Komatsu WA150PZ-5 Operation & Maintenance Manual
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Komatsu WA150PZ-5 Operation & Maintenance Manual

Komatsu WA150PZ-5 Operation & Maintenance Manual

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Operation & Maintenance
Manual
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept near the machine
for reference and periodically reviewed by all personnel
who will come into contact with it.
NOTICE
Komatsu has had the operating and maintenance in-
structions translated into all the languages of the mem-
ber states in the European Union. Should you wish to
have a version of the operating instructions in another
language, please don't hesitate to ask at your local
dealer's.
© 2005 Komatsu Hanomag GmbH
All Rights Reserved
Printed in Europe 06-05
WA150PZ-
WHEEL LOADER
SERIAL NUMBERS
WARNING
H50051
and up
VEAM420100
5

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Summary of Contents for Komatsu WA150PZ-5

  • Page 1 NOTICE Komatsu has had the operating and maintenance in- structions translated into all the languages of the mem- ber states in the European Union. Should you wish to have a version of the operating instructions in another language, please don’t hesitate to ask at your local...

  • Page 2: Foreword

    Foreword 1. Foreword WA150PZ-5 – VEAM420100...

  • Page 3: Foreword

    If you sell the machine, be sure to give this manual to the new owners together with the machine. KOMATSU delivers machines that comply with all appli- cable regulations and standards of the country to which it has been shipped. If this machine has been purchased...

  • Page 4: Eu Directives

    Make sure when installing the antenna that this is installed correctly with good earth connection between antenna and vehicle mass Also observe KOMATSU and manufacturer’s installation instruc- tions for wiring, installation and maximum permitted power con- sumption. WA150PZ-5 – VEAM420100...

  • Page 5: Safety Information

    When standing up from the operator's seat, always place the safety lock lever in the LOCK position. If you accidentally touch the control levers when they are not locked, this may cause a serious injury or death. WA150PZ-5 – VEAM420100...

  • Page 6: Safety Labels

    Continuing improvements in the design of this machine can lead to changes in detail which may not be reflected in this man- ual. Consult KOMATSU or your KOMATSU distributor for the latest available information of your machine or for questions regarding information in this manual.

  • Page 7: Introduction

    Front Bucket Left Right Rear GK032003 In this manual, the directions of the machine (front, rear, left, right) are determined according to the view from the operator's seat in the direction of travel (front) of the machine. WA150PZ-5 – VEAM420100...

  • Page 8: Necessary Information

    Foreword 1.4 Necessary information Necessary information When requesting service or ordering replacement parts, please inform your KOMATSU distributor of the following items. 1.4.1 PIN/Machine serial no. plate and position On the center right of the front frame. GK015035GB 1.4.2 Engine serial no. plate and position This is on the side face of the engine cover on the right side of the machine.

  • Page 9: Rops/Fops-Cab Serial No. Plate

    Axle serial no. plate This plate is located on the right of front axle and on the left of rear axle. GK032007 1.4.5 Transmission serial no. plate This plate is located in travel direction front, above the transmission output. GK032008 WA150PZ-5 – VEAM420100...

  • Page 10: Seat Operator Serial No. Plate

    GK032009 1.4.7 Position of service meter It is at the center bottom of the machine monitor. GK032010 1.4.8 Table to enter serial no. and distributor Machine serial No. Engine serial No. Distributor name Address Service Personnel Phone/Fax WA150PZ-5 – VEAM420100...

  • Page 11: Table Of Contents

    1.6.1 WA150PZ-5: Dimensions, weights and operating data ......1-17 CE-Conforming equipment ........... . 1-18 1.7.1...
  • Page 12 Normal starting ............3-68 1-11 WA150PZ-5 – VEAM420100...
  • Page 13 Precautions for low temperature ......... 3-109 1-12 WA150PZ-5 – VEAM420100...
  • Page 14 Grease ............. . 4-6 Carrying out KOWA (KOMATSU Oil Wear Analysis) ......4-7 Storing oil and fuel .
  • Page 15 Replace HST oil filter element ..........4-58 1-14 WA150PZ-5 – VEAM420100...
  • Page 16 Operating the central lubrication system ........6-18 1-15 WA150PZ-5 – VEAM420100...
  • Page 17 Notes ............8-1 1-16 WA150PZ-5 – VEAM420100...

  • Page 18: Dimensions, Weights And Operating Data

    Foreword 1.6 Dimensions, weights and operating data Dimensions, weights and operating data 1.6.1 WA150PZ-5: Dimensions, weights and operating data GK032011 Measurements, operating data without teeth and without BOC, Bucket capacity to ISO 7546 m³ without Quick coupler) Material density t/m³...

  • Page 19: Ce-Conforming Equipment

    416-71-H2C00 2,700 416-71-H2C10 2,700 416-71-H2C20 2,880 416-71-H2C30 2,700 416-71-H2C40 2,700 416-71-H2C50 2,880 Bucket WA150PZ-5 416-71-H2C60 2,880 416-71-H2C70 2,880 416-71-H2C80 3,060 416-71-H2D30 2,880 416-71-H2D20 2,880 416-71-H2D40 3,060 Fork 416-71-H2B00 3,400 Quick coupler 416-71-H2A90 4,000 GK032012 1-18 WA150PZ-5 – VEAM420100...

  • Page 20: Manufacturer-Supplied Ce-Conforming Equipment, According To Document 419-93-H1250

    The dimension Sh (smallest tyre radius) must be added to the dimension D2. The figure G (in kg) represents the maximum load (equipment and operating load) which may act upon this point. GK032013 1-19 WA150PZ-5 – VEAM420100...
  • Page 21 1.7 CE-Conforming equipment Foreword d1=d2 GK032014 1-20 WA150PZ-5 – VEAM420100...
  • Page 22 Bucket connection dimension d1 - d2, horizontally dis- placed Vision line Distance: bucket bottom edge - boom bolt hole Bolts Distance: centre of bolt - centre of fastening screw MICHELIN Tyres 17.5R25XHA 1,5 m³ Bucket 416-71-H2C00 1-21 WA150PZ-5 – VEAM420100...
  • Page 23 1.7 CE-Conforming equipment Foreword 1-22 WA150PZ-5 – VEAM420100...

  • Page 24: 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 oper- ating or servicing the machine, always follow these precautions strictly. WA150PZ-5 – VEAM420100...

  • Page 25: Safety Labels

    Do not use organic solvents or gasoline. These may cause the safety labels to peel off. Missing or damaged safety labels must be replaced. Order the new part from your KOMATSU distributor. 2.1.1 Location of safety labels "Z"...

  • Page 26: Presentation Of Safety Labels

    Safety 2.1 Safety labels 2.1.2 Presentation of safety labels GK032017 GK032016 GK032018 GK032019 GK032020 GK032021 GK032022 GK032022 GK032026 GK032023 GK032024 GK032025 GK032029 GK032027 GK032028 GK032030 WA150PZ-5 – VEAM420100...
  • Page 27 2.1 Safety labels Safety GK032017 GK032016 GK032018 GK032019 GK032020 GK032021 GK032022 GK032022 GK032025 GK032026 GK032023 GK032024 GK032029 GK032027 GK032028 GK032030 WA150PZ-5 – VEAM420100...
  • Page 28 Sign indicates to prevere severe injury or death Honk to alert people nearby. Be sure no one is on or near machine. Use spotter if view is obstructed. Use KOMATSU oil only (421-93-H1390) Do not enter (421-93-H1320) Sign indicates a crush hazard between the articulating parts of the vehicle.

  • Page 29: General Precautions

    Always wear a hard hat and safety shoes. If the nature of the work requires it, wear safety glasses, mask, gloves, ear plugs, and safety belt when operating or maintaining the GK032031 machine. Check that all protective equipment functions properly before using it. WA150PZ-5 – VEAM420100...
  • Page 30 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 WA150PZ-5 – VEAM420100...
  • Page 31 LOCK position, pull parking brake lever (2) to the LOCK position, then stop the engine. Use the key to lock all the equipment. Always remove the key, take it with you, and keep it in the specified place. Lock Free GK032036 WA150PZ-5 – VEAM420100...
  • Page 32 In addition, repair any damage and tighten any loose bolts. Do not get on or off the machine while holding tools in your hand. WA150PZ-5 – VEAM420100...
  • Page 33 Even when the oil has cooled down, loosen the plug slowly to relieve the internal pressure before removing the plug. GK032043 2-10 WA150PZ-5 – VEAM420100...
  • Page 34 Short circuits in the electrical system can cause fire. Always keep electric wiring connections clean and securely tightened. Check the wiring every day for looseness or damage. Tighten any loose connectors or wiring clamps. Repair or replace any damaged wiring. 2-11 WA150PZ-5 – VEAM420100...
  • Page 35 The ROPS can only provide maximum protection, if the driver wears the safety belt correctly. For this reason, the safety belt is to be worn when the machine is in operation. 2-12 WA150PZ-5 – VEAM420100...
  • Page 36 Any modification made without authorization from KOMATSU can create hazards. Before making a modification, consult your KOMATSU distributor. KOMATSU will not be responsible for any injuries, accidents, product failures or other property damages resulting from modifi- cations made without authorization from KOMATSU.
  • Page 37 Always do as fol- lows. Position a signalman if there are areas at the rear of the machine where the visibility is not good. 2-14 WA150PZ-5 – VEAM420100...
  • Page 38 Always observe the rules and regulations for the work site and environmental standards. This machine does not use asbestos, but there is a danger that imitation parts may contain asbestos, so always use genuine KOMATSU parts. 2-15 WA150PZ-5 – VEAM420100...

