)
Check the function of the oil pres-

Oil pressure switch is not function-
sure switch; replace defective oil
ing
pressure switch *)
Pressure is escaping from the pres- Add coolant (observe the correct
Coolant level in the radiator too low
sure valve of the radiator cap mixing ratio)
Check lines and hoses (visual
inspection: discharge of coolant)
Coolant level too low Coolant system leaky
Replace defective lines and
hoses *)
4-12 WA80M-7, WA100M-7 – VENAM03001

ENGINE (continued)
Fault Cause Remedy
Let the engine run in idle speed with-

out load until the engine has cooled
Engine overheated
down and the coolant temperature
gauge is in the green range
The background of the temperature Inside of coolant system calcified or

Clean inside of cooling system *)
display lights up in red and the clogged
acoustic warning signal sounds. Radiator (cooling surfaces, fins) is Clean the radiator (cooling surfaces,
dirty fins)
Check the function of the thermostat;

Thermostat is not functioning
replace defective thermostat *)
Replace defective radiator cap; fas-
Radiator cap defective or loose
ten loose radiator cap
No contact to the temperature sen-

The temperature gauge display Check the contacts or replace the
sor, or the temperature sensor is
flashes temperature sensor *).
defective.
Coolant temperature gauge:

Check the function of the coolant
The coolant temperature gauge Coolant temperature gauge is not
temperature gauge; replace defec-
does not show a temperature with functioning
tive coolant temperature gauge *)
the engine warm in operation
Fuel tank empty Add fuel and bleed the fuel system
Air in the fuel system Bleed the fuel system
Injection pump or injection nozzle is Replace injection pump or injection

Engine does not start
not functioning nozzle *)
Starter motor speed too low See “Electrical system”

Engine compression too low Check valve clearance *)
Oil level in the engine is too high Correct the oil level
Exhaust has a white or blue colour
Wrong fuel Use prescribed fuel
Clean or replace air cleaner filter
Air cleaner filter insert clogged
insert
Exhaust coloured black intermit-
tently Injection nozzle defective Replace injection nozzles *)
Engine compression too low Check valve clearance *)
Combustion sounds like breathing

Injection nozzles defective Replace injection nozzles *)
intermittently
WA80M-7, WA100M-7 – VENAM03001 4-13

ENGINE (continued)
Fault Cause Remedy
Wrong fuel Use prescribed fuel
Let engine cool down

Engine temperature too high See
Abnormal combustion noises
(Engine overheated) “Engine – Coolant temperature
gauge”
Muffler defective Replace muffler *)
Abnormal mechanical noises Valve clearance too large Adjust the valve clearance *)
The engine will not start or switches Clean the fuel prefilter or replace the
Fuel filter or fuel prefilter blocked
off during operation. fuel filter
The engine does not start or goes
out during operation and the back-
Fuel tank empty Add fuel and bleed the fuel system
ground of the fuel display lights up in
red.
Air cleaner caution lamp:

When the engine is running, the air Filter insert of the air cleaner Clean or replace the air cleaner filter
cleaner display lights up in the mid- clogged insert
dle monitor area
4-14 WA80M-7, WA100M-7 – VENAM03001

4.6.3 Hydraulic system

HYDROSTATIC DRIVE UNIT
Fault Cause Remedy
Parking brake is engaged Disengage the parking brake

Switch direction selector switch in
Direction selector switch in “N” Pos.
“F” or “R” position
Machine does not drive Direction selector switch is not func- Check the function of the direction
tioning selector switch *)
Oil level in the hydraulic tank is too

Fill up hydraulic oil.
low.
The hydrostatic engine is not work-
Check the system *)
ing properly.
Replace the hydrostatic engine*)
Hydrostatic engine is defective
Check the forward/reverse valve*)

Forward/reverse valve is defective Replace the defective forward/
reverse valve *)
Check the function of the switch

Switch relay is not functioning. relay; repair or replace a defective
switch relay *)
Check the function of the control
Control valve of the pump is not
valve; replace the control valve if it is
functioning.
defective *)
Hydrostatic pump is defective. Replace the hydrostatic pump *)

Machine only travels very slowly
Required pilot pressure not reached Check the pilot pressure, adjust if
and is not operating at full power
necessary *)
Required charge pressure not Check the supply pressure, adjust if
reached necessary *)
Check the high pressure, adjust if
Required high pressure not reached. necessary *)
Check the high pressure valve,
adjust if necessary *)
Check the pressure separation,
adjust if necessary *)
Check the pilot device, adjust if
necessary *)
Inch valve defective or incorrectly Check the setting of the inch valve *)
set Replace the defective inch valve *)
Replace the filter element of the

Hydraulic filter clogged
hydraulic filter.
WA80M-7, WA100M-7 – VENAM03001 4-15

HYDROSTATIC DRIVE UNIT (continued)
Fault Cause Remedy
Check the supply pressure *)

Purge valve is not working properly
Repair and inspect the purge
(purge quantity too low).
valve *)
Hydraulic oil cooler (cooling sur- Clean the hydraulic oil cooler
faces, fins) is dirty. (cooling surfaces, fins).
Hydrostatic drive unit overheated The fan is not working properly. Check the fan drive *)
Hydraulic filter is clogged (intake

Replace the filter element of the
quantity too small for the charge
hydraulic filter.
pump)
The oil level in the hydraulic tank is Correct the oil level in the hydraulic
too low or too high. tank.
Oil level in the hydraulic tank is too

low.
Abnormal noises Air trapped in lines and units of the
hydraulic system (incorrect bleed- Bleed the hydraulic system *)
ing)
WORK EQUIPMENT
Fault Cause Remedy
Hydraulic pump is defective. Repair the hydraulic pump*)

Lifting power too low Directional valve (DBV) is defective. Check and adjust the DBV *)
Cylinder is defective (leaks inside). Repair the cylinder *)
Rpm of diesel engine too low

Adjust speed *)
Hydraulic pump is defective.
Repair the hydraulic pump*)
Priority valve defective
Repair the priority valve *)
Directional valve or pilot control valve
Lifting speed too slow Repair the valves *)
defective
Cylinder is defective (leaks inside).
Repair the cylinder *)
Required charge pressure not
Adjust the supply pressure *)
reached
Refill with the prescribed hydraulic

Wrong hydraulic oil quality
oil.
Air bubbles in the hydraulic oil
Oil level in the hydraulic oil tank is too
low.
Oil level in the hydraulic oil tank is too Fill up hydraulic oil.
low.
Hydraulic pump is defective. Check the hydraulic pump; replace
if necessary *)
Cylinder movements are jerky.
Priority valve defective Check the priority valve; replace if
necessary *)
Directional valve defective Check the directional valve; replace
if necessary *)
4-16 WA80M-7, WA100M-7 – VENAM03001

4.6.4 Brakes
BRAKES
Fault Cause Remedy
Brake lining worn out Replace brake pads *)

Brake disc worn out Replace brake disc *)
Air in the brake system Bleed the brake system *)
Brake without effect Add brake oil
Check brake system for damages
Brake oil level in the brake oil con-
and leakages
tainer too low
(visual inspection: discharge of
brake oil)
PARKING BRAKE
Fault Cause Remedy
Tolerance of the brake lever of the

Adjust parking brake *)
parking brake is too high
Brake without effect
Brake lining worn out Replace brake pads *)
Brake discs worn out Replace brake discs *)
Parking brake does not function Brake cable torn Renew brake cable *)
4.6.5 Steering
STEERING
Fault Cause Remedy
Hydraulic system is not working Check the function of the hydraulic

Steering reacts sluggish
properly system *)
Check the mounting points of the

Tolerance of the steering cylinder
steering cylinder; replace defective
bolt is too large
Steering swivels steering cylinder bolts *)
Hydraulic system is not working Check the function of the hydraulic

properly system *)
WA80M-7, WA100M-7 – VENAM03001 4-17

4.6.6 Axles
AXLES
Fault Cause Remedy
Noises Oil level in the axle is too low Add oil
4.6.7 Operator's cab

OPERATOR'S CAB
Fault Cause Remedy
Blower: Air flow rate low Blower filter clogged Clean or replace the filter
4-18 WA80M-7, WA100M-7 – VENAM03001

Maintenance
5. Maintenance
WA80M-7, WA100M-7 – VENAM03001 5-1

5.1 Maintenance guide
Maintenance

Only qualified personnel may perform maintenance.
For details see “Precautions for maintenance (2-32)”.
Park the machine on solid, level ground before performing main-

tenance.
Always position the machine as specified for maintenance and

repairs.
Unless explicitly specified otherwise, the machine must be posi-

tioned as follows:
 Lower the work equipment to the ground.
 Set the multi-function lever to the '0' position, HOLD.
G0010009

WA80M-7
 Secure the articulated steering with the locking bolt.
 Block the wheels with wheel chocks.
WA100M-7
G0080301
5-2 WA80M-7, WA100M-7 – VENAM03001

Maintenance
5.1.1 Tipping up the operator's cab

1. Park the machine on solid, level ground.
2. Lower the work equipment to the ground and switch off the
engine.
3. Close the cab door.
4. Secure the articulated steering with the locking bolt.
For details see “Securing the articulated steering (2-35)”.
NOTICE
The machine has to be positioned as for driving in a straight line,
and the articulated steering has to be secured with the locking
bolt! If the operator's cab is tipped up while the machine is bent,
the front frame may damage the windscreen!
5. Open the bonnet.
6. Remove the fastening nuts (1) for the cabin on both sides.
7. Take the hand pump lever from its holder (2) and insert it into
the receptacle of the pump (3).
2 3
8. Set the lever at the pump to “pump up” and pump the cab
upward until it reaches the limit stop.
G0070267
WA80M-7, WA100M-7 – VENAM03001 5-3

Maintenance
9. Fold out the safety rod on the right side over the retaining pin.
10. Set the lever at the pump to “pump down” and pump the cab
downward until the safety rod is secure against the right side
of the cab floor.
G0070278
11. Remove the lever from the pump and fasten it in the door.
5-4 WA80M-7, WA100M-7 – VENAM03001

Maintenance
5.1.2 Tipping down the operator's cab

1. Stick 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.
G0070267
2. Fold in the safety rod on the right side and secure it in the
folded position (arrow).
3. Set the lever to “pump down” and pump the cab downward
until the cylinder is entirely retracted (the resistance at the
lever increases markedly).
G0070278
4. Remove the lever from the pump and fasten it in the door.
WA80M-7, WA100M-7 – VENAM03001 5-5

Maintenance
5. Screw the cabin on firmly at both sides using new locking nuts
(1).
Torque = 150 Nm. 1
6. Close the bonnet.
Checking the service meter
Check the service meter reading every day to see if there is main-
tenance work to be carried out.
Komatsu genuine replacement parts:
Only use Komatsu genuine parts specified as replacement parts

in the Parts Book. In order to ensure safe assembly and operation
of the machine, it is recommended that you use Komatsu genuine
parts.
Komatsu genuine oils:
Only use Komatsu genuine oils and grease. Choose oils and
grease with proper viscosities specified for ambient temperature.
Always use clean washer fluid:
Use ethanol-based window washer fluid and ensure it is not con-

taminated by dirt.
Always use clean oils and greases:
Use clean oils and lubricants. Also, keep the oil and lubricant res-
ervoirs clean. Prevent contamination of oils and greases by for-
eign materials.
Checking for foreign materials in drained oil and in filters:
After changing the oil and filter, check the drained oil and the fil-
ters for metal particles and foreign materials. If large quantities of
metal particles or foreign materials are found, always report to the
person in charge and perform the necessary measures.
Fuel strainer:
Do not remove the strainer from the filler neck when refilling the
fuel tank.
5-6 WA80M-7, WA100M-7 – VENAM03001

Maintenance
Welding instructions:
 Before beginning welding, proceed as follows:
 Turn the starting switch to the OFF position.
 Switch the battery main switch off once the green pilot
lamp on the relay box has gone out.
 Do not apply a continuous voltage of more than 200 V.
 Connect the earthing wire at a maximum distance of 1 m to

the weld area.
There must not be any gaskets or bearings between the weld

area and the earthing point.
Never weld lines or pipes containing fuel or oil.
Do not drop objects into the machine:
 When opening inspection windows or filler necks, be careful

not to drop screws, nuts, or tools into the machine.
If such objects are dropped into the machine, they will dam-
age the machine and cause malfunctions leading to machine
failure. If you drop anything inside the machine, always
remove it immediately.
 Do not carry unnecessary objects in your pockets. Carry only

the things that are necessary for the inspection.
Dusty worksites:
Proceed as follows when working in dusty environments:
 Frequently check the air cleaner caution lamp for clogging of

the air cleaner.
Clean the air cleaner more frequently.
 Periodically clean the cooler block to prevent clogging.
 Periodically clean and replace the fuel filter.
 Clean electrical components, especially the starter motor and

alternator, to prevent accumulation of dust.
 When inspecting or changing the oil, move the machine to a

place that is free of dust to prevent oil contamination.
WA80M-7, WA100M-7 – VENAM03001 5-7