  • Page 39: Precautions For Operation

    Adjust the mirrors so that the rear of the machine can be seen clearly from the operator's seat. See "Adjust rear view mirror (3-65)". Check that there are no persons or obstacles above, below, or in the area around the machine. 2-16 WA150PZ-5 – VEAM420100...
  • Page 40 Before charging or starting the engine with a different power source, melt the battery electrolyte and check that there is no leakage of electrolyte before starting. 2-17 WA150PZ-5 – VEAM420100...

  • Page 41: Operation

    Always lock the door and windows of the operator's com- partment in position (open or closed). On jobsites where there is a hazard of flying objects or of objects entering the operator's compartment, check that the door and windows are securely closed. 2-18 WA150PZ-5 – VEAM420100...
  • Page 42 This may cause the tires to burst. If a tire bursts, it produces an extremely large destruc- tive force, and this may cause serious injury or accident. If you are going to travel continuously, please consult your KOMATSU distributor. 2-19 WA150PZ-5 – VEAM420100...
  • Page 43 When traveling up or down hills with a loaded bucket, always travel with the bucket facing uphill. If the machine travels with the bucket facing downhill, there is danger that the machine may tip over. 2-20 WA150PZ-5 – VEAM420100...
  • Page 44 Push the pilot control lever slowly forward to the position LOWER. GK015136 EPC control lever 1. Turn the key in ignition switch (1) to ON. 2. Push the pilot control lever slowly forward to the position LOWER. GK015136 2-21 WA150PZ-5 – VEAM420100...
  • Page 45 To prevent accidents caused by hitting other objects, always operate the machine at a speed which is safe for operation, particular in confined spaces, indoors, and in places where there are other machines. GK032063 2-22 WA150PZ-5 – VEAM420100...
  • Page 46 The load may vary considerably, depending on the structure of the snow. For this reason, reduce the load and pay atten- tion that the machine does not start to skid. When traveling on snow-covered roads, always fit tire chains. 2-23 WA150PZ-5 – VEAM420100...
  • Page 47 Adhere to all regulations on parking vehicles and securing building sites Lock Free GK032036 If it is necessary to park the machine on a slope, set blocks under the wheels to prevent the machine from moving. GK032065 2-24 WA150PZ-5 – VEAM420100...

  • Page 48: Transportation

    Transportation The machine can be divided into parts for transportation, so when transportating the machine, please contact your KOMATSU distributor to have the work carried out. Loading and unloading When loading or unloading the machine, mistaken operation may bring the hazard of the machine tipping over or falling, so particular care is necessary.

  • Page 49: Battery

    Flammable hydrogen gas is generated when the battery is charged, so remove the battery from the chassis, take it to a well-ventilated place, and remove the battery caps before charging it. Tighten the battery caps securely. Install the battery securely to the determined place. 2-26 WA150PZ-5 – VEAM420100...
  • Page 50 When connecting a normal machine to a problem machine with booster cables, always use a normal machine with the same battery voltage as the problem machine. For details of the starting procedure when using booster cables, see "Starting engine with booster cable (3-119)". 2-27 WA150PZ-5 – VEAM420100...

  • Page 51: Towing

    Never tow a machine on a slope. GK032071 Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break during the towing operation. GK032072 2-28 WA150PZ-5 – VEAM420100...

  • Page 52: Precautions For Maintenance

    Appoint leader when working with others When repairing the machine or when removing and installing the work equipment, appoint a leader and follow his instructions dur- ing the operation. When working with others, misunderstandings between workers can lead to serious accidents. 2-29 WA150PZ-5 – VEAM420100...
  • Page 53 Pull parking brake lever (3) to the LOCK position, then put blocks under the front and the rear of the tires. Lock Free GK032036 Lock the front and rear frames with safety bar (4). Free Lock GK032075 2-30 WA150PZ-5 – VEAM420100...
  • Page 54 Inspection and maintenance after turning E.C.S.S. switch For machines equipped with a E.C.S.S. lower the bucket to the ground, turn the E.C.S.S. switch OFF, and stop the engine before starting inspection or maintenance. NEVER turn the switch ON during inspection or maintenance. 2-31 WA150PZ-5 – VEAM420100...
  • Page 55 GK032078 Do not hit or roll the accumulator, or subject it to any impact. When disposing of the accumulator, the gas must be released. Please contact your KOMATSU distributor to have this work performed. Personnel Only authorized personnel can service and repair the machine.
  • Page 56 GK032081 rounding area. Always check that there is no one in the surrounding area. There is a hazard that the pin hit with strong force may fly out and injure people in the surrounding area. 2-33 WA150PZ-5 – VEAM420100...
  • Page 57 If you are hit by a jet of high-pres- sure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medi- cal attention. 2-34 WA150PZ-5 – VEAM420100...
  • Page 58 If any damaged hoses are found, stop operations immedi- ately and contact your KOMATSU distributor. Replace all hoses every 2 years at the latest. The shelf life of the hose should not exceed 2 years.
  • Page 59 Replace or repair safety-critical parts if any defect is found, even when they have not reached the time specified interval. Replace all hoses every 2 years at the latest. The shelf life of the hose should not exceed 2 years. 2-36 WA150PZ-5 – VEAM420100...

  • Page 60: Precautions With Tires

    To maintain safety, always do as follows. Maintenance, disassembly, repair, and assembly of the tires and rims requires special equipment and special technology, so always ask your KOMATSU distributor to carry out these operations. GK032084 Inflate tyres up to the defined pressure. If the tyre pressure is too low, the tyres may heat up and burst.
  • Page 61 2.5 Precautions with tires Safety 2-38 WA150PZ-5 – VEAM420100...

  • Page 62: Operation

    Operation 3. Operation WARNING Please read and make sure that you understand the SAFETY section before reading this section. WA150PZ-5 – VEAM420100...

  • Page 63: General View

    (8) Turn signal lamp (2) Tilt lever (9) Head lamp (3) Front wheel (10) Lift cylinder (4) Bucket cylinder (11) Lift arm (5) Front working lamp (12) Rear working lamp (6) ROPS cab (13) Rear combination lamp (7) Rear wheel WA150PZ-5 – VEAM420100...

  • Page 64: General View Of Controls And Gauges

    (11) Monitor panel mode selector switch 1 (27) Radio (12) Monitor panel mode selector switch 2 (28) Room lamp switch (13) Cigarette lighter (29) Quick coupler switch (option) (14) Directional selector switch (30) Auxiling control lever (option) WA150PZ-5 – VEAM420100...
  • Page 65 (20) Engine oil pressure caution lamp (9) Turn signal pilot lamp (21) Central warning lamp (10) Head lamp high beam pilot lamp (22) Meter display pilot lamp (11) Fuel gauge (23) Character display (12) Parking brake pilot lamp WA150PZ-5 – VEAM420100...

  • Page 66: Explanation Of Components

    3.2.1 Machine monitor GK032089 A: Character display E: Pilot display B: Emergency stop items F: Meter display C: Caution items G: Central warning lamp D: Inspection and maintenance items WA150PZ-5 – VEAM420100...

  • Page 67: Monitor System

    After 3 seconds all lamps except lamps (2) go out. Lamps (2) go out after the engine starts. If any lamps do not light up there is probably a failure or a disconnection, so please ask your KOMATSU distributor to carry out inspection. GK032010...

  • Page 68: Types Of Warning

    This display portion (1) lights up if any emergency stop item, caution item, or mistaken operation of any switch or lever occurs. At the same time, the alarm buzzer sounds. Check the content of the display and carry out the specified action for the item. GK032010 WA150PZ-5 – VEAM420100...

  • Page 69: Character Display Portion

    Information regarding the failure of the machine or mainte- nance is displayed on the character display when the start- ing switch is at the ON position, check the display to confirm that there is no abnormality before starting to travel. WA150PZ-5 – VEAM420100...
  • Page 70 E03: When this code is displayed, stop the machine immedi- ately, check the failure code, and contact your KOMATSU dis- E 0 3 C A L L tributor for repairs.
  • Page 71 O I L O V E R H E If an action code is still displayed after doing this, check the fail- ure code and contact your KOMATSU distributor for repairs. REMARK “E02“ is displayed on the character display, and then the condition of the machine related to the overheating or over- run is displayed in turn with “E02“...
  • Page 72 If an action code is displayed on the character display, check the failure code according to the failure code display method given below. When contacting your KOMATSU distributor to request repairs, please inform your distributor of the failure code. Method of displaying failure code 1.
  • Page 73 ENG OIL Engine oil filter ENG FILT Fuel filter FUEL FILT Transfer oil 1000 TRANSF OIL HST oil filter 1000 HST FILT Hydraulic filter 2000 HYD FILT Hydraulic oil 2000 HYD OIL Axle oil 2000 AXLE OIL 3-12 WA150PZ-5 – VEAM420100...
  • Page 74 "Replace HST oil filter element (4-58)" Hydraulic filter "Change oil in hydraulic tank, replace hydraulic filter element (4-60)" Hydraulic oil "Change oil in hydraulic tank, replace hydraulic filter element (4-60)" Axle oil "Change axle oil (4-63)" 3-13 WA150PZ-5 – VEAM420100...

  • Page 75: Emergency Stop Item

    GK032089 (1) Brake oil pressure caution lamp (3) Battery charge circuit caution lamp (2) Engine oil pressure caution lamp (4) Steering oil pressure caution lamp 3-14 WA150PZ-5 – VEAM420100...
  • Page 76 At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop the machine immediately in a safe place, then stop the engine and carry out inspection. 3-15 WA150PZ-5 – VEAM420100...
  • Page 77 At the same time, “E03 CALL“ and “CHECK RIGHT NOW“ are displayed on the character display in turn, so stop the machine immediately in a safe place, then stop the engine and carry out inspection. 3-16 WA150PZ-5 – VEAM420100...

  • Page 78: Caution Items

    If these lamps light up, stop operations quickly and carry out the following action. GK032089 (1) Axle oil temperature caution lamp (4) Engine cooling water temperature caution lamp (2) Parking brake reminder caution lamp (5) Fuel level caution lamp (3) HST oil temperature caution lamp 3-17 WA150PZ-5 – VEAM420100...
  • Page 79 At the same time, “E02“ and “HST OVERHEAT“ are displayed on the character display in turn, so stop the machine and run the engine at a midrange speed under no load until the lamp goes out. 3-18 WA150PZ-5 – VEAM420100...

  • Page 80: Warning/Limit Functions For Travel Speed

    P R O T E C T If the alarm buzzer sounds, ease the accelerator pedal back and reduce speed. Travel speed limit function The travel speed is automatically controlled so that it does not go above approx. 44 km/h (27.3 MPH). 3-19 WA150PZ-5 – VEAM420100...

  • Page 81: Inspection And Maintenance Item

    Inspection and maintenance item CAUTION If these lamps light up, stop operations quickly and carry out the following action. GK032089 (1) Radiator coolant level caution lamp (3) HST oil filter clogging caution lamp (2) Maintenance caution lamp 3-20 WA150PZ-5 – VEAM420100...
  • Page 82 At the same time, “E01“ and “HST OIL FILTER“ are displayed on the character display in turn, so replace the oil filter. REMARK The lamp may light up in cold temperatures, but it should go out when the HST oil temperature gauge indicator enters the white range. 3-21 WA150PZ-5 – VEAM420100...

  • Page 83: Pilot Display Portion

    (5) Pilot lamp for speed range selector switch position (2) Preheating pilot lamp (6) Turn signal pilot lamp (3) Emergency steering pilot lamp (7) Head lamp high beam pilot lamp (4) Directional lever position pilot lamp 3-22 WA150PZ-5 – VEAM420100...
  • Page 84 F lights up: FORWARD N lights up: NEUTRAL R lights up: REVERSE REMARK GK032109 In the following conditions, it indicates the position of the directional selector switch. Directional selector actuation switch: ON position Directional lever: Neutral position 3-23 WA150PZ-5 – VEAM420100...
  • Page 85 If there is a disconnection in the turn signal lamp, the flash- ing interval becomes shorter. GK032111 7. Head lamp high beam pilot lamp This lamp (7) lights up when the head lamp is at high beam. GK032112 3-24 WA150PZ-5 – VEAM420100...

  • Page 86: Meter Display Portion

    Operation 3.2 Explanation of components Meter display portion GK032089 (1) HST oil temperature gauge (4) Speedometer (2) Engine cooling water temperature gauge (5) Meter display pilot lamp (3) Fuel gauge 3-25 WA150PZ-5 – VEAM420100...
  • Page 87 If it lights up, check the fuel level and add fuel. GK032115 4. Speedometer This meter (4) indicates the travel speed of the machine. GK032116 5. Meter display pilot lamp This lamp (5) displays the unit for the travel speed. GK032117 3-26 WA150PZ-5 – VEAM420100...

  • Page 88: Other Functions Of Machine Monitor

    1. 7. When resetting the replacement time for another item, carry out the procedure from Step 4. After completing, press ( ) of monitor panel mode selector switch 1 twice or turn the starting switch OFF. 3-27 WA150PZ-5 – VEAM420100...
  • Page 89 1. This confirms the language. To abort, press the ( ) of monitor mode selector switch 1. 6. When completing the operation, press ( ) of monitor panel mode selector switch 1 twice or turn the starting switch OFF. 3-28 WA150PZ-5 – VEAM420100...
  • Page 90 5. Press the ( ) of monitor mode selector switch 1. The HST selection is confirmed and the screen returns to the previous screen. 6. When completing the operation, press ( ) of monitor panel mode selector switch 1 twice or turn the starting switch OFF. 3-29 WA150PZ-5 – VEAM420100...

  • Page 91: Switches

    (7) E.C.S.S. switch (option) (17) Cigarette lighter (8) Lamp switch, Turn signal lever, Dimmer switch (18) Room lamp switch (9) Horn button (19) Rear heated wire glass switch (10) Hazard lamp switch (20) Quick coupler switch (option) 3-30 WA150PZ-5 – VEAM420100...
  • Page 92 The conditions for use may differ according to the condition of the road surface. Installed tire Max. speed [km/h (MPH)] Standard tire 5.0 - 13.6 (3.1 - 8.5) GK032121 (17.5 R25 XHA L3) 3-31 WA150PZ-5 – VEAM420100...
  • Page 93 2nd to 4th gears. GK032124 Position (ON): ON Position (OFF): OFF Reduction REMARK Traction control is effective in preventing the tires from slip- ping during light-duty operations. Travelling speed GK032125 3-32 WA150PZ-5 – VEAM420100...
  • Page 94 The E.C.S.S. is not actuated. REMARK The travel damper is automatically actuated when the travel speed becomes more than 5 km/h (3.1 MPH); when the GK032123 travel speed goes below 4 km/h (2.5 MPH) it is automatically disengaged. 3-33 WA150PZ-5 – VEAM420100...
  • Page 95 If it does not return, return it manually. Dimmer switch This switch (8) is used to switch the head lamps between high beam and low beam. Position (a): Low beam Position (b): High beam GK032128 3-34 WA150PZ-5 – VEAM420100...
  • Page 96 Working lamp and pilot lamp (A) light up Position (b): Working lamp goes out REMARK If the lamp switch is not at the ON position for the side clearance lamp or head lamp, the working lamp will not light GK032123 3-35 WA150PZ-5 – VEAM420100...
  • Page 97 Press here to go on to the next screen, or to move the cursor forward, or to increase the number when entering numerals Position (<): Press here to go back to the previous screen, or to move the cursor back, or to reduce the number when entering numerals 3-36 WA150PZ-5 – VEAM420100...
  • Page 98 17. Cigarette lighter This is used to light cigarettes. After cigarette lighter (17) is pushed in, it will return to its original position after a few seconds, then you may pull it out and light a cigarette. GK032135 3-37 WA150PZ-5 – VEAM420100...
  • Page 99 Position (a): quick coupler is locked Position (b): press here to unlock the quick coupler When the switch is released, it automatically returns to its origi- nal position. 3-38 WA150PZ-5 – VEAM420100...

  • Page 100: Control Levers, Pedals

    3.2 Explanation of components 3.2.3 Control levers, pedals GK015106 (1) Directional lever (5) Brake pedal (2) Safety lock lever (for work equipment lever) (6) Accelerator pedal (3) Work equipment lever (7) Parking brake lever (4) Auxiliary control lever (option) 3-39 WA150PZ-5 – VEAM420100...
  • Page 101 Push the safety lock lever down to lock it. REMARK If the safety lock lever is at the LOCK position, the work equipment will not move even when the work equipment control lever is operated. Lock GK032140 3-40 WA150PZ-5 – VEAM420100...
  • Page 102 (When multi-purpose bucket is installed) This lever (4) operates the clam on the multi-purpose bucket. Position (a): Clam closes Position (b): HOLD The clam stops and remains in the same position. GK015108 Position (c): Clam opens 3-41 WA150PZ-5 – VEAM420100...
  • Page 103 GK032145 6. Accelerator pedal This pedal (5) controls the engine speed and output. The engine speed can be freely controlled between low idling and full speed. GK032146 3-42 WA150PZ-5 – VEAM420100...
  • Page 104 If the parking brake has been used as an emergency brake when traveling at high speed (near the maximum speed), contact your KOMATSU distributor to have the parking brake checked for any abnormality. This lever (6) operates the parking brake.