Maintenance
Do not mix oils:
If oil of a different brand or grade needs to be used, completely

drain the oil and replace it with oil of the new brand or grade. Do
not mix oils of different brands or grades.
Bleeding air from the hydraulic circuit:
After repairing or replacing parts or lines of the hydraulic circuit it

is necessary to bleed the air from the circuit.
Precautions when installing hydraulic hoses:
 When removing parts with sealing rings or o-rings, clean the

surface and replace the rings or seals with new parts.
Be careful not to forget to install the o-rings and seals.
 When installing the hoses, do not twist them or bend them into
loops with a small radius.
This will cause damage to the hose and markedly reduce its
service life.
5-8 WA80M-7, WA100M-7 – VENAM03001

Maintenance
Checks after inspection and maintenance:
Neglecting to perform these checks after inspection and mainte-

nance may cause unexpected problems resulting in serious injury
or property damage. Always proceed as follows:
 Checks after operation (with engine off)
 Were any inspection and maintenance points forgotten?
 Were all inspection and maintenance items carried out

correctly?
 Were any tools or parts dropped into the machine? It is

very dangerous if parts are dropped inside the machine
and become caught in the lever linkage.
 Is there any leakage of water or oil? Have all the bolts

been tightened?
 Checks with the engine running:
If a maintenance task must be carried out with the engine run-

ning, perform the task with at least two workers and proceed
as follows:
 Park the machine on solid, level ground. Lower the work

equipment to the ground.
 One worker must always sit in the operator's seat and be

ready to stop the engine at any time. The workers must
always maintain contact with each other.
 Engage the work equipment lock lever.
 Do not touch the control levers.
 If any control lever must be operated, give a signal to the

other workers to warn them to move to a safe place.
 Increase the engine speed to check for fuel and oil leak-
age.
WA80M-7, WA100M-7 – VENAM03001 5-9

5.2 Basic maintenance guidelines
Maintenance

 Exclusively use Komatsu genuine parts, greases and oils.
 When changing the oil or adding oil, do not mix different types
of oil. When changing the type of oil, drain the oil completely
and refill the system with the new oil. Also be sure to replace
the oil filter. (There is no problem if the small amount of oil
remaining in the piping mixes with the new oil.)
 Unless specifically required otherwise, the machine is deliv-

ered with fuel, coolant, and lubricants as shown in the table
below.
Component Type
Engine oil pan Engine oil 15W-40-LA (Komatsu genuine parts)
Transmission case Shell Spirax S4 TXM
Shell Tellus S2 M46 hydraulic oil (Komatsu genuine parts)

WA80M-7 serial numbers from H62051 to H62063
WA100M-7 serial numbers from H62051 to H62184
Hydraulic system
Engine oil EO10W30-DH (Komatsu genuine parts)
WA80M-7 serial numbers from H62064
WA100M-7 serial numbers from H62185
Axles Shell Spirax S4 TXM
Cooling system Supercoolant AF-NAC (density: 50%) (Komatsu genuine parts)
Tank window washer system Ethanol-based (only use ethanol-based)
5.2.1 Fuel, coolant and lubricant specifications
Oil
 Oil is used in the engine and in the work equipment under
extremely severe conditions (high temperature, high pres-
sure) and deteriorates with use.
Always use oil that matches the grade and temperature range
specified in the Operation and Maintenance Manual.
Even if the oil is not contaminated, it needs to be changed

after the specified interval.
 Oil in a machine corresponds to the blood in a human body.

Handle it carefully to prevent contamination (water, metal par-
ticles, dirt, etc.).
The majority of problems with machines are caused by such

impurities.
Take particular care to prevent contamination during storage

or when refilling.
 Never mix oils of different grades or brands.
5-10 WA80M-7, WA100M-7 – VENAM03001

Maintenance
 Always add the specified amount of oil.
Both too much and too little oil may cause problems.
 If the oil in the work equipment is not clear, there is probably

water or air entering the circuit. In such cases, please consult
your Komatsu distributor for information.
 When changing the oil, always replace the related filters at

the same time.
 We recommend having the oil analysed periodically to check

the condition of the machine. For those who wish to use this
service, please contact your Komatsu distributor.
 When using commercially available oil, it may be necessary

to reduce the oil change interval.
 We recommend using the Komatsu oil clinic for a detailed

check of the oil characteristics.
Fuel
 The fuel pump is a precision instrument. It does not work
properly if the fuel contains water or dirt.
 Be careful to prevent fuel contamination during storage or

when refilling.
 Always use the fuel specified in the Operation and Mainte-

nance Manual.
If the fuel is used at temperatures lower than the specified

temperature (particularly at temperatures below -15 °C), the
fuel will solidify.
If the fuel is used at temperatures higher than the specified

temperature, its viscosity will decrease. This may cause a
loss of output performance.
 To prevent the moisture in the air from condensing and form-

ing 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 after the filters have been
replaced, it is necessary to bleed the air from the circuit.
 If there is any foreign material in the fuel tank, flush the tank
and the fuel system.
NOTICE
Exclusively use diesel fuel with an extremely low sulphur content
(10 ppm). Never use any other fuel. Using low-viscosity fuel with
poor lubricating characteristics will cause a marked reduction in
the durability of the engine.
WA80M-7, WA100M-7 – VENAM03001 5-11

Maintenance
Coolant
 The coolant has the important function of preventing corro-
sion and freezing.
 Komatsu machines are shipped with Komatsu Supercoolant

(AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent
anti-corrosive, antifreeze and cooling properties and can be
used continuously for 2 years or 4000 hours.
 We recommend using Komatsu genuine Supercoolant (AF-

NAC) exclusively. Using any other coolant may cause serious
damage such as corrosion of the engine or of cooling system
components that use light metals like aluminium.
 When using Komatsu Supercoolant (AF-NAC) there is no

need to use anti-corrosive.
For details see “Cooling system – cleaning internal area of the

cooling system (5-32)”.
 Use distilled water or tap water (soft water) for diluting the
antifreeze coolant.
 Natural water, such as a river water or well water (hard water),

contains large amounts of minerals (calcium, magnesium,
etc.). This accelerates the formation of scale inside the
engine or the radiator. Once present, scale is very difficult to
remove. It also causes overheating due to poor heat
exchange. We recommend using water with an overall hard-
ness of less than 100 ppm to dilute the coolant.
 When using antifreeze, always observe the precautions given

in the Operation and Maintenance Manual.
 Antifreeze is flammable, so be extremely careful not to

expose it to flame or fire.
 The ratio of Supercoolant (AF-NAC) to water varies according

to the ambient temperature.
 Even in areas where no freezing temperatures occur, use

Supercoolant (AF-NAC) in a mixing ratio of at least 30% to
prevent corrosion of the cooling system.
 Supercoolant (AF-NAC) may be supplied already mixed. In

this case, do not dilute with water.
 If the engine overheats, wait for the engine to cool before add-
ing coolant.
 A low coolant level causes overheating and corrosion due to

air in the coolant.
5-12 WA80M-7, WA100M-7 – VENAM03001

Maintenance
Grease
 Grease is used to prevent wear and noise at the joints.
 This construction machine is used under heavy-duty condi-

tions. Always use the recommended grease and follow the
change intervals and ambient temperature recommendations
given in this Operation and Maintenance Manual.
 The nipples not included in the maintenance section are only

used in repairs and do not need to be greased.
When using the machine after it has been in storage for a long
time, carry out greasing if there is any stiffness or screeching.
 Always wipe off all of the old grease that is pushed out when
greasing.
Be particularly careful to wipe off the old grease in places

where sand or dirt sticking in the grease would cause wear of
the rotating parts.
Storing oil and fuel

 Keep indoors to prevent contamination with water, dirt, or
other foreign materials.
 When storing drum cans for a long period, put the drum on its
side so that the filler port of the drum can is at the side to pre-
vent moisture from being sucked in.
If drum cans have to be stored outdoors, cover them with a

waterproof sheet or take other protective measures.
 To prevent deterioration of the quality during storage, be sure

to use fuels and lubricants in the order of first in – first out (use
the oldest oil or fuel first).
WA80M-7, WA100M-7 – VENAM03001 5-13

Maintenance
Filters
 Filters are extremely important safety components. They pre-
vent impurities in the fuel and air circuits from entering impor-
tant equipment and causing problems.
Replace all filters periodically. For details see: “Maintenance

schedule (5-25)”.
However, when working in rough conditions, replace the fil-

ters at shorter intervals according to the oil and fuel (sulphur
content) being used.
 Never try to clean filters (cartridge type) and use them again.
Always replace with new filters.
 When replacing oil filters, check if the old filter contains any
metal particles. If any metal particles are found, please con-
tact your Komatsu distributor.
 Do not open packs of spare filters until just before they are to
be used.
 Exclusively use Komatsu genuine filters.
Biodegradable hydraulic oil and lubricants

The use of biodegradable hydraulic oils and lubricants based on
synthetic esters with Komatsu machines is permitted. For infor-
mation on products cleared for use and best suited for your appli-
cation, please contact your Komatsu distributor.
5.2.2 Outlines of the electrical system

 It is extremely dangerous if the electrical equipment becomes
wet or the covering of the wiring is damaged. This will cause
an electrical short circuit and may lead to malfunctions of the
machine. Do not wash the inside of the operator's cab with
water. When washing the machine, be careful not to let any
water enter the electrical components.
 The maintenance of the electrical system involves checking

fan belt tension, checking the fan belt for damage or wear,
and checking the battery fluid level.
 Never install any electric components other than those spec-

ified by Komatsu.
 External electro-magnetic interference may cause a malfunc-

tion of the system controller. Please contact your Komatsu
distributor before installing a radio receiver or other wireless
equipment.
 When working close to the sea, carefully clean the electrical

system to prevent corrosion.
 Never connect an external power source to the fuses, the

starting switch, or the battery relay.
5-14 WA80M-7, WA100M-7 – VENAM03001

5.3 Wear parts list
Maintenance
5.3 Wear parts list

Replace wear parts such as the filter insert or the air cleaner
insert during periodic maintenance, before they reach the wear
limit. Replace wear parts correctly to ensure the efficient use of
the machine. When replacing parts, always use Komatsu genuine
parts.
As a result of our continuous efforts to improve product quality,

part numbers may change. Inform your Komatsu distributor of the
machine serial number and check for the latest part number when
ordering parts.
5.3.1 Wear parts list

The parts in parentheses need to be replaced at the same time.
*: Order numbers for the parts: See the Parts Book (Komatsu).
Item Part no. Part name Quantity Replacement interval
Filter insert 1
Hydraulic oil filter * (O-ring) (1) Initial maintenance after 50 service hours
(O-ring) (1)
Engine oil filter * Cartridge 1 Maintenance every 500 service hours
Cartridge 1
Fuel prefilter * (O-ring) (1) Maintenance every 500 service hours
(O-ring) (1)
Fuel filter * Cartridge 1 Maintenance every 1000 service hours
Filter insert 1 Corrective maintenance

Air cleaner *
Safety filter 1 (about every 1000 service hours)
Filter insert 1
Hydraulic oil filter * (O-ring) (1) Maintenance every 1000 service hours
(O-ring) (1)
Engine: Gasket 1
* Maintenance every 2000 service hours
Valve cover O-ring 3
Cartridge 1
CCV filter * Maintenance every 2000 service hours
O-ring (1)
WA80M-7, WA100M-7 – VENAM03001 5-15

5.4 Fuel, lubricants, and coolants; quantities
Maintenance
5.4.1 Lubrication table
5-16 WA80M-7, WA100M-7 – VENAM03001

Maintenance
Symbol Meaning of the symbol Symbol Meaning of the symbol
Read the Operation and Maintenance

Lubricating
Manual
Changing engine oil Checking engine oil level
Change hydraulic oil Checking hydraulic oil level
Changing gear oil Checking gear oil level
Changing axle oil Checking axle oil
Changing brake oil Checking brake oil level
Changing coolant Checking coolant
Renewing engine oil filter Renewing hydraulic oil filter
Renewing KCCV filter Renewing fuel filter
Draining water from the water separator
The maintenance intervals apply to all Machines WA80M-7 from

serial number H62051.
The maintenance schedule in the Operation and Maintenance

Manual is binding, see “Maintenance schedule (5-25)”.
WA80M-7, WA100M-7 – VENAM03001 5-17

Maintenance
5-18 WA80M-7, WA100M-7 – VENAM03001

Maintenance
Symbol Meaning of the symbol Symbol Meaning of the symbol
Read the Operation and Maintenance

Lubricating
Manual
Changing engine oil Checking engine oil level
Change hydraulic oil Checking hydraulic oil level
Changing gear oil Checking gear oil level
Changing axle oil Checking axle oil
Changing brake oil Checking brake oil level
Changing coolant Checking coolant
Renewing engine oil filter Renewing hydraulic oil filter
Renewing KCCV filter Renewing fuel filter
Draining water from the water separator
The maintenance intervals apply to all Machines WA100M-7 from

serial number H62051.
The maintenance schedule in the Operation and Maintenance

Manual is binding, see “Maintenance schedule (5-25)”.
WA80M-7, WA100M-7 – VENAM03001 5-19