  • Page 105: Steering Tilt Lock Lever

    Lock To lock the cap Open 1. Turn the cap until tight, then insert the key into the key slot. GK032150 2. Turn the key counterclockwise and take the key out. 3-44 WA150PZ-5 – VEAM420100...

  • Page 106: Safety Bar

    This is a device used to lock the front and rear frames during maintenance or when transporting the machine. It prevents the front and rear frames from articulating. Free Lock GK032152 3-45 WA150PZ-5 – VEAM420100...

  • Page 107: Towing Pin

    In addition, form the rubber ring into a figure of 8 as shown in the diagram on the right, and secure in position. GK032155 3.2.9 Cab door inner lock (Right door) Press cab door inner lock to lock the door. Position (a): Lock Position (b): Release GK032156 3-46 WA150PZ-5 – VEAM420100...

  • Page 108: Cab Door Open Lock

    Grip lock cancel knob (1) to release the lock, and move it down to a lower lock position. Release lock cancel knob (1). There is 1 point for lock position (2). GK032159 3-47 WA150PZ-5 – VEAM420100...

  • Page 109: Fuse

    Auxiliary pwe (Battery +24V) Head Lamp L.H. Head Lamp R.H. (10) Turn signal lamp (11) Back lamp, Stop lamp (12) HST control B (13) Work equipment positioner (14) Wiper Front of machine (15) Radio B GK032161 3-48 WA150PZ-5 – VEAM420100...

  • Page 110: Slow Blow Fuse

    For details of the method of replacing the slow blow fuse, see "Replace slow blow fuse (4-37)" GK015033 Slow blow fuse (A) 80A: Chassis power source (B) 120A: Engine preheating power source (C) 30A: Battery power (starting switch, hazard) (D) 30A: Fuel solenoid power source 3-49 WA150PZ-5 – VEAM420100...

  • Page 111: Power Outlet

    Use this box to keep small items and tools. REMARK The storage box is not waterproof. When washing the floor, remove all documents and other items that may be dam- aged by water, and keep them in a waterproof bag. GK032165 3-50 WA150PZ-5 – VEAM420100...

  • Page 112: Air Conditioner

    When the fan switch is turned ON and the air conditioner switch is pressed, the indicator lamp above the switch lights up. When the switch is pressed again, the switch is turned OFF and the indicator lamp goes out. GK032168 3-51 WA150PZ-5 – VEAM420100...
  • Page 113 If the air conditioner is used at the FRESH position, the inside of the cab will be pressurized and this will prevent the entry of dust. The higher the position of the fan switch, the more effective the 3-52 WA150PZ-5 – VEAM420100...

  • Page 114: Method Of Operation

    If the temperature inside the cab is low, the air conditioner may not work. In such cases, use the recirculated air to heat up the inside of the cab, then turn the air conditioner switch on to run the air conditioner. 3-53 WA150PZ-5 – VEAM420100...

  • Page 115: Precautions When Using

    (1) is angled with the wiper blade (2) locked to the arm (the bottom of the blade is caught on the arm), abnormal force is brought to bear on the mounting bracket and the bracket may break. GK032173 3-54 WA150PZ-5 – VEAM420100...

  • Page 116: Operation

    Leakage of fuel or oil will cause the machine to catch fire. Check carefully, and be sure to repair any abnormalities, or please contact your KOMATSU distributor. If the machine is at an angle, reposition it level before checking.
  • Page 117 If the belt is damaged or fluff is starting to form, or if there is any damage or deformation of the seat belt holders, replace the seat belt. GK015036 13. Clean cab window. Clean the cab window to ensure good visibility when operat- ing the machine. 3-56 WA150PZ-5 – VEAM420100...
  • Page 118 Deteriorated, deformed or abnormally damaged tires which do not seem usable 15. Inspect rims. WARNING Check the rims (wheels) and rings for deformation, corro- sion and cracks. In particular, check the side rings, lock rings and rim flanges thoroughly. 3-57 WA150PZ-5 – VEAM420100...

  • Page 119: Check Before Starting

    When checking the oil level after the engine has been oper- ated, wait for at least 15 minutes after stopping the engine before checking. If the machine is at an angle, make it horizontal before GK032178 checking. GK015002 3-58 WA150PZ-5 – VEAM420100...
  • Page 120 For details of the method of cleaning the element, see “CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT (4-20)“. After checking, cleaning, and replacing, press the knob of dust indicator (1) to return the red piston to its original position. GK015004 GK020011 3-59 WA150PZ-5 – VEAM420100...
  • Page 121 Check for damage or wear to the tires and the rims. Check for loose wheel hub nuts (bolts). The appropriate inflation pressure differs according to the type of work, see "Handling the tires (3-100)" 3-60 WA150PZ-5 – VEAM420100...
  • Page 122 If fuses are frequently blown or if there are traces of short- circuiting on the electrical wiring, promptly ask your KOMATSU distributor to locate the cause and make the repair. Keep the top surface of the battery clean and check the breather hole in the battery cap.
  • Page 123 For details of the method for opening and closing the cap, START see "Method of opening and closing cap with lock (3-44)" GK032182 3. After adding fuel, tighten the cap securely. Fuel tank capacity: 133 liters (35.14 US gal) GK032010 GK032183 3-62 WA150PZ-5 – VEAM420100...

  • Page 124: Adjustment

    KOMATSU distributor for adjustment. Check brake pedal Drive the machine forward and check the effect of the brakes. If there is any abnormality in the actuation of the brakes, please contact your KOMATSU distributor to have the brakes adjusted. Adjustment Seat adjustment WARNING...

  • Page 125: Safety Belt

    The belt cannot be pulled out unless it is completely wound GK015036 Taking off the safety belt Press the orange button to release the lock of the safety belt and allow the belt to wind up. 3-64 WA150PZ-5 – VEAM420100...
  • Page 126 Sit in the operator's seat and adjust the rear view mirror so that you can see properly to the rear. Be careful to have free visibility to the mirrors. Put no obstacles in the view area. GK015005 3-65 WA150PZ-5 – VEAM420100...

  • Page 127: Operations And Checks Before Starting Engine

    When directional selector switch actuation switch (3) is ON, the engine will not start if directional lever (2) and direc- tional selector switch (4) are not both at the N position. GK032190 GK032329 3-66 WA150PZ-5 – VEAM420100...
  • Page 128 3 seconds, and the alarm buzzer sounds for approx. 1 sec. If any monitor does not light up, there is probably a failure or START disconnection, so contact your KOMATSU distributor for inspection. GK032182 3-67...

  • Page 129: Starting Engine

    (4) that is connected to the ignition key (1) with a chain must be resting on the plastic panelling under the arm rest when starting the ignition. If this is not the case, the engine will not start. 3-68 WA150PZ-5 – VEAM420100...
  • Page 130 (1) to the START position to start the engine. START GK032192 4. After the engine starts, release the key in starting switch (1). The key will automatically return to the ON position. START GK032193 3-69 WA150PZ-5 – VEAM420100...
  • Page 131 Engine water Preheating time temperature [°C The table shown below gives a guide to preheating time. (sec) (°F)] below -30 (-22) -25 (-13) -20 (-4) -15 (5) -10 (14) -5 (23) 0 (32) above 0 (32) 3-70 WA150PZ-5 – VEAM420100...
  • Page 132 10. Keep stepping on accelerator pedal (3) until the engine is fully running. START GK032193 REMARK Keep the accelerator pedal depressed after the engine starts up, until engine warming-up run is finished. Do not step on the pedal to the full stroke. GK032191 3-71 WA150PZ-5 – VEAM420100...
  • Page 133 Breaking-in the machine CAUTION Your KOMATSU machine has been thoroughly adjusted and tested before shipment. However, operating the machine under severe conditions at the beginning can adversely affect the performance and shorten the machine life.
  • Page 134 The relief time at the tilt position (e) should be a maximum of 10 seconds. With this operation, the oil will reach the relief pressure and this will warm up the hydraulic oil more quickly. GK015140 3-73 WA150PZ-5 – VEAM420100...
  • Page 135 1. Run the engine at low idling for about 5 minutes to cool down gradually. 2. Turn the key of starting switch (1) to the OFF position to stop the engine. 3. Remove the key from starting switch (1). START GK032196 3-74 WA150PZ-5 – VEAM420100...
  • Page 136 1. Check that caution lamp (1) is not lighted up. GK032010 GK015139 2. Check that the work equipment control lever (3) is at the HOLD position, then set safety lock lever (2) to the FREE Free position. Lock GK032194 3-75 WA150PZ-5 – VEAM420100...
  • Page 137 Position (b): REVERSE Check that the backup alarm sounds when the directional lever is set to REVERSE. If the backup alarm does not sound, please contact your KOMATSU distributor for repairs. GK032139 7. Release brake pedal (4), then depress accelerator pedal (8) to move the machine.
  • Page 138 Position (a): FORWARD Position N: NEUTRAL Position (b): REVERSE Check that the backup alarm sounds when the directional lever GK032139 is set to REVERSE. If the backup alarm does not sound, please contact your KOMATSU distributor for repairs. 3-77 WA150PZ-5 – VEAM420100...
  • Page 139 1. Place the directional lever (1) at the N position. GK032190 2. Place the directional selector switch (2) at the N position. GK032329 3. Place the directional selector switch actuation switch (3) at the ON position (a). GK032123 3-78 WA150PZ-5 – VEAM420100...
  • Page 140 (2). Priority is given to the operation of the directional lever. When using directional selector switch (2) again, set direc- tional lever (1) and directional selector switch (2) to the N position. 3-79 WA150PZ-5 – VEAM420100...
  • Page 141 GK032198 2. Place directional lever (3) in N (neutral) position. GK032190 3. Pull parking brake lever (4) and set it to the LOCK position to apply the parking brake. Lock Free GK032147 3-80 WA150PZ-5 – VEAM420100...
  • Page 142 Check that there is a play of 50 to 100 mm (2.0 to 3.9 in) in the steering wheel. Check also that the steering works properly. If any abnormality is found, please contact your KOMATSU distributor for inspection. 3-81 WA150PZ-5 – VEAM420100...
  • Page 143 (red) (3) may light up for a moment, but if the lamp goes out again soon, there is no problem. When the emergency steering system detects that the oil pres- sure in the steering circuit has been restored, the actuation of the emergency steering system is stopped. 3-82 WA150PZ-5 – VEAM420100...
  • Page 144 HOLD position. Raise Position (b): HOLD The lift arm is kept in the same position. Position (c): LOWER Position (d): FLOAT Lower The lift arm moves freely under external force. GK032142 3-83 WA150PZ-5 – VEAM420100...
  • Page 145 TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, and the lever is returned to the HOLD position. Position (b): HOLD GK015142 The bucket is kept in the same position. Position (f): DUMP Tilt Dump GK032144 3-84 WA150PZ-5 – VEAM420100...
  • Page 146 350mm. Dump the quick coupler so that it is nearly in a horizontal position. Then move the machine so that the coupler is parallel with and at the center of the attachment to be installed. GK015111 3-85 WA150PZ-5 – VEAM420100...
  • Page 147 8. Check that the lock pin indicators on left and right side have visuable has been inserted. view from rear multi coupler GK015114 9. The protrusion (X) on left and right side should be 30mm. GK015115 3-86 WA150PZ-5 – VEAM420100...
  • Page 148 Precautions for use GK015116 Check that the lock pin has been inserted securely, then operate the lift arm and bucket control levers. Precautions when removing the attachment Before removing the attachment, disconnect the hydraulic cou- pling. 3-87 WA150PZ-5 – VEAM420100...
  • Page 149 Try to keep the load in the center of the bucket; if the load is on one side of the bucket, the load will be unbalanced. GK020022 3-88 WA150PZ-5 – VEAM420100...
  • Page 150 3. Operate the work equipment control lever slightly up and down to reduce the resistance when driving the machine for- ward. When digging with the bucket, avoid imposing the digging force onto only one side of the bucket. GK032209 3-89 WA150PZ-5 – VEAM420100...
  • Page 151 Pushing operation CAUTION Never set the bucket to the DUMP position when carrying out pushing operation. When carrying out pushing operations, set the bottom of the bucket parallel to the ground surface. 3-90 WA150PZ-5 – VEAM420100...
  • Page 152 If the E.C.S.S. system (option) is switched on, the work equipment may move. NOTE If the tires slip, the tire life will be reduced, so do not allow the tires to slip during operation. Avoid excessive bucket shaking. 3-91 WA150PZ-5 – VEAM420100...
  • Page 153 Precautions when piling up loads When forming products into a pile, be careful not to let the rear counterweight come into contact with the ground. Do not set the bucket to the DUMP position when piling-up loads. 3-92 WA150PZ-5 – VEAM420100...
  • Page 154 NOTE If the parking brake has been used as an emergency brake, contact your KOMATSU distributor to have the parking brake checked for any abnormality. Precautions when driving up or down slopes Lower the center of gravity when turning When turning on slopes, lower the work equipment to lower the center of gravity before turning.
  • Page 155 The most suitable tire pressure, travel speed, or tire type dif- fer according to the condition of the travel surface. Contact your KOMATSU distributor or tire dealer for information. When traveling on a paved road surface using normal tires (16.9-24-10 PR), the guideline for the appropriate tire infla- tion pressure and travel speed is as follows.
  • Page 156 Tightening torque: 14.7 to 19.6 N·m (1.5 to 2.0 kgf·m, 10.8 to 14.5 lbft) 4. After adjusting, start the engine and operate the lift arm con- trol lever. Check that the lever is automatically returned to HOLD when the bucket reaches the desired height. GK015117 3-95 WA150PZ-5 – VEAM420100...
  • Page 157 Bucket level indicator (A) and (B) at the top rear of the bucket are the level indicators, so the bucket angle can be checked during operations. (A): Parallel with cutting edge (B): 90 degrees to cutting edge GK032219 3-96 WA150PZ-5 – VEAM420100...
  • Page 158 Apply the parking GK015139 brake only after the machine has stopped. 1. Release accelerator pedal (1), then depress brake pedal (2) to stop the machine. GK032220 2. Place directional lever (3) in N (neutral) position. GK032190 3-97 WA150PZ-5 – VEAM420100...
  • Page 159 4. Operate work equipment control lever (5) to lower the bucket to the ground. GK032064 5. Check that the work equipment control lever (5) is at the HOLD position, then set safety lock lever (6) to the LOCK Free position. Lock GK032035 3-98 WA150PZ-5 – VEAM420100...
  • Page 160 Always lock the following parts. (1) Fuel filler cap (2) Rear grill (3) Engine side cover (2 places) (4) Cab door (2 places) REMARK GK032221 The starting switch key is used also for locks (1), (2), (3) and (4). GK032222 3-99 WA150PZ-5 – VEAM420100...
  • Page 161 Deformation or damage which makes the tyre unsuit- Side wall able for use. Bead GK032223 Please contact your KOMATSU distributor when replacing the tires. It is dangerous to jack up the machine without taking due care. Tire pressure Measure the tire pressure before starting operations, when the tires are cool.
  • Page 162 If this is not done, the tires will be damaged, so contact your KOMATSU dis- tributor or tire dealer when selecting tires.
  • Page 163 Always drive slowly over this point. When loading or unloading, always use ramps or a platform and carry out the operation as follows. 3-102 WA150PZ-5 – VEAM420100...
  • Page 164 3. Pull parking brake lever and set it to the LOCK position to apply the parking brake. Lock 4. Turn the starting switch to the OFF position to stop the engine, and pull out the starting switch key. Free GK032147 3-103 WA150PZ-5 – VEAM420100...
  • Page 165 To avoid damage to the machine, only fasten the eye hooks of the stay ropes at the marked attachment points on the machine as shown in the diagram on the right.. 7. Always retract the car radio antenna fully (if equipped). GK043041 3-104 WA150PZ-5 – VEAM420100...