Maintenance
Fuel, lubricants, and coolants; quantities
Temperature Viscosity
Fuel, lubricants, and coolants BI abbreviations Quality classifications
ranges classifications
Engine oil EO EO15W40 LA API CH 4 or 15 °C to 45 °C SAE 15W 40 1)

Engine
(Komatsu genuine parts) EO10W30 LA API CI 4 20 °C to 30 °C SAE 10W 30
AGIP ROTRA MULTI THT API GL4 SAE 80
ESSO TORQUE FLUID 56 API GL4 SAE 80
MOBILFLUID 424 API GL4 SAE 80
Transfer case GO 80 –
MOBILLUBE D LS 80W 90 API GL 5 SAE 80W 90
ESSO TORQUE FLUID 62 API GL4 SAE 10W 30
SHELL SPIRAX S4 TXM API GL4 SAE 10W 30 1)
Front axle GO 80 –
Rear axle GO 80 –
Komatsu
Hydraulic oil HYD – 20 °C to 50 °C ISO VG 46
HO46 HM
Komatsu
Power train oil 20 °C to 50 °C
Hydraulic system, TO10
Steering Engine oil EO EO15W40 DH API CH 4 or 15 °C to 45 °C SAE 15W 40
(Komatsu genuine parts) EO10W30 DH API CI 4 20 °C to 30 °C SAE 10W 30 1)
HEES (acc. to VDMA
or BIO E HYD hydraulic oil BIO E HYD 0530 15 °C to 20 °C ISO VG 46
fluid technology)
Service brake AGIP LHM Super HYD – – –
Cooling system Antifreeze and anti corrosive AF NAC Komatsu Supercoolant 1)

(Note 1)
ASTM no. 2 10 °C to 50 °C
Fuel tank Diesel (EN590) ASTM no. 1 (for DIN EN 590 30 °C to 20 °C –
use in winter)
Grease nipple Multi purpose lithium grease – Lithium EP grease – NLGI 2
R134a (FCKW free)
Refrigerant NRS
Air conditioner PAG (Polyalkylenegly – –
Refrigerator oil NRS
col)
The specified filling quantities are for guidance only; the information on the inspection gauges is binding. Select the viscosity class according
to the long term ambient temperature. The upper and lower temperature limits are guidelines; exceeding for a short time is permissible.
1) Factory filling
Note 1: Supercoolant (AF NAC)
For details see “Coolant (5 12)”.
5 20 WA80M 7, WA100M 7 – VENAM03001

Maintenance
WA80M-7 WA100M-7
Specification Specification
Tank capacity Refill amount Refill amount
(litres) (litres)
Engine oil pan 11.5 11 11.5 11
Transmission 1.3 1.3

Hydraulic system 50 50
Front and rear axles (per axle)
Planetary gear: 2 × 0.7 2 × 1.3
Differential: 8.0 8.0
Brakes 1.2 1.2
Cooling system 14.5 11.5 14.5 11.5

Fuel tank 130 130
Air conditioner 1200g 1200g 1200 g 1200 g
WA80M-7, WA100M-7 – VENAM03001 5-21

Maintenance
5.4.2 Recommended brands, recommended quality for products other

than Komatsu genuine oil
Please contact your Komatsu distributor when using commer-
cially available oils other than Komatsu genuine oil.
5-22 WA80M-7, WA100M-7 – VENAM03001

5.5 Tools
Maintenance
5.5 Tools
5.5.1 List of required tools
No. Tool name Part no. Notes

1. Tool 42W-98-41100 Standard
1. Tool 42W-98-41100
2. Hose 42U-09-H2670
3. Grease pump 424-98-H1010
Extended
4. Hose 424-98-H1020 Grease pump hose
5. Hammer 421-98-H1140
6. Wrench 42T-09-H0450
Re-order damaged parts from your Komatsu distributor.
WA80M-7, WA100M-7 – VENAM03001 5-23

5.6 Periodic replacement of safety-critical parts
Maintenance
5.6 Periodic replacement of safety-critical parts

To ensure safety at all times when operating or driving the
machine, the user of the machine must carry out periodic main-
tenance. In addition, to further improve safety, the parts in the list
of safety-critical parts on the next page must also be replaced at
the specified intervals. These parts are particularly important for
safety and fire prevention. Please contact your Komatsu distribu-
tor to have them replaced.
The material quality of these parts can change as time passes,

and they are likely to wear out or deteriorate. However, it is diffi-
cult to determine the extent of wear or deterioration during peri-
odic maintenance. Hence it is required to replace these parts
regardless of their condition after a certain period of usage. This
is important to ensure that these parts maintain their full perfor-
mance at all times.
Furthermore, should anything abnormal be found on any of these

parts, replace it with a new one even if the replacement interval
for the part has not yet expired.
If any of the hose clamps show deterioration like warping or

cracks, replace the clamps with the hoses.
Also perform the following checks on those hydraulic hoses that

do not need to be replaced periodically. Tighten loose clamps and
replace defective hoses as required.
When replacing the hoses, always replace the o-rings, gaskets,

and similar parts at the same time.
Contact your Komatsu distributor for the replacement of safety-

critical parts.
5-24 WA80M-7, WA100M-7 – VENAM03001

5.7 Maintenance schedule
Maintenance
Maintenance procedure see page

5.8.1 Checks before starting the engine 5-27
5.8.2 Corrective maintenance 5-28
Air conditioner – checking 5-28
Window washer fluid level – checking, adding fluid 5-30
Battery – charging the built-in battery 5-30
Air grille – cleaning 5-31
Radiator fins – cleaning 5-31
Cooling system – cleaning internal area of the cooling system 5-32
Air cleaner – checking, cleaning 5-35
Air cleaner – renewing, renewing safety filter 5-39
5.8.3 Maintenance after the first 50 service hours 5-40
Hydraulic system – change filter insert 5-40
Wheel nuts – checking and retightening 5-40
Rear axle – lubricating 5-41
5.8.4 Maintenance after the first 500 service hours 5-42
Front and rear axle – change oil 5-42
Transfer case – change oil 5-42
5.8.5 Maintenance every 10 service hours 5-43
Articulated steering – lubricating 5-43
Check coolant level – add coolant 5-43
Water separator – draining water and dirt accumulations 5-43
Check engine oil level – add engine oil (WA80M-7) 5-43
Work equipment – lubricating 5-44
Central lubrication system – checking, replenishing grease 5-46
Check engine oil level – add engine oil (WA100M-7) 5-47
Service brake – check the brake pads 5-48
Steering cylinder – lubricating 5-49
Rear axle – lubricating 5-50
Wheel nuts – checking and retightening 5-50
Manual pump – check oil level 5-51
Service brake – check brake pads and brake disc, check oil level 5-52
Engine oil – changing 5-53
Oil filter cartridge – renewing 5-54
WA80M-7, WA100M-7 – VENAM03001 5-25

Maintenance
Maintenance procedure see page
Heating/air conditioner – clean/renew filter cloth, clean condenser 5-55

Pressure accumulator for multi-function lever – checking gas pressure 5-56
E.C.S.S. pressure accumulator – check gas pressure 5-56
Front and rear axle – check oil level 5-57
Transfer case – check oil level, add oil 5-58
Fuel prefilter – changing filter cartridge 5-59
Alternator V-belt – checking 5-60
Service brake – checking, changing brake fluid 5-61
System pressures – check and adjust 5-61
Hydraulic system – renewing filter insert, renewing venting filters 5-62
Fuel filter – change filter cartridge 5-63
Fuel system – bleeding 5-64
Front and rear axle – change oil 5-65
Transfer case – change oil 5-67
Valve clearance – checking and setting 5-68
Water pump – checking 5-68
Alternator and starter – checking 5-68
Fuel pump – checking 5-68
Hydraulic system – change hydraulic oil 5-69
CCV filter – renewing 5-71
Fuel and coolant hoses – checking, replacing/renewing if required 5-73
Water pump – checking 5-73
Checking the clamp of the high-pressure line is firmly seated and checking for embrittlement of the rubber 5-73
Checking for missing fuel spray prevention cap and checking for embrittlement of the rubber 5-74
Clamps of the high-pressure line – renewing 5-75
Fuel spray prevention cap – renewing 5-75
5-26 WA80M-7, WA100M-7 – VENAM03001

5.8 Maintenance procedure
Maintenance Checks before starting the engine
5.8.1 Checks before starting the engine

For the following points see “Checks before starting the engine
(3-52)”.
 Check coolant level – add coolant
 Radiator – clean radiator fins
 V-belt – check condition
 Check engine oil level – add engine oil
 Check the fuel level – add fuel
 Additional water separator (optional)
 Water separator – draining water and dirt accumulations
 Check gauges and indicators
 Check electrical connections
 Heating/air conditioner – check airflow
 Check lights for function, dirt, and damages.
 Check gauges.
 Check horn and back-up warning system.
 Check steering play and function.
 Check rearview mirror for function, dirt, and damages.
WA80M-7, WA100M-7 – VENAM03001 5-27

Corrective maintenance Maintenance
5.8.2 Corrective maintenance
Air conditioner – checking

Inspect the air conditioner at least twice per year, in spring and in
autumn. The filter dryer has to be replaced every 2 years, or each
time work is done on the cooling circuit.
A = Filter dryer
B = Condenser A
Cleaning the condenser of the air conditioner
NOTICE
Do not wash the condenser with a steam cleaner. The condenser
may overheat and fail.
If the cooling performance of the air conditioner is too low, check

whether the condenser is dirty.
Clean a dirty condenser with cold water.
If the water pressure is too high, the fins may warp. Keep a suffi-
cient distance when cleaning with a high-pressure washing
machine.
Checking the refrigerant level (gas)
WARNING
 The refrigerant in the air conditioner may cause blindness or
frostbite if it comes into contact with your eyes or hands. Do
not touch the refrigerant.
 Never loosen any parts of the coolant circuit.
 When working on the air conditioning system, wear protective

goggles and rubber gloves.
5-28 WA80M-7, WA100M-7 – VENAM03001

Maintenance Corrective maintenance
If the cooling effect of the air conditioner is poor, this may be

caused by lack of refrigerant (gas).
In this case, check the sight glass (2) of the filter dryer (1). The
sight glass is installed at the side of the condenser, on the con-
tainer.
Create the following conditions before inspecting:
 Start the engine and let it run at 1000 rpm.
 Turn the air conditioner ON.
 Set the airflow to maximum.
 Set the temperature to minimum.
 Open the doors and windows fully. 2

 Turn the air conditioner switch ON.
If the condition of sight glass (2) is “correct” as shown in the dia- Refrigerant Status at the sight glass
gram on the right, the condition is normal. (When the air condi-
tioner is switched on, you will see a few bubbles. After this, the Correct
liquid takes on a translucent, milky white colour.) Level
If the condition of sight glass (2) is “insufficient” as shown in the

diagram on the right, the refrigerant level is too low. Consult your Insufficient
(When the air conditioner is switched on, there will always be a

few bubbles.)
A = Bubbles in the liquid refrigerant

B = The refrigerant is clear
C = Oil and refrigerant are separated; liquid is a thin, milky
white.
Operating the air conditioner off-season
Even during the off-season, operate the air conditioner for 3 – 5

minutes once a month to maintain the oil film at all parts of the
compressor.
WA80M-7, WA100M-7 – VENAM03001 5-29

Window washer fluid level – checking, adding fluid

 Check the washer fluid level in washer tank (1). If the level is
too low, add ethanol-based window washer fluid.
1
 Be careful not to let dust get into the fluid.
Battery – charging the built-in battery

For safety instructions see “Battery (2-30)”.
WARNING
 Danger of injury! Battery contains highly corrosive battery
acid!
 Wear safety goggles and rubber gloves when working on the

battery. Immediately wash battery acid from your skin and
eyes with large amounts of water and consult a doctor.
 Gases that form in the battery may explode.
 Do not bring open fire or sparks near the battery. Do not

smoke.
Before charging, switch off the main battery switch to interrupt the
power supply. Otherwise the alternator may be damaged by peak
voltages.
 Interrupt the charging process if the temperature of the bat-

tery fluid exceeds 45 °C.
 Turn off the charger as soon as the battery is completely

charged. Overcharging the battery may result in the following
conditions:
 Battery overheats
 Low battery fluid level
 Damage to the electrode plates
 Do not swap the wires (positive (+) and negative (-)).
Disconnect the cables from the terminals during maintenance

work on the battery.
5-30 WA80M-7, WA100M-7 – VENAM03001

Air grille – cleaning

 Clean the air grilles from both sides if they are dirty.
NOTICE
Do not use a high-pressure cleaner to clean the air grilles.
Radiator fins – cleaning

Clean the radiator fins when they are dirty.
For details see “Radiator – clean radiator fins (3-53)”
WA80M-7, WA100M-7 – VENAM03001 5-31