  • Page 166 5. Check that the work equipment control lever is at the HOLD position, then set the safety lock lever to the FREE position. Free 6. Determine the direction of the ramps, then drive the machine slowly down the ramps to unload the machine. Lock GK032194 3-105 WA150PZ-5 – VEAM420100...
  • Page 167 The lifting procedure applies to machines with standard specifications. The method of lifting differs according to the attachments and options actually installed. In such cases, please con- tact your KOMATSU distributor for information. For details of the weight, see "Weight table (3-107)". 3-106 WA150PZ-5 – VEAM420100...
  • Page 168 There is a serious danger that the machine will lose its balance. GK032227 Weight table Center of gravity Machine weight Front wheel load Rear wheel load (from front axle) WA150PZ-5 8,090 kg 6,935 kg 3,310 kg 840 mm At travel posture (With 1.5 m3 bucket, B.O.C.) 3-107 WA150PZ-5 – VEAM420100...
  • Page 169 For machines equipped with a rear full fender, remove the rear full fender before carrying out the operation. 5. When the machine leaves the ground, stop for a moment and wait for the machine to stabilize, then continue the lifting operation slowly. GK032228 3-108 WA150PZ-5 – VEAM420100...
  • Page 170 When changing the coolant or when handling coolant containing antifreeze that has been drained when repair- ing the radiator, please contact your KOMATSU distribu- tor. Antifreeze is toxic, so do not let it flow into drainage ditches or spray it on to the ground surface.
  • Page 171 If the electrolyte level is low, add distilled water in the morn- ing before beginning work. Do not add the water after the day's work so as to prevent fluid in the battery from freezing in the night. 3-110 WA150PZ-5 – VEAM420100...
  • Page 172 10 minutes to warm up the oil.) NOTE Unlock the safety bar. Operate the steering wheel a little and stop in that position. Then, confirm that the machine is steered by an angle equivalent to the turning angle of the steering wheel. 3-111 WA150PZ-5 – VEAM420100...
  • Page 173 KOMATSU distributor. When using the machine after long-term storage, do as follows before using it. Wipe off the grease from the hydraulic cylinder rods. Add oil and grease to all lubrication points. 3-112 WA150PZ-5 – VEAM420100...
  • Page 174 When a machine is stored for a long period, moisture in the air will get into the oil. Check the oil for presence of water before and after starting the engine. If there is water in the oil, change the oil. 3-113 WA150PZ-5 – VEAM420100...
  • Page 175 The machine must not be towed for long distances. For details of the procedure for towing a machine when it has broken down, please contact your KOMATSU dis- tributor. This machine must not be towed except in emergencies. When towing the machine, take the following precautions.
  • Page 176 The operator should sit on the machine being towed and operate the steering in the direction that the machine is towed. 3-115 WA150PZ-5 – VEAM420100...
  • Page 177 The normal gear shifting operation is carried out by electric sig- nals. If there should be a failure in the electrical system and the machine does not move, please contact your Komatsu distribu- tor to have the machine moved. NOTE Always request your Komatsu distributor to carry out the emergency travel operation.
  • Page 178 3. When installing the battery, connect the ground cable last. Insert the hole of the terminal on the battery and tighten the nut. Tightening torque: 5.9 to 9.8 N·m (0.6 to 1.0 kgf·m, 4.3 to 7.2 lbft) 3-117 WA150PZ-5 – VEAM420100...
  • Page 179 If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power source. There is a hazard that this will ignite the battery electrolyte and cause the battery to explode. 3-118 WA150PZ-5 – VEAM420100...
  • Page 180 Make sure that the cables and clips are firmly con- nected. Check that the safety lock levers and parking brake levers of both machines are in the LOCK position. Check that each lever is in the NEUTRAL position. 3-119 WA150PZ-5 – VEAM420100...
  • Page 181 GK032232 3. Remove one clip of booster cable (A) from the positive (+) terminal of the normal machine. 4. Remove the other clip of booster cable (A) from the positive (+) terminal of the problem machine. 3-120 WA150PZ-5 – VEAM420100...
  • Page 182 Operation 3.7 Troubleshooting 3.7.4 Other trouble Electrical system ): Always contact your KOMATSU distributor when deal- ing with these items. In cases of abnormalities or causes which are not listed below, please contact your KOMATSU distributor for repairs. Problem Main causes...
  • Page 183 3.7 Troubleshooting Operation Chassis ): Always contact your KOMATSU distributor when deal- ing with these items. In cases of abnormalities or causes which are not listed below, please contact your KOMATSU distributor for repairs. Problem Main causes Remedy Release parking brake...
  • Page 184 VICE for details of adding oil Lack of oil pressure in air See EVERY 2000 HOURS SER- VICE for details of bleeding air Add oil to specified level. Irregular movement of cylinder Lack of oil See EVERY 100 HOURS SER- VICE 3-123 WA150PZ-5 – VEAM420100...
  • Page 185 3.7 Troubleshooting Operation Engine ): Always contact your KOMATSU distributor when deal- ing with these items. In cases of abnormalities or causes which are not listed below, please contact your KOMATSU distributor for repairs. Problem Main causes Remedy Add oil to specified level.
  • Page 186 Maintenance 4. Maintenance WARNING Please read and make sure that you understand the SAFETY section before reading this section. WA150PZ-5 – VEAM420100...
  • Page 187 Check the service meter reading every day to see if the time has come for any necessary maintenance to be carried out. KOMATSU genuine replacement parts: Use KOMATSU genuine parts specified in the Parts Book as replacement parts. KOMATSU genuine oils: Use KOMATSU genuine oils and grease.
  • Page 188 If the hydraulic oil equipments have been repaired or replaced and if the hydraulic hoses, pipes, etc. have been disconnected, it is necessary to bleed air in the circuit. See "Change oil in hydraulic tank, replace hydraulic filter element (4-60)". WA150PZ-5 – VEAM420100...
  • Page 189 (2-31)" in the section on safety for checking when the engine is running. Pay attention to safety. Check if the inspected and maintenance area is operat- ing normally Increase the engine speed to check for fuel and oil leak- age. WA150PZ-5 – VEAM420100...
  • Page 190 4.2 Outlines of service Maintenance Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Outlines of service 4.2.1 Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Oil is used in the engine and hydraulic equipment under extremely severe conditions (high temperature, high pres- sure), and deteriorates with use.
  • Page 191 4.2 Outlines of service Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Maintenance 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.
  • Page 192 4.2 Outlines of service Maintenance Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Carrying out KOWA (KOMATSU Oil Wear Analysis) The oil clinic samples the oil periodically and analyzes it. This is a preventive maintenance service, which provides early discov- ery of abnormal parts and wear of the drive parts of the machine.
  • Page 193 4.2 Outlines of service Handling oil, fuel, coolant, grease and carrying out KOWA (KOMATSU Oil Wear Analysis) Maintenance Oil sampling Sampling interval 250 hours: Engine 500 hours: Other components Precautions when sampling Make sure that the oil is well mixed before sampling.
  • Page 194 Biodegradable hydraulic oil and lubricants The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic esters - for KOMATSU machines is permitted. For information on the products cleared for use and best suited for your application contact our authorized service workshops.
  • Page 195 KOMATSU genuine parts. As a result of our continuous efforts to improve product quality, the part number may change, so inform your KOMATSU distrib- utor of the machine serial number and check the latest part num- ber when ordering parts.
  • Page 196 250-hour operation and thereafter at change period as shown in this chart. 5. Refer to operation and maintenance manual for details. Binding is the maintenance schedule chart in operation and maintenance manual, see "Maintenance schedule chart (4-20)". 4-11 WA150PZ-5 – VEAM420100...
  • Page 197 Air conditioner Coolant R134a (CFC-free) 860 g * Work filling ** Top-up quantity *** North American manufacted DONAX TD 20W-40 must not be used. **** North American manufacted TORQUE FLUID 56 must not be used. 4-12 WA150PZ-5 – VEAM420100...
  • Page 198 Maintenance Proper selection of fuel, coolant and lubricants (1): Please use SAE10W30 for the oil in the hydraulic system. If KOMATSU genuine oil is not available, select the oil from the table below. Supplier Engine oil (The 15W40 oil marked * is CE.)
  • Page 199 (SAE10W-30, 15W-40), but be sure to add single grade oil that matches the temperature range in the table. We recommend KOMATSU genuine oil which has been spe- cifically formulated and approved for use in engine and hydraulic work equipment applications.
  • Page 200 Super duty motor oil Multi-purpose gear Gulfcrown EP2 Antifeeze and GULF *Super duty plus lubricant Gulfcrown EP special coolant Delvac 1300 Mobilux EP2 Mobilube GX MOBIL *Delvac super Mobilgease 77 – Mobilube HD 10W-30, 15W-40 Mobilgrease special 4-15 WA150PZ-5 – VEAM420100...
  • Page 201 Starplex 2 antifreeze coolant Total EP Rubia S TOTAL Total Transmission Multis EP2 Antigal/antifreeze *Rubia X UNION *Guardol MP gear lube LS Unoba EP – *Turbostar Multigear VEEDOL *Diesel star Multigear B Antifreeze – Multigear C 4-16 WA150PZ-5 – VEAM420100...
  • Page 202 Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. If it is necessary to replace any nut or bolt, always use a KOMATSU genuine part of the same size as the part that was replaced. Tightening torque...