Cooling system – cleaning internal area of the cooling system
WARNING
 Danger of scalding! The coolant is pressurised while the
engine is hot. Hot coolant may spurt out when the cooling sys-
tem is opened.
 Wait until the engine has cooled down before checking the
coolant level. Slowly unscrew the cap (arrow) to let the pres-
sure escape.
Clean the inside of the cooling system and change the coolant
according to the table below.
Interval for cleaning the inside of the cooling system

Coolant/antifreeze
and changing the coolant
Komatsu Supercoolant Every two years or every 4000 service hours,

(AF-NAC) whichever is earlier.
Park the machine on solid, level ground before cleaning the cool-
ing system or changing the coolant.
The important task of the coolant is to prevent corrosion and offer

frost protection.
It is essential to use antifreeze even in areas where there is no

risk of frost.
Komatsu machines are supplied with amine-free engine coolant

(AF-NAC). The amine-free engine coolant (AF-NAC) has excel-
lent anti-corrosion, antifreeze and cooling properties, and can be
used continuously for two years or 4000 hours.
Komatsu recommends using a amine-free engine coolant (AF-

NAC). If you use a different coolant, this can lead to serious prob-
lems such as corrosion in the engine and aluminium parts of the
cooling system.
In order to maintain the anti-corrosion properties of the amine-

free engine coolant (AF-NAC), keep the density of the amine-free
engine coolant between 30% and 64% at all times.
The amine-free engine coolant (AF-NAC) is already diluted with

distilled water. With regard to using the coolant, check what was
the lowest temperature recorded in the past and then decide
according to the mixing table below which coolant density is
required.
When you are deciding on the density of the coolant, determine

it for a temperature of 10 °C below the actual temperature.
The coolant density changes depending on the ambient temper-

ature, but it must always be at least 30%.
5-32 WA80M-7, WA100M-7 – VENAM03001

Coolant density table
Minimum ambient
°C Above -10 -15 -20 -25 -30 -35 -40 -45 -50
temperature
Density (%) 30 36 41 46 50 54 58 61 64
WARNING
 Coolant is toxic. When you open the drain valve, make sure
you do not get any coolant on your body. If it gets into your
eyes, rinse your eyes with a large volume of fresh water and
seek medical assistance immediately.
 Please contact your Komatsu distributor when you are chang-

ing the coolant or processing the cooling water containing
coolant which has been drained in the course of repairing the
radiator; alternatively, have this work done by a specialist
company. Coolant is toxic. Do not let it flow away in drainage
channels, and do not sprinkle it on the ground either.
The amine-free engine coolant (AF-NAC) is already diluted with

distilled water, which makes it nonflammable.
Check the density using a coolant tester.
Place a container ready to collect the drained coolant; the volume

of the container should be larger than the specified volume of
coolant.
Prepare a hose for filling the coolant with.
WA80M-7, WA100M-7 – VENAM03001 5-33

Draining the coolant
1. Switch off the engine and let it cool down.
2. Slowly turn the radiator cap (arrow) to the first stop and let the
pressure escape. Then push the cap down and continue turn-
ing until it can be removed.
3. Install a hose to the outlet (1) of the drain valve and route the
end of the hose to the drain tray.
4. Open the drain valve and drain the coolant.
5. Close the drain valve.
Cleaning the cooling system
NOTICE
Fill the cooling system slowly. Otherwise the enclosed air may not
be able to escape fully. After filling, wait for three more minutes
and top off fluid if required.
1. Slowly fill the cooling system with tap water.
2. Once the radiator has been filled with water, start the engine. 1
3. Press the accelerator pedal down slightly and allow the
engine to run at moderate engine revs for about 5 minutes,
without load.
4. After cleaning, switch off the engine and open the drain valve
(1) to drain the cooling system completely.
If the drained water is not clean yet, flush the cooling system
again until the draining water is clean.
5. Close the drain valve (1) again and slowly fill the cooling sys-
tem with clean, amine-free coolant.
5-34 WA80M-7, WA100M-7 – VENAM03001

Filling coolant
1. Drain and clean the expansion tank.
2. Mix coolant as specified.
3. Slowly fill the cooling system with coolant up to the spillover.
NOTICE
Do not fill the cooling system faster than 8 l/min.
4. To bleed the cooling system, remove the radiator cap and let
the engine run at low idle for five minutes, then for another
five minutes at high idle. If the coolant level in the radiator
drops, add coolant.
5. Switch off the engine, wait for about three minutes and add
coolant up to the spillover of the radiator. Close the radiator.
6. Drain coolant from the coolant expansion tank, clean the

inside of the coolant expansion tank and fill it with amine-free
coolant until the midpoint between FULL and LOW.
Air cleaner – checking, cleaning
WARNING
When using compressed air, there is a danger of flying dirt caus-
ing injuries. Always wear protective equipment such as protective
goggles and a dust mask.
NOTICE
 Dirt can get into the engine if inspection, cleaning or mainte-
nance work is carried out with the engine running; this can
cause damage to the engine. Make sure to stop the engine
before you carry out such interventions.
 If the air cleaner is not sufficiently clean, the air cleaner cau-
tion lamp (1) on the main screen will indicate a malfunction.
The engine power will decrease.
Design of the air cleaner
The air cleaner is made up of the air cleaner housing, the dust
eject valve, the filter insert, and the safety filter.
WA80M-7, WA100M-7 – VENAM03001 5-35

Required maintenance
1
NOTICE
Do not clean the air cleaner element before the air cleaner cau-
tion lamp (1) on the main screen lights up.
If the air cleaner caution lamp (1) lights up, the air cleaner insert
is clogged. Clean or replace it immediately.
Dirt in the safety filter indicates a damaged filter insert. In this

case, the filter insert and the safety filter need to be replaced. G0010011C
Removing the filter insert
WARNING
While the engine is running, moving parts in the engine compart-
ment may cause severe injuries. Do not work in the engine com-
partment while the engine is running.
1. For maintenance work, park and secure the machine as

described in chapter “Maintenance guide (5-2)”.
2. Open the bayonet lock of the air cleaner cap (2).
3. Remove the cover of the air cleaner housing.
4. Pull out the filter insert (3). 2

5. Thoroughly clean the inside of the air cleaner housing with a
cloth. Do not use compressed air!
5-36 WA80M-7, WA100M-7 – VENAM03001

Cleaning the filter insert
Depending on the degree of clogging, the filter insert of the air

cleaner may be cleaned with compressed air.
NOTICE
 If the air cleaner pilot lamp lights up again a short time after
cleaning, replace the filter insert.
 Do not clean the safety filter.
 For details see “Air cleaner – renewing, renewing safety filter

(5-39)”.
Cleaning with pressurised air
ATTENTION
 Flying dust particles may cause injury to the eyes. Wear
safety goggles when cleaning the filter inserts with pressur-
ised air.
 Hazardous dusts may cause lung irritation.
 Wear a dust mask when cleaning filter inserts with pressur-

ised air.
Blow out the air cleaner insert with dry pressurised air (max. 2
bar) from the inside to the outside. Move the air jet up and down
at minimum distance of 3 cm to the paper. The cleaning process
ends when no more dust is ejected.
Do not knock the insert for cleaning, and do not knock the insert
against other objects.
NOTICE
If dirt adheres to the seal (A) of the main filter, clean it to prevent
dirt getting in.
G0010047
WA80M-7, WA100M-7 – VENAM03001 5-37

1. Renew the main filter after it has been cleaned six times.
Renew the safety filter at the same time.
2. Renew the main filter and the safety filter if the air cleaner
caution lamp lights up again shortly after cleaning, even if the
filter has not yet been cleaned six times.
3. Remove a number each time the main filter is cleaned.
Checking the filter insert
Always check the filter insert before installing.
Check filter inserts for damaged seals.
NOTICE
Also check any new filter inserts before installing.
Installing the filter insert
1. Check the safety filter for firm seat.
2. Insert the filter insert into the housing so that the seal of the
insert rests firmly on the binding at the rear of the housing.
3. Install the air cleaner cap.
NOTICE
If the air cleaner caution lamp lights up again after a short time,
replace both the filter insert and the safety filter.
For details see “Air cleaner – renewing, renewing safety filter

(5-39)”
5-38 WA80M-7, WA100M-7 – VENAM03001

Air cleaner – renewing, renewing safety filter

Changing the filter insert
NOTICE
Renew the safety filter after the filter insert has been renewed six
times.
1. Open the air cleaner housing, remove the filter insert (1).
For details see “Air cleaner – checking, cleaning (5-35)”. 1
2. Install the filter insert.
Changing the safety filter
NOTICE
Do not clean the safety filter. Renew it after the filter insert has
been renewed six times. Keep the working area clean. Do not
allow any dirt to get behind the safety filter.
1. Open the air cleaner housing, remove the filter insert (1).
For details see “Air cleaner – checking, cleaning (5-35)”.
2. Clean the inside of the air cleaner housing.
3. Pull out the safety filter (2) and replace it with a new element.
4. Install the filter insert.

1
5. Replace the sticker with a new one.
WA80M-7, WA100M-7 – VENAM03001 5-39

Maintenance after the first 50 service hours Maintenance
5.8.3 Maintenance after the first 50 service hours

Carry out the following maintenance only after the first 50 service
hours.
Hydraulic system – change filter insert

For details see “Hydraulic system – renewing filter insert, renew-
ing venting filters (5-62)”.
Wheel nuts – checking and retightening
WARNING
Loose wheel nuts may cause severe accidents.
Periodically check and retighten the wheel nuts.
Loose wheel nuts (1) increase tyre wear and may cause acci-
dents.
1. Check for loose nuts, and tighten if necessary.
When checking for loose nuts, always turn the nuts in the
direction of tightening.
Torque: 450–500 Nm 1
2. If any stud bolt is broken, replace all the stud bolts for that
wheel.
5-40 WA80M-7, WA100M-7 – VENAM03001

Maintenance Maintenance after the first 50 service hours
Rear axle – lubricating
NOTICE
Shorten the maintenance intervals if working continuously in wet
or salty environments.
DANGER
 Performing maintenance on a machine that is not properly
parked and secured may cause severe accidents!
 Park the machine on solid, level ground. Secure the machine

before beginning maintenance work.
1. For maintenance work, park the machine as described in

chapter “Maintenance guide (5-2)”. 1
2. Clean the indicated grease nipple.
3. Use a grease pump to press a sufficient amount of grease into

the grease nipples.
4. Remove any excess old grease that is pushed out at the bear-
ings. 2
Rear axle pivot bearing (1) (2).
WA80M-7, WA100M-7 – VENAM03001 5-41

Maintenance after the first 500 service hours Maintenance
5.8.4 Maintenance after the first 500 service hours

Carry out the following maintenance only after the first 500 ser-
vice hours.
Front and rear axle – change oil

For details see “Front and rear axle – change oil (5-65)”.
Transfer case – change oil

For details see “Transfer case – change oil (5-67)”.
5-42 WA80M-7, WA100M-7 – VENAM03001

Maintenance Maintenance every 10 service hours
5.8.5 Maintenance every 10 service hours
Articulated steering – lubricating
DANGER


chapter “Maintenance guide (5-2)”.
2. Clean the grease nipples indicated by the arrows.
Articulated steering (2 points)

the grease nipples.
ings.
NOTICE
Check coolant level – add coolant

For details see “Check coolant level – add coolant” (3-52).
Water separator – draining water and dirt accumulations

For details see “Water separator – draining water and dirt accu-
mulations” (3-58).
Check engine oil level – add engine oil (WA80M-7)

For details see “Check engine oil level – add engine oil” (3-55).
WA80M-7, WA100M-7 – VENAM03001 5-43

Maintenance every 50 service hours Maintenance

Also perform all maintenance tasks scheduled to be carried out
every 10 service hours.
Work equipment – lubricating
DANGER


chapter “Maintenance guide (5-2)”.
2. Clean the indicated grease nipples.

the grease nipples.
ings.
(1) Tilt rod (2 points)
(2) Multi-purpose bucket (6 points)
(3) Upper and lower lift cylinders (4 points)
(4) Tilt arm (2 points)
(5) Left and right boom (4 points)

(6) Tilt cylinder (2 points)
5-44 WA80M-7, WA100M-7 – VENAM03001

1
G0070248
G0070247C
WA80M-7, WA100M-7 – VENAM03001 5-45

Central lubrication system – checking, replenishing grease

The following maintenance work is to be carried out as required
or every 50 service hours:
 General function check
The basic function of the pilot device and the system compo-
nents can be checked by activating intermediate lubrication.
 Regular check of the system components for leakage and

damage.
 Visual inspection of the state of lubrication of the bearings and

observation of the lubrication pattern.
In the event of fault indications, consult your Komatsu distributor

to rectify the fault.
NOTICE
Only refill using clean lubricant and a suitable filling device (A or
B). Contaminated lubricant can lead to serious system malfunc- 1, 2
tions.
A
Permitted lubricants
B
Grease of NLGI class 2 with EP additives, compatible with plas- 1 M20X1,5
tics, NBR elastomers, copper and copper alloys and a max. flow
pressure of 700 mbar.
Temperature range of grease Viscosity classes 2 3

-20 °C to 120 °C G2 LI
-40 °C to 100 °C GLT2 LI
Fill the lubricant container to above the “MIN” marking but no

higher than the “MAX” marking.
When using the factory setting, it is sufficient to fill up for a mini-

mum of 50 hours.
If the lubrication times have been changed or several intermedi-

ate lubrications have been carried out, the level check must be
brought forward.
Depending on the design, lubricant can only be added via:

1 2 3
1. Cone-shaped grease nipple
2. Filling attachment
3. Filling cylinder
The connecting pieces must be free from dirt.
The transparent lubricant container allows you to carry out a vis-

ual level check.
If the container has been emptied to below the “MIN” mark, the
entire system must be bled. Consult your Komatsu distributor to
have the system bled.
5-46 WA80M-7, WA100M-7 – VENAM03001

Check engine oil level – add engine oil (WA100M-7)

For details see “Check engine oil level – add engine oil” (3-55).
WA80M-7, WA100M-7 – VENAM03001 5-47


every 10 and every 50 service hours.
Service brake – check the brake pads
WARNING
Danger of accidents! If the brake oil level is too low, the service
brake might fail.
ATTENTION
 Danger of accidents! Using commercially available brake fluid
may reduce the performance of the brake system.
 Only fill with the specified oil. Do not use brake fluid! Keep
extremely clean!