  • Page 203 84 - 132 8.5 - 13.5 61.5 - 97.6 1 -14UNS 16.0 115.7 128 - 186 13.0 - 19.0 94.0 - 137.4 13/16 -12UN 22.0 159.1 177 - 245 18.0 - 25.0 130.2 - 180.8 GK032237 4-18 WA150PZ-5 – VEAM420100...
  • Page 204 When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your KOMATSU distributor to replace the critical parts. Replacement Safety critical parts for periodic replacement Q'ty...
  • Page 205 Lubricate rear axle pivot pin 4-41 Clean element in air conditioner fresh air filter 4-41 Check oil level in hydraulic tank, add oil 4-42 Lubricating 4-43 4.8.6 Every 250 hours service 4-44 Check battery electrolyte level 4-44 4-20 WA150PZ-5 – VEAM420100...
  • Page 206 Check engine valve clearance, adjust 4-64 Check brake disc wear 4-65 Clean and check turbocharger 4-66 Check accumulator gas pressure 4-66 Check vibration damper 4-66 4.8.10 Every 4000 hours service 4-67 Lubricating 4-67 Check water pump 4-67 4-21 WA150PZ-5 – VEAM420100...
  • Page 207 In addition, dust sticking to the element falls into the inner ele- ment each time the element is cleaned. GK015004 4-22 WA150PZ-5 – VEAM420100...
  • Page 208 Replace the inner element at the same GK032241 time. 7. Replace both inner and outer elements when the dust indi- cator red piston appears soon after installing the cleaned outer element even though it has not been cleaned 6 times. 4-23 WA150PZ-5 – VEAM420100...
  • Page 209 1. Open the engine side cover on the right side of the machine. 2. Remove three clips (2), then remove cover (3). GK015004 3. Remove outer element (4). Do not remove inner element (5) at this time, however. GK032239 4-24 WA150PZ-5 – VEAM420100...
  • Page 210 The intake screen and the dust extractor gap (at the bottom cir- cumference of the pre-cleaner) must always be kept clean. The pre-cleaner should be unscrewed and its condition checked from time to time depending on use. If necessary, blow out the pre-cleaner from the inside. GK032243 4-25 WA150PZ-5 – VEAM420100...
  • Page 211 Super Coolant (AF-ACL) has an anti-corrosion effect as well as an antifreeze effect. The ratio of antifreeze to water depends on the ambient temper- ature, but to obtain the corrosion resistance effect, a minimum ratio of 30% by volume is necessary. 4-26 WA150PZ-5 – VEAM420100...
  • Page 212 4.8 Service procedure Maintenance When required In areas where the water is hard, always add KOMATSU genu- ine corrosion resistor agent KI. One packet of corrosion resistor (No. 600-411-1120) agent contains 100g (0.22 lb). The standard density of the mixture should be 7g/liter (0.065 oz/US gal).
  • Page 213 FULL and LOW level. 12. Stop the engine. About 3 minutes later, supply city water up to the water filler, then close radiator cap. GK015004 GK032247 4-28 WA150PZ-5 – VEAM420100...
  • Page 214 5. If the oil is above the H mark, drain the excess engine oil from drain plug (P), and check the oil level again. 6. If the oil level is correct, insert dipstick (G) in the dipstick guide, then tighten the cap. GK015012 4-29 WA150PZ-5 – VEAM420100...
  • Page 215 (P) and check the oil level again. 6. If the oil level is correct, install plug (1). Tightening torque: 93 to 123 N·m (9.5 to 12.5 kgf·m, 68.7 to 90.4 lbft) Oil level range GK032253 4-30 WA150PZ-5 – VEAM420100...
  • Page 216 Remove all mud and dirt from around the rubber cap of the slack adjuster for the brake circuit at the axle with a brush. GK015028 When cleaning the slack adjusters, clean the rubber caps at two places (front and rear). GK015013 4-31 WA150PZ-5 – VEAM420100...
  • Page 217 Check window washing fluid level, add fluid Check the washing fluid levels in washer tank (1). When the fluid has run low, add automotive window washing fluid. Be careful not to let dust get into the fluid. GK015015 4-32 WA150PZ-5 – VEAM420100...
  • Page 218 5. After cleaning, close fan guard (2), apply the lock, then close rear grill (1). Check electrical intake air heater Before the start of the cold season (once a year), contact your Komatsu distributor to have the electrical intake air heater checked for dirt or disconnections. 4-33 WA150PZ-5 – VEAM420100...
  • Page 219 5. Tighten nuts and bolts (1) uniformly so that there is no gap between the bucket and cutting edge. Tightening torque for mounting bolt: 392 to 530 N·m (40 to 54 kgf·m, 289.3 to 390.6 lbft) 6. Tighten the mounting bolts again after operating for several hours. 4-34 WA150PZ-5 – VEAM420100...
  • Page 220 3. Fit new tooth (1) in adapter (3), push in pin (2) partially by hand, then knock it in with a hammer. 4. After operating the machine for a few hours, check that the pin does not come out. GK032260 4-35 WA150PZ-5 – VEAM420100...
  • Page 221 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. 4-36 WA150PZ-5 – VEAM420100...
  • Page 222 5. Using screws (4) and (5), install a new slow blow fuse together with electric wiring 7 and 8 to the slow blow fuse box, then close covers (1), (2), and (3). 6. Install the slow blow fuse box to the chassis. GK032262 4-37 WA150PZ-5 – VEAM420100...
  • Page 223 Select the tires according to the conditions of use and the weight of the attachments of the machine. Since the travel speed indicated on the speedometer varies with the tire size, consult your KOMATSU distributor when using optional tires. Check inflation pressure of tires...
  • Page 224 The proper inflation pressure is shown below. Front wheels Rear wheels Tire size Standard 17.5 R25 XHA L3 NOTE The optimum inflation pressure differs according to the type of work. For details, see "Handling the tires (3-100)". 4-39 WA150PZ-5 – VEAM420100...
  • Page 225 Check brake pedal 4.8.4 Every 50 hours service Drain water, sediment from fuel tank Loosen valve (1) on the left side of the tank so that the sediment and water will be drained together with fuel. GK032263 4-40 WA150PZ-5 – VEAM420100...
  • Page 226 3. Direct dry compressed air (less than 0.69 MPa (7 kgf/cm², 99.4 PSI)) to the element from inside along its folds, then direct it from outside along its folds and again from inside. 4. When installing, fit filter (3) into bracket (2), then install. GK032265 4-41 WA150PZ-5 – VEAM420100...
  • Page 227 Keep lock pin (2) pulled, then turn oil filler cap (F) coun- GK020029 terclockwise and remove it. Refill the specified quantity of oil through oil filler (F). After adding oil, install oil filler cap (F) and cover (1). Proper range GK032267 4-42 WA150PZ-5 – VEAM420100...
  • Page 228 2. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 3. After greasing, wipe off any old grease that was pushed out. GK032064 (1) Bucket pin (2 places) (2) Bucket link pin (2 places) GK015029 GK015030 4-43 WA150PZ-5 – VEAM420100...
  • Page 229 If it is possible to check the electrolyte level from the side of the battery, check as follows. 1. Open the cover of the battery box. There are two battery boxes: One on each side at the rear of the machine. 4-44 WA150PZ-5 – VEAM420100...
  • Page 230 MUM) UPPER LEVEL line. Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your KOMATSU distributor or battery maker. When it is impossible to check electrolyte level from side of...
  • Page 231 Neutralize the removed fluid with baking soda (sodium bicarbonate), then flush it away with a large amount of water or consult your KOMATSU distributor or battery maker. When it is possible to use indicator to check electrolyte...
  • Page 232 GK015021 that the V-belt is not touching the bottom of the V- groove. In case any of the following occurs, ask the KOMATSU distributor in your territory to replace the belts with new ones. The fan belt has elongated, leaving little allowance for adjustment.
  • Page 233 3. Clean with compressed air in the same way as for the fresh air filter. If the filter is extremely dirty, rinse it in water. After rinsing the filter, dry it completely before installing it again. GK015023 4-48 WA150PZ-5 – VEAM420100...
  • Page 234 3. After greasing, wipe off any old grease that was pushed out. GK032064 (1) Dump cylinder pin (2 places) (2) Lift cylinder pin (4 places) (3) Lift arm pivot pin (2 places) (4) Tilt lever pin (1 place) (5) Steering cylinder pin (4 places) GK015031 GK015032 4-49 WA150PZ-5 – VEAM420100...
  • Page 235 4. Loosen drain plug (P) slowly and drain the oil. Be careful not to get oil on yourself. 5. Check the drained oil, and if there are excessive metal parti- cles or foreign material, please contact your KOMATSU dis- GK015001 tributor.
  • Page 236 12. Run the engine at idling for short time, then stop the engine, and check that the oil is between the H and L marks on the dipstick. For details, see "Check oil level in engine oil pan, add oil (3-58)". GK032178 4-51 WA150PZ-5 – VEAM420100...
  • Page 237 If any damage or foreign material is found in the packing, replace the cartridge with a new part, then repeat Steps 4 - 10 to install the filter cartridge. 4-52 WA150PZ-5 – VEAM420100...
  • Page 238 If any damage or foreign material is found in the packing, replace the cartridge with a new part, then repeat steps 4 to 10 to install the filter cartridge. 4-53 WA150PZ-5 – VEAM420100...
  • Page 239 14. After bleeding the air, tighten air bleed plug (5), then push in the knob of priming pump (6) and tighten it. Tightening torque for air bleed plug: 7.8 to 11.8 N·m (0.8 to 1.2 kgf·m, 5.8 to 8.7 lbft) GK015025 4-54 WA150PZ-5 – VEAM420100...
  • Page 240 Lubricating 1. Using a grease pump, pump in grease through the grease fittings marked by the arrows. 2. After greasing, wipe off any old grease that was pushed out. (1) Center hinge pin (2 places) GK032291 4-55 WA150PZ-5 – VEAM420100...