2. Check brake disc and brake pads for wear and damages.
3. Check the brake oil level.
5-48 WA80M-7, WA100M-7 – VENAM03001

Steering cylinder – lubricating
NOTICE
DANGER


chapter 5.1 “Maintenance guide” (5-2). 1

the grease nipples.
ings. 2
(1) Front left steering cylinder (1 point)
(2) Rear left steering cylinder (1 point)
3) Rear right steering cylinder (1 point)
(4) Front right steering cylinder (1 point)
WA80M-7, WA100M-7 – VENAM03001 5-49

Rear axle – lubricating
NOTICE
DANGER


chapter “Maintenance guide (5-2)”. 1

the grease nipples.
ings. 2
Rear axle pivot bearing (1) (2).
Wheel nuts – checking and retightening

For details see “Wheel nuts – checking and retightening (5-40)”.
5-50 WA80M-7, WA100M-7 – VENAM03001


every 10, 50, 100, and 250 service hours.
Manual pump – check oil level

1. The oil level in the hand pump is checked with the cab tipped
down. 1
2. Remove the screw plug (1).
3. The oil level should be at the lower edge of the filling hole
(arrow).
4. Add oil if required.
For details see “Fuel, lubricants, and coolants; quantities

(5-16)”.
5. Insert the screw plug into the filling hole and fasten finger-
tight.
G0070267
WA80M-7, WA100M-7 – VENAM03001 5-51

Service brake – check brake pads and brake disc, check oil level
WARNING
Danger of accidents! If the oil level is too low, the service brake
might fail.
ATTENTION
extremely clean!

Komatsu workshop.

2. Check the brake fluid level at the expansion tank. The oil level
should be between the “MIN” and “MAX” marks.
3. If the oil level is too low, have the brake system inspected.
4. Check brake disc and brake pads for wear and damages.
5-52 WA80M-7, WA100M-7 – VENAM03001

Engine oil – changing
WARNING
 As soon as the engine has stopped, its parts and oil are still
very hot and can cause injuries through burning. Wait until
they have cooled down before starting work.
 Wear rubber gloves and hold the oil drain tray underneath the
drain in a way that prevents the oil from making contact with
your body.
ATTENTION

G0010083
NOTICE
Change the oil only with the engine off and at operating temper-
ature.

described in section “Maintenance guide (5-2)”.
2. Place the tray underneath the drain screw (arrow).
4. Screw a drain hose (2) onto the drain valve. This opens the 1
drain valve.
5. Drain the oil.
6. Inspect the drained oil: If the oil is contaminated with metal

shavings or foreign particles, notify your Komatsu distributor.
Unscrew the drain hose (2) from the drain valve. This closes
the drain valve.
7. Reinstall the cap (1) on the drain valve.
WA80M-7, WA100M-7 – VENAM03001 5-53

Oil filter cartridge – renewing

1. Unscrew the cover (1).
2. Use the filter wrench to unscrew the filter cartridge (2) anti-
clockwise.
3. Clean the filter holder. Apply a thin layer of engine oil to the 1
seal and the threads of the new filter cartridge. Screw on the
filter cartridge.
4. When installing, the sealing surface of the filter cartridge must

contact the filter holder lightly. Then tighten the filter cartridge
as specified by the filter manufacturer.
5. After renewing the filter cartridge, fill clean engine oil through
the oil filler neck (3) until the oil level reaches the (H) mark on
the dipstick (4).
For details see “Fuel, lubricants, and coolants; quantities 1

(5-16)”.
6. Close the oil filler neck.
7. Let the engine run at idle for approx. five minutes and check
for engine oil leakage.

WA80M-7
9. Screw on the cover (1)
10. Re-check the oil level approx. ten minutes after switching off
the engine. The oil level must be between the 'H' and 'L'
marks on the dipstick.
3 4
For details see “Check engine oil level – add engine oil
(3-55)”.
WA100M-7
3 4
5-54 WA80M-7, WA100M-7 – VENAM03001

Heating/air conditioner – clean/renew filter cloth, clean condenser
Cleaning the filter cloth in the heater/air conditioner
NOTICE
Replace the filter cloth if it is excessively dirty.
1. Unscrew the front panel (1) of the cab (4 screws).
2. Remove the filter cloth (2) from the heater (3).
3. Clean the filter cloth in warm water (30–40 °C) added with a
mild detergent.
Caution: Do not rub or wring the filter cloth.
4. Dry the filter cloth.
5. Insert the dry filter cloth (2) into the heater (3).
6. Turn on the blower and check the airflow at the nozzles to the
left and to the right of the steering column. a a
NOTICE
All air outlet nozzles (a) must be open!
a a
7. Replace the filter cloth if the airflow is low.
8. Reinstall the front panel (1).
a a
G0010035
WA80M-7, WA100M-7 – VENAM03001 5-55

Cleaning the condenser of the air conditioner
NOTICE
Do not wash the condenser with a steam cleaner. The condenser
may overheat and fail.
If the cooling performance of the air conditioner is too low, check

whether the condenser is dirty.
Clean a dirty condenser with cold water.
If the water pressure is too high, the fins may warp. Keep a suffi-
cient distance when cleaning with a high-pressure washing
machine.
Pressure accumulator for multi-function lever – checking gas pressure

Have the gas pressure in the pressure accumulator checked by
your Komatsu distributor every 500 service hours as part of the
maintenance procedures (gas pressure: 20 bar).
E.C.S.S. pressure accumulator – check gas pressure

(Option)
Have the gas pressure in the pressure accumulator checked by

your Komatsu distributor every 500 service hours as part of the
maintenance procedures (gas pressure: 20 bar).
5-56 WA80M-7, WA100M-7 – VENAM03001

Front and rear axle – check oil level
DANGER

For maintenance work, park and secure the machine as

Epicyclic gearing
1. Start the engine, raise the work equipment, and move the
machine until the oil level mark of the epicyclic gearing on the
wheel to be checked is horizontal.
Switch off the engine, lower the work equipment, and apply
the parking brake.
2. Remove the screw plug (1) from the check bore.
3. Check the oil level. The oil level should be at the lower edge
of the check bore.
2
4. If the oil level is too low, add oil through the check bore of the
screw plug.
For more information on recommended oils, see chapter

“Fuel, lubricants, and coolants; quantities (5-16)”.
5. Insert the screw plug and tighten firmly.
6. Torque (1) = 60 Nm
7. Check the oil level at the other wheels on the front and rear
axles as described in items 1. to 5. above.
Differential
1. Remove the screw plug (2) of the check bore at the front axle. 3
Check the oil level as described under “epicyclic gearing” in
items 3. to 5.
2. Remove the screw plug (3) of the check bore at the rear axle.
Check the oil level as described under “epicyclic gearing” in
items 3. to 5.
Torque (2) and (3) = 60 Nm
WA80M-7, WA100M-7 – VENAM03001 5-57

Transfer case – check oil level, add oil
NOTICE
When the engine is off, the oil level in the transmission may rise
considerably. Therefore, check the transmission oil level only with
the engine at idle and the transmission at operating temperature.
The direction selector switch must be in the neutral position, 'N'.
DANGER


1
2. Clean the screw plug (1) and the surrounding area.
3. Remove the screw plug.
4. Check the oil level. The oil level should be at the lower edge
of the screw plug check bore.
5. If the oil level is too low, add oil through the check bore of the
screw plug (1).
6. Clean the screw plug and install new sealing ring.
Torque (1) = 60 Nm
5-58 WA80M-7, WA100M-7 – VENAM03001

Fuel prefilter – changing filter cartridge
DANGER
 Danger of fire! Fuel may ignite when making contact with hot
surfaces!
 Wait until the engine has cooled down before you exchange
the filter cartridge. Keep open flames and sparks away from
fuel. Do not smoke.

WA80M-7
described in chapter “Maintenance guide (5-2)”. 5
2. Clean the area around the fuel filters (1).
3. Unplug the connector (2) of the sensor (3).
4. Use the filter wrench to unscrew the fuel filter (1) anticlock- 1
wise.
5. Unscrew the sensor (3) and the drain valve (7) with o-rings
(4) and (6) from the fuel filter.
6. Screw the sensor (3) and the drain valve (7) with new o-rings
(4) and (6) to the new fuel filter. WA100M-7 5
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

cartridge.
1
10. When reinstalling the filter cartridge, screw it in by hand until
the seal makes contact. Then tighten the filter cartridge by
hand (observe the instructions of the filter manufacturer).
11. Reconnect the connector (2) of the sensor (3).
12. Bleed the fuel system.

5
For details see “Fuel system – bleeding (5-64)”.
13. Start the engine and check for leakage.

1
6
4
7
3
2
G0070282
WA80M-7, WA100M-7 – VENAM03001 5-59


every 10, 50, 100, 250, and 500 service hours.
Alternator V-belt – checking
DANGER
 Danger of injury! While the engine is running, moving parts in

the engine compartment may cause severe injuries. Do not
work in the engine compartment while the engine is running.
An automatic tensioning device is installed, so there is no need

to set the tension.

The alternator drive belt will have to be renewed if it reveals any

of the following conditions. In such a case, contact your Komatsu
distributor and ask for it to be renewed.
 If a vertical crack (2) is apparent which intersects with a hori-

zontal crack (1).
 If a part of the belt is broken (3).
There is no need for a renewal if only a horizontal crack (4) is

detected.
5-60 WA80M-7, WA100M-7 – VENAM03001

Service brake – checking, changing brake fluid
WARNING
Danger of accidents! If the oil level is too low, the service brake
might fail.
ATTENTION
extremely clean!

Komatsu workshop.

 Change brake oil.
 Check hoses and lines.
 Check brake disc and brake pads for wear and damages.
 Readjust the parking brake.
System pressures – check and adjust

Have the system pressures measured and adjusted in a Komatsu
workshop.
WA80M-7, WA100M-7 – VENAM03001 5-61

Hydraulic system – renewing filter insert, renewing venting filters
WARNING
 Repeated skin contact with used hydraulic oil can cause skin
damage and other bodily harm!
 Wear rubber gloves when changing the filter. Carefully wash

off hydraulic oil that has come into contact with the skin.
 Use only the prescribed supporting prop to support the work

unit. Never use other objects as supports.
1. Park the machine on level, solid ground.

2 1
2. Raise the boom and tilt the bucket.
WARNING
Danger of injury caused by boom! It is only permitted to step into
the area below the boom if the boom is supported.
4. Position the supporting prop underneath the boom.
5. With the engine switched off, lower the boom slowly until it
rests safely on the supporting prop.
G0010042
6. Clean the filter cap (2) and the surrounding area.
7. Remove the filter cap.

4
8. Pull out the filter insert (3) at the handle (4).
3
9. Pull the filter insert off its handle and discard it.
10. Clean the inside of the filter. Check for foreign materials
before cleaning.
11. Attach the handle to a new filter insert.
12. Insert the new filter element into the housing.
13. Screw on the filter cap and tighten to 20 Nm.
14. Clean the venting filters (1) and the surrounding area.
15. Screw in new venting filters (1) with O-ring, tighten by hand.
17. Actuate the boom and bucket several times.
18. Check the hydraulic oil level.
19. Do a trial run to check that the system is leak-free.
5-62 WA80M-7, WA100M-7 – VENAM03001

Fuel filter – change filter cartridge
DANGER
 Danger of fire! Fuel may ignite when making contact with hot
surfaces!
 Wait until the engine has cooled down before you exchange
the filter cartridge. Keep open flames and sparks away from
fuel. Do not smoke.

WA80M-7
described in chapter “Maintenance guide (5-2)”. 5
2. Clean the area around the fuel filters (1).
3. Unplug the connector (2) of the sensor (3).
4. Use the filter wrench to unscrew the two fuel filters (1) anti-
clockwise.
5. Unscrew the sensor (3) and the drain valve (7) with o-rings 1
(4) and (6) from the fuel filter.
6. Screw the sensor (3) and the drain valve (7) with new o-rings
(4) and (6) to the new fuel filter. WA100M-7 5
7. Clean the two filter heads (5).
8. Fill the two new filter cartridges (1) with clean fuel.
9. Apply a thin layer of oil to the sealing surfaces of the filter car-
tridge.
1
10. When reinstalling the filter cartridge, screw it in by hand until
the seal makes contact. Then tighten the filter cartridge by
hand (observe the instructions of the filter manufacturer).
11. Reconnect the connector (2) of the sensor (3).
12. Bleed the fuel system.

5
For details see “Fuel system – bleeding (5-64)”.
13. Start the engine and check for leakage.

1
6
4
7
3
2
G0070282
WA80M-7, WA100M-7 – VENAM03001 5-63

Fuel system – bleeding
DANGER
The fuel in the injection system is pressurised! Ejected fuel may
puncture the skin and cause blood poisoning. Wear safety gog-
gles and rubber gloves when working on the injection pump. In
the event of being hit by a high-pressure fuel jet, immediately con-
sult a doctor.

1. Loosen the bleed screw (1) on the fuel filter.

WA80M-7
2
2. Operate the pump button (2) on the fuel filter until there are
no more bubbles in the fuel flowing from the bleed screw.
3. Retighten the bleed screw (1).
WA100M-7 1
5-64 WA80M-7, WA100M-7 – VENAM03001


every 10, 50, 100, 250, 500, and 1000 service hours.
Front and rear axle – change oil
WARNING

DANGER

Epicyclic gearing
1. Start the engine, raise the work equipment, and move the
machine until the screw plug (1) of the epicyclic gearing on
the wheel to be checked is at the lowest point. Switch off the
engine, lower the work equipment, and apply the parking
brake.
2. Place a drain tray underneath the screw plug (1).
3. Remove the screw plug (1) and drain the oil.
4. Move the machine until the plug bore (1) of the epicyclic gear-
ing is horizontal.
5. Fill the epicyclic gearing with oil until the oil level reaches the
lower edge of the plug bore (1).
For more information on recommended oils, see chapter

“Fuel, lubricants, and coolants; quantities (5-16)”.
6. Clean the screw plug and install an intact seal.
Torque (1) = 60 Nm
8. Change the oil on the other wheels at the front and rear axle
as described in items 1. to 7.
WA80M-7, WA100M-7 – VENAM03001 5-65

Differential
1. Place a drain tray underneath the oil drain openings (2).
2. Remove the three screw plugs of the drain holes (2) and the
two screw plugs of the filling and check bores (1). Drain the
oil.
3. Clean the screw plugs and install an intact seal.
4. Insert the screw plugs (2) and tighten firmly.

1
5. Fill in oil through the filling and check bore (1) until the oil 2
reaches the lower edge.
6. Insert the screw plugs (1) and tighten firmly.
7. Perform this task at the front and the rear axles.
5-66 WA80M-7, WA100M-7 – VENAM03001

Transfer case – change oil
WARNING

DANGER

Provide a sufficiently large drain tray.
1. For maintenance work, park and secure the machine as 1

2. Remove screw plugs (1) and (2).

2
3. Drain the oil.
4. Clean the screw plugs and install new sealing rings.
5. Insert the screw plug (2) and tighten firmly.
6. Fill in oil through the check bore (1) until the oil has reached
the lower edge of the check bore.
7. Insert the screw plug (1) and tighten firmly.
WA80M-7, WA100M-7 – VENAM03001 5-67


every 10, 50, 100, 250, 500, and 1000 service hours.
Valve clearance – checking and setting

Have the valve clearance checked and adjusted by a Komatsu
distributor.
Water pump – checking

Check the water pump to see if water is coming out of it, and if
you discover anything unusual contact your Komatsu workshop
in order to have repairs or a replacement carried out.
Alternator and starter – checking

Have the alternator and the starter motor checked and adjusted
in a Komatsu workshop.
Fuel pump – checking

Have the fuel pump checked in a Komatsu workshop.
5-68 WA80M-7, WA100M-7 – VENAM03001

Hydraulic system – change hydraulic oil
WARNING
Wear rubber gloves when changing the filter. Carefully wash
 Danger of scalding! The hydraulic reservoir is pressurised.

Hot hydraulic oil may spurt out and cause scalding.
Wear rubber gloves and hold the oil drain tray underneath the
drain in a way that prevents the oil from making contact with
your body.
Provide a sufficiently large drain tray.
1. Park the machine on level ground.
4. Secure the articulated steering on the right side with the

steering lock.
5. Place the oil drain tray underneath the drain screw.
7. Screw a drain hose (2) onto the drain valve. This opens the
drain valve.
8. Drain the oil.
9. Once the oil has drained out, unscrew the drain hose (2) and
screw on the cap (1). 1
WA80M-7, WA100M-7 – VENAM03001 5-69

10. Fill oil through the opening of the venting filters (3) until the oil
level is between the centre and top edge of the sight glass (4).
3
12. Repeatedly raise and lower the work equipment while tilting
and dumping the bucket.
13. Lower the bucket to the ground and set it to the scraping posi-
tion.
14. Check the oil level while the engine is running at low idle.
NOTICE 4
Do not overfill with hydraulic oil! The pressure in the hydraulic oil
reservoir could become excessively high and cause leakage.
G0010042
5-70 WA80M-7, WA100M-7 – VENAM03001

CCV filter – renewing
WARNING
After the engine has been running, all parts will be very hot; as a
result, do not renew the filter element immediately. Wait until all
parts have cooled down. Always stop the engine before you start
work.
NOTICE
 If the engine is operated without a filter element, the turbo-
charger and aftercooler will be contaminated, their power will
be reduced, and this can lead to engine problems such as a
spillover due to sucking in oil. Consequently, do not start the
engine without the filter element.
 The filter element cannot be cleaned. If the filter element is

cleaned or serviced, the filter capacity will be reduced. As a
result, the turbocharger and the aftercooler will be contami-
nated and the crankcase pressure will increase. Never reuse
the filter element, doing so can lead to an engine failure.
 After the filter element has been renewed, oil or blow-by gas
can come out if the KCCV is not installed correctly. Use the
correct process for renewing the filter element.
Prepare the special spanner for the KCCV and a container to col-
lect the oil.
The KCCV is located in the positions shown in the illustration on

the right. 2
1
1. Unfasten the piping clamp (1) and pull off the hose (2).
2. Use the special spanner to unscrew the cap (3) of the KCCV
fan (4).
3
G0010050
WA80M-7, WA100M-7 – VENAM03001 5-71

3. After the cap (3), remove the filter element (5) from the hous-
ing (4).
3
Oil can collect in the container (4) and in the filter element (5),
or stick to it. If you renew the filter element (5), make sure that
the oil does not spray out.
5
REMARK
If the ambient temperature is low, water or emulsion can stick to
the inside of the KCCV as a result of water vapour in the blow-by 4
G0010051
gas condensing. However, this is not a problem as long as the
coolant level is normal.
4. Coat both O-rings (6) with engine oil and attach them to the
6
top and bottom of the new filter element. You can install the
filter element with either side up or down.
G0010052
5. Replace the O-ring (7) with a new one. Coat it with engine oil
and fit the cap (3).
7
3
6. Tighten the cap (3) by hand or using the filter wrench as far
as the stop.
G0010053
7. Install the hose (2) so the hose (3) is at a 45° angle and
tighten the piping clamp (1). 2 3
Torque (1) = 3.0–3.5 Nm
8. Check the KCCV hoses for leaks, damage and loose piping 1
clamps, and replace them if necessary.
5-72 WA80M-7, WA100M-7 – VENAM03001


every 10, 50, 100, 250, 500, 1000, and 2000 service hours.
Fuel and coolant hoses – checking, replacing/renewing if required

Have the fuel and coolant hoses checked and replaced, if
required, at a Komatsu workshop.
Water pump – checking

Have the water pump checked in a Komatsu workshop
Checking the clamp of the high-pressure line is firmly seated and checking for
embrittlement of the rubber
Perform a visual and manual check to ensure that the rubber
between the feed pump and common rail has not undergone
embrittlement at the holding clamps of the high-pressure line, and
that the screws (2 positions) are not loose. Renew the parts in
question if there are any problems. In such a case, contact your
Komatsu workshop and ask for it to be renewed.
WA80M-7, WA100M-7 – VENAM03001 5-73

Checking for missing fuel spray prevention cap and checking for embrittlement of the
rubber
The fuel spray prevention cap (10 positions) on the fuel injection
lines as well as at both ends of the high-pressure lines prevent
any fuel which emerges or sprays out from coming into contact
with hot parts of the engine and causing a fire. Perform a visual
and manual check to ensure that no caps are missing, no screws
have come loose and the rubber has not undergone embrittle-
ment. Renew the parts in question if there are any problems. In
such a case, contact your Komatsu workshop and ask for it to be
renewed.
5-74 WA80M-7, WA100M-7 – VENAM03001


every 10, 50, 100, 250, 500, 1000, and 2000 service hours.
Clamps of the high-pressure line – renewing

Please contact your Komatsu workshop to have the piping
clamps of the high-pressure line renewed.
Fuel spray prevention cap – renewing

Please contact your Komatsu workshop to have the fuel spray
prevention cap renewed.
WA80M-7, WA100M-7 – VENAM03001 5-75

5-76 WA80M-7, WA100M-7 – VENAM03001

Technical data
6. Technical data
WA80M-7, WA100M-7 – VENAM03001 6-1

6.1 Technical data Technical data
6.1 Technical data
6.1.1 WA80M-7
Power
Type Komatsu SAA4D95LE-6

Engine power 52 kW (ISO 14396)
Torque, max. 266 Nm
Engine
Starter motor 12 V – 2.2 kW
Alternator 12 V – 120 A
Battery 100 Ah
1nd speed range 0–5 km/h
Driving speed forward and reverse: Standard
version
1st speed range 0–7.5 km/h
Driving speed forward and reverse: 30 km/h
20 km/h 4197 daN
Max tractive force
30 km/h 3998 daN
Outer edge of bucket 4290 mm
Min. turn radius
Outer edge of tyre 3875 mm
Bucket, standard 1.0 m³
6.1.2 WA100M-7
Power
Type Komatsu SAA4D95LE-6

Engine power 66 kW (ISO 14396)
Torque, max. 320 Nm
Engine
Starter motor 12 V – 2.2 kW
Alternator 12 V – 120 A
Battery 100 Ah
Driving speed forward and reverse: Standard
version
1st speed range 0–6.6 km/h
Driving speed forward and reverse: 30 km/h
20 km/h 5400 daN
Max tractive force
30 km/h 5050 daN
Outer edge of bucket 4731 mm
Min. turn radius
Outer edge of tyre 4210 mm
Bucket, standard 1.25 m³
6-2 WA80M-7, WA100M-7 – VENAM03001

Technical data 6.2 Noise emission levels
6.2 Noise emission levels

Two signs are attached to the machine that indicate the noise
emission level of the machine.
 Acoustic pressure level in the operator's cab measured in

accordance with ISO6396 (dynamic test procedure, simu-
lated work process).
In accordance with ISO 11201, the greatest value for the

standard deviation of the average measured A-rated acoustic
pressure level at the operator's seat is A dB.
WA80M-7 WA100M-7
A 2.5 2.5
 Acoustic power level generated by the machine measured in

accordance with ISO 6395 (dynamic test procedure, simu-
lated work cycle). This is the value guaranteed in accordance
with the data from the European Directive 2000/14/EC.
This is the guaranteed value in accordance with EU Directive

2000/14/EC. This value includes a margin of B dB.
WA80M-7 WA100M-7
B 1.58 1.98
WA80M-7, WA100M-7 – VENAM03001 6-3

6.3 Vibration levels Technical data
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 effective acceleration value for the upper limbs is less than
2.5 m/s². The margin for this value is C m/s² in accordance with C D
EN 12096:1997.
WA80M-7 0.73 0.59
The effective acceleration value for the body is less than 0.5 m/
s². The margin for this value is D m/s² in accordance with EN WA100M-7 0.75 0.43
12096:1997.
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 conditions
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.
 Tyre pressures
 Brake and steering systems
 Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and travelling

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.
6-4 WA80M-7, WA100M-7 – VENAM03001

Technical data 6.3 Vibration levels
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 minimise the

vibration level.
 When pushing with bucket or blade, avoid sudden load-

ing; 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 travelling path as large as pos-

sible.
 Travel at low speed when travelling around sharp curves.
7. Minimise vibrations for long work cycle or long distance trav-

elling.
 Reduce speed to prevent bounce.
 Transport machines long distances between worksites.
8. The following guidelines can be effective to minimise 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.
WA80M-7, WA100M-7 – VENAM03001 6-5

6.4 Limit values for slopes Technical data
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, 35° downhill or 35° sideways. If you angle the machine
at more than 35° during operation, the motor, transmission,
hydraulic system or axles, will not be supplied with sufficient oil
and can be damaged.
WA80M-7,WA100M-7
A Uphill 35°
B Downhill 35°
C Sideways 35°
Tipping angle, theoretically
The tipping angle is a calculated value. This states the angle at

which the machine at rest can stand on a slope without tipping
over. You must not work with the machine at these angles as the
motor, transmission, hydraulic system or axles, will not be sup-
plied with sufficient oil and can be damaged. The specified angle
refers to the transport position. The angle changes if you raise or
lower the work unit.
All data was measured with:
 Standard bucket filled (bulk weight => 1.8t/m³)
 Standard tyres
 Counterweight
WA80M-7 WA100M-7
Uphill with operating load 56° 59°
A
Uphill without operating load 39° 40°
Downhill with operating load 45° 40°
B
Downhill without operating load 58° 57°
Lateral with operating load 38° 39°
C
Lateral without operating load 38° 39°
6-6 WA80M-7, WA100M-7 – VENAM03001

Special equipment, attachments
7. Special equipment,
attachments
WA80M-7, WA100M-7 – VENAM03001 7-1

7.1 E.C.S.S. Special equipment, attachments
7.1 E.C.S.S.
Read this section carefully prior to use in order to ensure using
the E.C.S.S. safely and effectively.
7.1.1 Design and functional principle of the E.C.S.S.