  • Page 241 7. After filling with oil, check that the oil is at the specified level. For details, see "Check oil level in transfer case, add oil (4-29)". 8. Check that there is no oil leakage from the transfer case. GK032288 4-56 WA150PZ-5 – VEAM420100...
  • Page 242 2. Remove the mud and dirt from around the breather (2), then remove breather (2). After removing the breather, take steps to prevent dirt or dust from entering the mount. 3. Soak the breather (2) in washing liquid and wash it. GK032290 4-57 WA150PZ-5 – VEAM420100...
  • Page 243 9. After completing the air bleed operation, install cover (1). Replace the HST filter element if the HST oil filter clogging warn- ing pilot lamp lights up, even if 1000 hours or 1 year has not passed. 4-58 WA150PZ-5 – VEAM420100...
  • Page 244 Please contact your KOMATSU distributor to have the tightening portions checked. Check play of turbocharger rotor Please contact your KOMATSU distributor to have the rotor play checked. Check alternator driving belt tension and replacement Since inspection and replacement of the fan belt require special tools, contact your KOMATSU distributor.
  • Page 245 (3.9 in) before the end of stroke). NOTE If the engine is run immediately at high speed or the cylin- der is operated to the end of its stroke, the air inside the cyl- inder will cause damage to the piston packing. 4-60 WA150PZ-5 – VEAM420100...
  • Page 246 3. Remove element (4). 4. Coat O-ring (5) of the new element with grease, then install. 5. Align cap cover (3) with the grooves in the body, then tighten with bolt (2). 6. Install cover (1). GK032294 4-61 WA150PZ-5 – VEAM420100...
  • Page 247 11. Start the motor and let it run until the brake accumulator is full. Switch off the motor. 12. Check the level of the hydraulic oil. Refill if required. 13. Bleed the hydraulic system and close the hydraulic tank. 14. Screw the cover back on. 4-62 WA150PZ-5 – VEAM420100...
  • Page 248 5. After adding oil, check that the oil is at the specified level. For details, see "Check axle oil level, add oil (4-30)". REMARK For operations where the brake is used frequently, change the axle oil at shorter intervals. 4-63 WA150PZ-5 – VEAM420100...
  • Page 249 (4-41)". Check alternator, starting motor The brush may be worn or have no grease on the bearing, so contact your KOMATSU distributor for inspection or repair. If the engine is started frequently, carry out inspection every 1000 hours.
  • Page 250 (3) and plate (4). 4. If the inspection gauge can be inserted into the tooth portion, the disc has reached the wear limit. Please ask your Komatsu distributor to carry out the replace- ment. 5. After checking, install check plug (1).
  • Page 251 Check vibration damper Check that there are no cracks or peeling in the outside surface of the rubber. If any cracks or peeling are found, contact your KOMATSU dis- tributor to have the parts replaced. 4-66 WA150PZ-5 – VEAM420100...
  • Page 252 Check water pump Check that there is no play in the pulley or any grease leakage, water leakage, or clogging of the drain hole. If any abnormality is found, contact your KOMATSU distributor for disassembly and repair or replacement. 4-67...
  • Page 253 4.8 Service procedure Every 4000 hours service Maintenance 4-68 WA150PZ-5 – VEAM420100...
  • Page 254 Technical Data 5. Technical Data WA150PZ-5 – VEAM420100...
  • Page 255 Operating weight (including 1 operator: 75 kg 8,684 (165 lb) and additional counter weight) Normal load 2,880 Bucket capacity m³ Engine model Komatsu SAA4D102E-2 diesel engine Flywheel horsepower kW (HP)/rpm 71 (97)/2000 Overall length 6,457 Overall height 3,063 Max. dimension when shaking bucket...
  • Page 256 Technical Data 5.1 Technical data GK032301 WA150PZ-5 – VEAM420100...
  • Page 257 0.5 m/s². These values were determined using a representative machine and with the help of the measurement procedures that are defined in the directives ISO 2631/1 and ISO 5349. WA150PZ-5 – VEAM420100...
  • Page 258 Attachments, Options 6. Attachments, Options WARNING Please read and make sure that you understand the SAFETY section before reading this section. WA150PZ-5 – VEAM420100...
  • Page 259 6.1 Selecting bucket and tires Attachments, Options Selecting bucket and tires Select the most suitable bucket and tires for the type of work and the ground conditions on the jobsite. When installing optional tires, please contact your KOMATSU distributor. WA150PZ-5 – VEAM420100...
  • Page 260 Attachments, Options 6.2 Method of using 2 levers Method of using 2 levers 6.2.1 Explanation of components GK032138 (1) Lift arm control lever (3) Directional selector switch (2) Bucket control lever (4) Directional selector actuation switch WA150PZ-5 – VEAM420100...
  • Page 261 HOLD position. Position (b): HOLD GK032143 The bucket is kept in the same position. Position (c): DUMP Tilt Dump GK032144 WA150PZ-5 – VEAM420100...
  • Page 262 At any other position, this switch does not work. Even if the directional selector switch is functioning, when the directional lever is operated, the operation of the direc- tional lever is given priority. WA150PZ-5 – VEAM420100...
  • Page 263 Priority is given to the operation of the directional lever, so be careful when operating. 1. Place the directional lever (1) at the N position. GK032190 2. Place the directional selector switch (2) at the N position. GK032122 WA150PZ-5 – VEAM420100...
  • Page 264 (2). Priority is given to the operation of the directional lever. When using directional selector switch (2) again, set direc- tional lever (1) and directional selector switch (2) to the N position. WA150PZ-5 – VEAM420100...
  • Page 265 When the work equipment control lever is pulled further from the TILT position, the lever is stopped in this position until the fork reaches the preset position of the positioner, and the lever is returned to the HOLD position. GK015120 Position (f): DUMP WA150PZ-5 – VEAM420100...
  • Page 266 4. Raise the forks so that they are several inches above the ground or the load under the forks, then tilt the forks and set so that the load rests against the backrest of the carriage. GK015122 WA150PZ-5 – VEAM420100...
  • Page 267 When transporting on rough ground or slopes, travel at low speed. When transporting on slopes, travel with the load on the uphill side. If the load obstructs the view to the front, travel facing in GK015124 reverse. 6-10 WA150PZ-5 – VEAM420100...
  • Page 268 2. Drive slowly forward to the stacking point with the forks hori- zontal. 3. Lower the load. GK015122 4. Drive the machine slowly in reverse and remove the forks from the load. 5. Lower the forks. GK015121 6-11 WA150PZ-5 – VEAM420100...
  • Page 269 Method of using 3 levers 6.4.1 Explanation of components GK015125 (1) Lift arm control lever (4) Directional selector switch (2) Bucket control lever (5) Directional selector actuation switch (3) Auxiliary control lever (6) Switch for quick coupler (option) 6-12 WA150PZ-5 – VEAM420100...
  • Page 270 HOLD position. Position (b): HOLD The bucket is kept in the same position. GK015128 Position (c): DUMP Tilt Dump GK015129 6-13 WA150PZ-5 – VEAM420100...
  • Page 271 At any other position, this switch does not work. GK015132 Even if the directional selector switch is functioning, when the directional lever is operated, the operation of the direc- tional lever is given priority. 6-14 WA150PZ-5 – VEAM420100...
  • Page 272 Position (a): quick coupler is locked Position (b): press here to unlock the quick coupler When the switch is released, it automatically returns to its origi- nal position. 6-15 WA150PZ-5 – VEAM420100...
  • Page 273 Priority is given to the operation of the directional lever, so be careful when operating. 1. Place the directional lever (1) at the N position. GK015134 2. Place the directional selector switch (2) at the N position. GK015131 6-16 WA150PZ-5 – VEAM420100...
  • Page 274 (2). Priority is given to the operation of the directional lever. When using directional selector switch (2) again, set direc- tional lever (1) and directional selector switch (2) to the N position 6-17 WA150PZ-5 – VEAM420100...
  • Page 275 If the mixer blades are turning inside the grease container, the lubrication system is OK. If the mixer blades are not turning, no automatic lubrication is taking place. To eliminate the malfunction, contact your KOMATSU dealer. 6.5.2 Display and control unit The display and control unit is protected by a transparent plastic cover against splashing water and mechanical damage.
  • Page 276 (PS) 6. Fault message (FAULT) Pushbuttons 1. Turn on display Display values and parameters Set values and parameters 2. Change between programming and display mode Confirm values (SET) 3. Activatev intermediate lubrication Clear fault message (DK) 6-19 WA150PZ-5 – VEAM420100...
  • Page 277 6.5 Central lubrication system Attachments, Options 6.5.3 Changing the lubrication interval times The settings when shipping from factory are as follows: Greasing interval: after 1 hour Greasing time: 8 minutes. 6-20 WA150PZ-5 – VEAM420100...
  • Page 278 Index 7. Index WA150PZ-5 – VEAM420100...
  • Page 279 Fresh air filter ......4-41 Cap with lock ......3-44 WA150PZ-5 – VEAM420100...
  • Page 280 Alternator belt ......4-59 KOWA (KOMATSU Oil Wear Analysis) ..4-5 Axle case breather .
  • Page 281 Maintenance ......2-29 Every 1000 hours ..... . 4-56 WA150PZ-5 – VEAM420100...
  • Page 282 Transfer oil cooler fins ..... 4-33 Transportation, machine ....2-25, 3-102 WA150PZ-5 – VEAM420100...
  • Page 283 7.1 Index Index WA150PZ-5 – VEAM420100...
  • Page 284 Notes 8. Notes WA150PZ-5 – VEAM420100...
  • Page 285 Notes WA150PZ-5 – VEAM420100...
  • Page 286 Notes WA150PZ-5 – VEAM420100...
  • Page 287 Notes WA150PZ-5 – VEAM420100...
  • Page 288 Notes WA150PZ-5 – VEAM420100...
  • Page 289 Notes WA150PZ-5 – VEAM420100...

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