The E.C.S.S. uses the hydraulic spring effect of the pressure
accumulator, installed in the circuit at the end of the piston head
of the lift cylinder, to dampen vibrations that occur when the
machine is moving. This makes smooth driving at high speeds
possible.
The E.C.S.S. consists of the E.C.S.S. electronics and the corre-

sponding switches, the pressure accumulator and the solenoid
valve. When the E.C.S.S. is activated, the solenoid valve opens
and the circuit at the piston head of the lift cylinder is connected
to the pressure accumulator.
7.1.2 Precautions when switching on the E.C.S.S.
WARNING
If, while the machine is moving with the attachment raised, the
E.C.S.S. is automatically activated based on the speed, the
attachment could possibly move up or down, depending on the
load. Therefore proceed only with utmost caution when the
E.C.S.S. is on.
For inspection and maintenance tasks, lower the work unit to the
ground, switch off the E.C.S.S. and depressurise the pressure
accumulator before starting with the maintenance tasks.
NOTICE
The E.C.S.S. activates if the transmission is at speed range 2 and
the machine travels at a speed greater than 5 km/h.
7-2 WA80M-7, WA100M-7 – VENAM03001

Special equipment, attachments 7.1 E.C.S.S.
7.1.3 Operating the E.C.S.S.
Switching on the E.C.S.S.

1. Prerequisite:
Speed range 2 has to be on for the E.C.S.S. to activate. If nec-

essary, press the Speed Range 2 button.
2. Press the E.C.S.S. button.
The yellow pilot lamp in the switch goes on.
 If the machine is travelling at a speed higher than 5 km/h,

the E.C.S.S. system is activated automatically and the
G0070432
E.C.S.S. pilot lamp on the machine monitor lights up.
 If the machine is travelling at a speed lower than 5 km/h,

the E.C.S.S. system is deactivated and the pilot lamp on
the machine monitor goes out.
 The yellow pilot lamp in the E.C.S.S. switch remains on.
NOTICE
 When carrying a load, do not tilt the bucket back completely
to allow the E.C.S.S. to work.
 Do not support the boom when travelling on roads.
Switching off the E.C.S.S.

1. Press the E.C.S.S. button.
7.1.4 Precautions when handling the pressure accumulator

For details see “Handling the pressure accumulator (2-41)”.
WA80M-7, WA100M-7 – VENAM03001 7-3

7.2 Bucket position indicator Special equipment, attachments
7.2 Bucket position indicator

(Option)
The bucket position indicator shows the status of the bucket.
Mark A = Cylinder marking for horizontal fork position

(fork on the ground)
Mark B =
Cylinder mark for bucket in scraping position
B A
NOTICE
When the quick coupler is dismounted, the clamp at the piston rod
(C) and indicator rod (D) have to be dismounted as well. Else the D
cylinder seal could be damaged.
7-4 WA80M-7, WA100M-7 – VENAM03001

Special equipment, attachments 7.3 Central lubrication system
7.3 Central lubrication system

The central lubrication system is used for automatic lubrication of
the lubrication points connected to the machine.
7.3.1 Changing the lubrication intervals and duration

The central lubrication system is preset for normal use.
The settings have been preset in the factory for delivery as fol-
lows:
WA80M-7
 Lubrication interval: after 1 hour
 Lubrication duration: 7 minutes.
WA100M-7
 Lubrication interval: after 1 hour
 Lubrication duration: 6 minutes.
NOTICE
To adjust lubrication times under greater loads, please contact
your Komatsu distributor.
7.3.2 Operating the central lubrication system

Position of the lubrication pump:
Left under the cabin.
For more details see “Central lubrication system – checking,

replenishing grease (5-46)”.
This switches on the lubrication pump.

1
2. Observe the grease container.
When the paddle agitator operates in the grease container,

the lubricating system is in order. A B
If the paddle agitator does not turn, then the automatic lubri-
cation does not function. C
Consult your Komatsu distributor to rectify the fault.
If grease has leaked out of the pressure control valve (1),

please contact your Komatsu distributor.
G0070421
WA80M-7, WA100M-7 – VENAM03001 7-5

7.3 Central lubrication system Special equipment, attachments
7.3.3 Display and operating unit

The display and operating unit is protected by a transparent plas-
tic cover against sprayed water and mechanical damages. For
programming, the cover needs to be removed and remounted
afterwards.
LED display
1
Three-digit LED display
1.
Values and operational condition
2
2. Intermission sequence
3
3. Pump operation
4. Monitoring the system function by external cycle switch 4
5. Non-functioning
6. Fault indication 5
6
G0070304
Buttons
1
Switch on the display
1.  Display values and parameters
 Set values and parameters
2
Switch between programming and display mode
2.
 Confirm values
Activate intermediate lubrication

3. 3
 Clear fault indication G0070305
7-6 WA80M-7, WA100M-7 – VENAM03001

Special equipment, attachments 7.3 Central lubrication system
Three-digit LED display

Under normal operation, the display is switched off. It is activated
by briefly pressing one of the two buttons. Current values and pre-
set parameters are displayed. The display also serves as a user
guide when programming operating parameters.
Display Meaning Statement Control function
The pilot device works as a time-

t = TIMER controlled contact transmitter Part of the lubrication cycle input
PA = PAUSE (TIMER) and is found in the PAUSE and display value in hours
operating mode.
c = COUNTER Caution! Do not use

PA = PAUSE This mode triggers a malfunction
The pilot device works as a time-

CONTACT = time during which the
t = TIMER controlled contact transmitter
pump is pumping
CO = CONTACT (TIMER) and is found in the pump
Input and display value in minutes
running time (CONTACT).
c = COUNTER Caution! Do not use

CO = CONTACT This mode triggers a malfunction
C = Cycle
Display of the start of the menu
O = OFF
“Monitoring settings”
P = Pressure
Monitoring The monitoring functions CS and PS

No system monitoring
OFF are switched off.
During the pump running time

Cycle Switch
Cycle switch monitoring is activated CONTACT, the cycle switch is
Cycle switch
monitored for signal emission.
Fault Low Level

Fault: too low Not used
level
Fault Cycle Switch

Not used
Fault: Cycle switch
Operation Hour Meter

The values displayed are the operating hours of the pilot device.
Service meter
Fault Hour Meter The values displayed are the fault hours. Time during which the machine
Fault hour meter was operated in the FAULT operating mode.
Missing signal from cycle switch. The pilot device is still within the
Block operation monitoring process, which is different from normal operation. If the fault
persists over 3 pump running times, a fault indication is issued.
WA80M-7, WA100M-7 – VENAM03001 7-7

7.3 Central lubrication system Special equipment, attachments
7-8 WA80M-7, WA100M-7 – VENAM03001

Index
8. Index
WA80M-7, WA100M-7 – VENAM03001 8-1

8.1 Index Index
8.1 Index
A D
accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
adjust steering column . . . . . . . . . . . . . . . . . . . . . 3-35 dimensions, machine . . . . . . . . . . . . . . . . . . . . . . 1-20
adjusting operator's seat . . . . . . . . . . . . . . . . . . . 3-61 direction selector lever . . . . . . . . . . . . . . . . . . . . . 3-72
adjusting seat belt . . . . . . . . . . . . . . . . . . . . . . . . 3-65 door release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
adjusting the steering column . . . . . . . . . . . . . . . 3-64 driving the machine . . . . . . . . . . . . . . . . . . . . . . . 3-69
air cleaner, filter insert . . . . . . . . . . . . . . . . . . . . . 5-35
air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 E
E.C.S.S.
B design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
battery main switch . . . . . . . . . . . . . . . . . . . . . . . 3-32 precautions . . . . . . . . . . . . . . . . . . . . . . . . 7-2, 7-3
Bleeding the fuel system . . . . . . . . . . . . . . . . . . . 5-64 switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
booster cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
brake emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
checking the parking brake . . . . . . . . . . . . . . . . 4-9 emergency lowering . . . . . . . . . . . . . . . . . . 2-25, 4-10
checking the service brake . . . . . . . . . . . . . . . . 4-9 emergency steering . . . . . . . . . . . . . . . . . . . . . . . 4-10
insufficient brake power . . . . . . . . . . . . . . . . . . 4-9 engine
brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
brakes starting with booster cables . . . . . . . . . . . . . . . . 4-7
with the service brake . . . . . . . . . . . . . . . . . . . 3-74 switching off . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
bucket equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
level indicator . . . . . . . . . . . . . . . . . . . . . . . . . 3-93 EU directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
manual lowering . . . . . . . . . . . . . . . . . . . . . . . 2-25 excavating
bucket positioner . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 using the machine
excavating . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
C
carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84 F
caution lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
caution lamps, overview . . . . . . . . . . . . . . . . . . . . . 3-6 fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
CE-conforming . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 first aid kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
CE-conforming equipment . . . . . . . . . . . . . . . . . . 1-22 FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Central lubrication system . . . . . . . . . . . . . . . . . . . 7-5 fuel, coolant and lubricant, general . . . . . . . . . . . 5-10
central lubrication system fuel, fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
changing the lubrication intervals and duration . 7-5 fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
display and operating unit . . . . . . . . . . . . . . . . . 7-6
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 G
changing direction . . . . . . . . . . . . . . . . . . . . . . . . 3-72
check, before starting . . . . . . . . . . . . . . . . . . . . . . 3-49 gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94 coolant temperature gauge . . . . . . . . . . . . . . . 3-21
cigarette lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
cleaning cooling system . . . . . . . . . . . . . . . . . . . . 5-32 service meter . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
control lever general view
additional functions . . . . . . . . . . . . . . . . . . . . . 3-78 controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
control levers machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
special equipment . . . . . . . . . . . . . . . . . . . . . . 3-37
controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 H
caution lamps . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
control levers . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 high-pressure line . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
general view . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 hydraulic system, changing filter insert . . . . . . . . 5-40
pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
pilot lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
I
intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
8-2 WA80M-7, WA100M-7 – VENAM03001

Index 8.1 Index
K engine
changing filter cartridge . . . . . . . . . . . . . . . 5-54
key data of the machine . . . . . . . . . . . . . . . . . . . . 1-9
engine oil change . . . . . . . . . . . . . . . . . . . 5-53
KOMTRAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
front axle
checking oil level . . . . . . . . . . . . . . . . . . . . 5-57
L oil change . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83 fuel and coolant hoses . . . . . . . . . . . . . . . . . . 5-73
levers fuel filter, changing filter cartridge . . . . . . . . . 5-63
multi-function lever . . . . . . . . . . . . . . . . . . . . . 3-36 fuel prefilter, changing filter cartridge . . . . . . . 5-59
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 heater/air conditioner
special equipment control lever . . . . . . . . . . . 3-37 cleaning/renewing filter cloth . . . . . . . . . . . 5-55
steering column adjustment . . . . . . . . . . . . . . 3-35 hydraulic system
lifting, machine . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 changing filter insert . . . . . . . . . . . . . . . . . 5-40
loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 hydraulic oil change . . . . . . . . . . . . . . . . . 5-69
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95 lubrication
lubricant articulated steering . . . . . . . . . . . . . . . . . . 5-43
general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 rear axle . . . . . . . . . . . . . . . . . . . . . . 5-41, 5-50
table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 refill grease in central lubrication system . 5-46
steering cylinder . . . . . . . . . . . . . . . . . . . . 5-49
M work equipment . . . . . . . . . . . . . . . . . . . . . 5-44
maintenance guide . . . . . . . . . . . . . . . . . . . . . . 5-2
machine maintenance schedule . . . . . . . . . . . . . . . . . . 5-25
breaking in . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 rear axle
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 oil change . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 safety-critical parts . . . . . . . . . . . . . . . . . . . . . 5-24
engine serial no. plate . . . . . . . . . . . . . . . . . . . 1-9 service brake, checking oil . . . . . . . . . . . . . . . 5-61
general view . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 transfer case
intended use . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 adding oil . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103 checking oil level . . . . . . . . . . . . . . . . . . . . 5-58
loading . . . . . . . . . . . . . . . . . . . . . . . . . 3-99, 3-100 oil change . . . . . . . . . . . . . . . . 5-42, 5-67, 5-73
locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95 V-belts, checking . . . . . . . . . . . . . . . . . . . . . . 5-60
long-term storage . . . . . . . . . . . . . . . . . . . . . 3-108 wheel nuts, checking, retightening . . . . . . . . . 5-40
machine serial no. plate . . . . . . . . . . . . . . . . . . 1-9 window washer fluid . . . . . . . . . . . . . . . . . . . . 5-30
operating data . . . . . . . . . . . . . . . . . . . . . . . . 1-20 maintenance procedure
parking . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29, 3-76 after the first 250 service hours . . . . . . . . . . . 5-42
parking on a slope . . . . . . . . . . . . . . . . . . . . . 3-76
after the first 50 service hours . . . . . . . . . . . . 5-40
starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
before starting . . . . . . . . . . . . . . . . . . . . . . . . 3-49
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
corrective . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76
every 10 service hours . . . . . . . . . . . . . . . . . . 5-43
technical data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
every 1000 service hours . . . . . . . . . . . . . . . . 5-60
towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
towing, after towing . . . . . . . . . . . . . . . . . . . . . 4-5
transport . . . . . . . . . . . . . . . . . . . . . . . . . 2-29, 3-99
every 250 service hours . . . . . . . . . . . . . . . . . 5-48
turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
every 50 service hours . . . . . . . . . . . . . . . . . . 5-44
weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
every 500 service hours . . . . . . . . . . . . . . . . . 5-51
machine monitor, description . . . . . . . . . . . . . . . 3-10
machine monitor, general view . . . . . . . . . . . . . . . 3-6
multi-function lever
maintenance
operation . . . . . . . . . . . . . . . . . . . . . . . . 3-36, 3-77
air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
changing filter insert . . . . . . . . . . . . . . . . . 5-39
changing safety filter . . . . . . . . . . . . . . . . . 5-39 N
air conditioner, checking . . . . . . . . . . . . . . . . 5-28 Nameplate
bleeding fuel system . . . . . . . . . . . . . . . . . . . 5-64 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
checking system pressures . . . . . . . . . . . . . . 5-61 noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
checking valve clearance . . . . . . . . . . . . . . . . 5-68
cleaning air grille . . . . . . . . . . . . . . . . . . . . . . 5-31 O
cleaning the radiator fins . . . . . . . . . . . . . . . . 3-53
operating conditions
cooling system
working on loose ground . . . . . . . . . . . . . . . . 2-27
maintenance
operating data, machine . . . . . . . . . . . . . . . . . . . 1-20
cleaning internal area
operating precautions . . . . . . . . . . . . . . . . . . . . . 3-87
of the cooling system . . . . . . . . . . . . . 5-32
WA80M-7, WA100M-7 – VENAM03001 8-3

8.1 Index Index
operation safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

adjusting operator's seat . . . . . . . . . . . . . . . . . 3-61 signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
adjusting seat belt . . . . . . . . . . . . . . . . . . . . . . 3-65 tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
adjusting steering column . . . . . . . . . . . . . . . . 3-64 safety instructions
air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 asbestos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
changing direction . . . . . . . . . . . . . . . . . . . . . . 3-72 leaving the machine . . . . . . . . . . . . . . . . . . . . 2-11
cold weather . . . . . . . . . . . . . . . . . . . . . . . . . 3-106 loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
decelerating . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74 pressure accumulator . . . . . . . . . . . . . . . . . . . 2-41
digging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80 safety clothing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
driving the machine . . . . . . . . . . . . . . . . . . . . . 3-69 workplace . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
handling tyres . . . . . . . . . . . . . . . . . . . . . . . . . 3-96 safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6, 2-2
heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47 safety-critical parts . . . . . . . . . . . . . . . . . . . . . . . . 5-24
loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 secondary switch for engine shut-off . . . . . . . . . . 3-33
parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 serial no. plate
precautions . . . . . . . . . . . . . . . . . . . . . . 2-21, 3-87 engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
starting the engine . . . . . . . . . . . . . . . . . . . . . . 3-66 FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
stockpiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85 machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-76 operator's seat . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
switching off the engine . . . . . . . . . . . . . . . . . . 3-94 ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
visual check . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
v-shape loading . . . . . . . . . . . . . . . . . . . . . . . . 3-85 service brake, checking brake pads . . . . . . . . . . . 5-48
wheel loader . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 service meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
work equipment . . . . . . . . . . . . . . . . . . . . . . . . 3-77 slope angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
P standards, EU directives . . . . . . . . . . . . . . . . . . . . 1-4
starting switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
pedals steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . 3-36 storage, long-term . . . . . . . . . . . . . . . . . . . . . . . 3-108
brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 switch
pilot lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6, 3-16 secondary switch for engine shut-off . . . . . . . . 3-33
PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9 window wiper . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
power outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
precautions 100 % differential lock switch . . . . . . . . . . . . . 3-29
driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 3th control circuit . . . . . . . . . . . . . . . . . . . . . . . 3-29
driving on slopes . . . . . . . . . . . . . . . . . . . . . . . 2-24
air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
auto-inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Back-up light switch . . . . . . . . . . . . . . . . . . . . . 3-28
tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
blower switch . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
pressure accumulator
cab light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
E.C.S.S. pressure accumulator . . . . . . . . 5-56, 7-3
direction selector . . . . . . . . . . . . . . . . . . . . . . . 3-30
safety instructions . . . . . . . . . . . . . . . . . . . . . . 2-41
E.C.S.S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
fan reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
R general view . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
reading error code . . . . . . . . . . . . . . . . . . . . . . . 3-112 hazard warning light . . . . . . . . . . . . . . . . . . . . 3-24
rear window wiper . . . . . . . . . . . . . . . . . . . 3-24, 3-25 horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
renewing CCV filter . . . . . . . . . . . . . . . . . . . . . . . 5-71 light switch . . . . . . . . . . . . . . . . . . . . . . . 3-24, 3-26
return to dig quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 rear window defroster . . . . . . . . . . . . . . . . . . . 3-26
ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 rear window wiper . . . . . . . . . . . . . . . . . 3-24, 3-25
speed range 2 . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
speed regulator . . . . . . . . . . . . . . . . . . . . . . . . 3-31
S sprayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 starting switch . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 temperature switch . . . . . . . . . . . . . . . . . . . . . 3-28
fire extinguisher . . . . . . . . . . . . . . . . . . . . . . . . 2-10 turn signal lever . . . . . . . . . . . . . . . . . . . . . . . . 3-26
first aid kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 warning beacon . . . . . . . . . . . . . . . . . . . . . . . . 3-26
impermissible work . . . . . . . . . . . . . . . . . . . . . 2-24 work light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
parking the machine . . . . . . . . . . . . . . . . . . . . 2-29 T
ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
8-4 WA80M-7, WA100M-7 – VENAM03001

Index 8.1 Index
maximum slope angle . . . . . . . . . . . . . . . . . . . 6-6

noise emission . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
temperature gauge . . . . . . . . . . . . . . . . . . . . . . . 3-21
tipping up the operator's cab . . . . . . . . . . . . . . . . 2-37
tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
tow hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
towing
after towing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
towing machine . . . . . . . . . . . . . . . . . . . . . . . . 4-2
transport, machine . . . . . . . . . . . . . . . . . . . 2-29, 3-99
troubles, table . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
troubleshooting table
axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
electrical system . . . . . . . . . . . . . . . . . . . . . . 4-11
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
operator's cab . . . . . . . . . . . . . . . . . . . . . . . . 4-18
steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
tyre pressure,chart . . . . . . . . . . . . . . . . . . . . . . . 3-97
tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43, 3-96
U
using the machine
carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
forklift attachment . . . . . . . . . . . . . . . . . . . . . . 3-85
levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
near high-voltage cables . . . . . . . . . . . . . . . . 2-17
on snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
saving the tyres . . . . . . . . . . . . . . . . . . . . . . . 3-78
V
vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
W
wear parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
weights, machine . . . . . . . . . . . . . . . . . . . . . . . . 1-20
window washer fluid . . . . . . . . . . . . . . . . . . . . . . 5-30
windscreen wiper . . . . . . . . . . . . . . . . . . . . . . . . 3-26
work conditions
material containing asbestos . . . . . . . . . . . . . 2-20
work equipment
adjusting . . . . . . . . . . . . . . . . . . . . . . . . . 3-89, 3-94
attaching . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
control with multi-function lever . . . . . . . . . . . 3-77
manual lowering . . . . . . . . . . . . . . . . . . . . . . . 2-25
operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77
removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
selecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
work equipment lock lever . . . . . . . . . . . . . . . . . 3-38
work equipment, lock lever . . . . . . . . . . . . . . . . . 3-38
work place, safety . . . . . . . . . . . . . . . . . . . . . . . . 2-27
WA80M-7, WA100M-7 – VENAM03001 8-5

8.1 Index Index
8-6 WA80M-7, WA100M-7 – VENAM03001

Notes
9. Notes
WA80M-7, WA100M-7 – VENAM03001 9-1

Notes
9-2 WA80M-7, WA100M-7 – VENAM03001

Notes
WA80M-7, WA100M-7 – VENAM03001 9-3

Notes
9-4 WA80M-7, WA100M-7 – VENAM03001

Notes
WA80M-7, WA100M-7 – VENAM03001 9-5

Notes
9-6 WA80M-7, WA100M-7 – VENAM03001

WA80 WA100M 7 Operation Manual

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WA80 WA100M 7 Operation Manual

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Operation and VENAM03001

© 2016 Komatsu Hanomag GmbH

WA80M-7, WA100M-7 – VENAM03001 1-1

 Be sure to read and understand this manual thoroughly

 Read the safety messages given in this manual and the

 Keep this manual at the storage location for the Operation

 Have all personnel read the manual periodically. If this man-

 If you sell the machine, be sure to hand over this manual to

 Komatsu delivers machines that comply with all applicable

1-2 WA80M-7, WA100M-7 – VENAM03001

The operating manual is to be considered part of the machine and

Any safety-relevant modification to the machine by the owner

Our continuous efforts to improve the machine's design may

The introduction of these improvements however does not con-

WA80M-7, WA100M-7 – VENAM03001 1-3

If there is any question about whether your product complies with

Notes on subsequent installation of electrical and electronic

Electrical and electronic equipment and/or components installed

If you are installing electrical or electronic equipment and/or com-

The following requirements also have to be met for subsequent

 Only equipment approved by national legislation (e.g. BZT

 The unit must be fixed in position.

 Portable or mobile units may only be used inside the vehicles

 The transmitter unit must be spatially separated from the

 Ensure that the antenna is installed properly with a good

Also observe installation instructions by Komatsu or the manufac-

1-4 WA80M-7, WA100M-7 – VENAM03001

1.2 Safety information

1.2.1 Signal words

Example of safety message using a signal word.

 Accidentally touching the control levers when they are not

Other signal words

In addition to the above, the following signal words are used to

WA80M-7, WA100M-7 – VENAM03001 1-5

1.2.2 Safety labels

For details see “Safety labels (2-2)”.

Safety labels using pictograms

Safety pictograms use a picture to express a hazard level that

Komatsu cannot predict every circumstance that might involve a

If any procedures or actions not specifically recommended or

The explanations, values, and illustrations in this manual were

1-6 WA80M-7, WA100M-7 – VENAM03001

This Komatsu machine is designed to be used mainly for the fol-

1.3.1 Intended use

The transport of persons in the work equipment is strictly forbid-

For details of the operating procedure, see chapter “Working with

WA80M-7, WA100M-7 – VENAM03001 1-7

1.3.2. Breaking in the machine

If the machine is worked excessively hard during the breaking-in

Particularly observe the following points:

 Let the engine run at idle for 5 minutes after starting.

 Avoid operation with heavy loads or at high engine speeds.

 Avoid sudden starts and stops, hard acceleration and sudden

The precautions for operation and maintenance in this manual as

1-8 WA80M-7, WA100M-7 – VENAM03001

1.4 Key data of the machine

The plate is on the right side of the machine's front frame.

1.4.2 Engine serial no. plate

WA80M-7, WA100M-7 – VENAM03001 1-9

1.4.3 Axle serial no. plate

Rear axle: Left 1

Front axle: Right

1.4.4 Transmission serial no. plate