KOMATSU WA380-7 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A64001 & UP) KOMATSU WA380-7 – PDF DOWNLOAD

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KOMATSU WA380-7 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A64001 & UP) KOMATSU WA380-7

KOMATSU WA380-7 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A64001 & UP) KOMATSU WA380-7 – PDF DOWNLOAD:

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KOMATSU WA380-7 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A64001 & UP) KOMATSU WA380-7

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical, and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
• If this manual is lost, damaged, or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. The explanations, values, and illustrations in this manual have been prepared based on the latest information available at the date of its publication.
• Continuing improvements in the design of this machine may lead to additional changes that are not reflected in this manual. Consult Komatsu or your Komatsu distributor for the latest available information concerning your machine or with questions regarding information contained in this manual.
• This manual may contain attachments and optional equipment that are not available in your area. Consult your local Komatsu distributor for items that you may require. The numbers in the illustrations correspond to the numbers in ( ) in the text.

TABLE OF CONTENTS:

KOMATSU WA380-7 WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A64001 & UP) KOMATSU WA380-7

CEAM025804 WA380-7 S/N A64001 and UP..............................................................................  1
	INTRODUCTION - Section 0......................................................................................  3
		FOREWORD..................................................................................................  4
		SAFETY INFORMATION........................................................................................  5
		APPROVED AND NON-APPROVED USES............................................................................  6
			Approved Functions....................................................................................  6
			Non-Approved Functions................................................................................  6
		VISIBILITY STANDARD.......................................................................................  7
			Visibility in Immediate Area..........................................................................  7
			12-M Radius Visibility................................................................................  7
		PRODUCT IDENTIFICATION....................................................................................  8
			Directions of Machine.................................................................................  8
			Machine Serial Number.................................................................................  8
			Engine Serial Number, EPA Regulations.................................................................  9
			Service Meter Location................................................................................  9
		SERIAL NUMBERS AND DEALER INFORMATION..................................................................... 10
			Model: WA380-7........................................................................................ 10
		TABLE OF CONTENTS......................................................................................... 11
	SAFETY - Section 1............................................................................................ 27
		SAFETY AND WARNING DECALS................................................................................. 28
			Location of the Safety Decals......................................................................... 28
			Safety Labels......................................................................................... 30
		GENERAL SAFETY RULES AND PRECAUTIONS...................................................................... 38
			General Safety Rules.................................................................................. 38
				Unauthorized Modifications........................................................................ 38
				General Safety at Job Site........................................................................ 39
				Working on Loose Ground........................................................................... 39
			Safety Features....................................................................................... 39
			Personal Protective Equipment......................................................................... 40
			Fire and Explosion Prevention......................................................................... 40
				Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid...................................... 40
				Fire Caused by Accumulation of Flammable Material................................................. 41
				Fire Caused by Electrical Wiring.................................................................. 41
				Fire Caused by Hydraulic Lines.................................................................... 41
				Fire Caused by Lighting Equipment................................................................. 41
			Action if Fire Occurs................................................................................. 42
			Fire Extinguisher and First Aid Kit................................................................... 42
			Mounting and Dismounting.............................................................................. 43
			Inside Operator’s Compartment......................................................................... 44
			Precautions When Standing Up from Operator’s Seat..................................................... 45
			Precautions Related to Roll Over Protective Structure (ROPS).......................................... 46
			Unauthorized Modification............................................................................. 46
			Emergency Escape from Operator’s Cab.................................................................. 46
			Leaving Operator’s Compartment........................................................................ 47
			Precautions When Cleaning Cab Glass................................................................... 48
			Asbestos Hazard Alert................................................................................. 48
			Crush or Pinch-Point Dangers.......................................................................... 49
			Precautions for Ventilation Exhaust Gas............................................................... 49
		PRECAUTIONS BEFORE STARTING OPERATIONS.................................................................... 50
			Pre-Operational Checks................................................................................ 50
				Ensure Good Visibility............................................................................ 50
				Confirmation of Marks............................................................................. 50
				Precaution for Warning Tag........................................................................ 51
				Checks Before Starting Engine, Adjustments........................................................ 51
				Precautions When Starting......................................................................... 52
			Seat Belt Inspection.................................................................................. 53
			Work Site Hazards..................................................................................... 54
			Avoiding Dangerous Situations......................................................................... 55
			Working Clearances.................................................................................... 56
			Working Near High-Voltage Cables...................................................................... 57
		RULES FOR TRAVEL.......................................................................................... 58
			Traveling in Reverse.................................................................................. 58
			Working on Loose or Unstable Ground................................................................... 59
			Operating on Snow or Frozen Surfaces.................................................................. 59
			Travel on Slopes...................................................................................... 60
			Using the Brakes...................................................................................... 61
			Parking the Machine................................................................................... 62
		PRECAUTIONS DURING MAINTENANCE OPERATIONS................................................................. 63
			Warning Tags.......................................................................................... 63
			Equipment Storage..................................................................................... 63
			Work at High Places................................................................................... 64
			Proper Tools.......................................................................................... 64
			Keeping the Machine Clean............................................................................. 65
			Using Drop Lamps...................................................................................... 65
			Working Under the Machine............................................................................. 65
			Stopping Machine During Inspection and Maintenance.................................................... 66
			Precautions When Using Hammer......................................................................... 67
			Noise................................................................................................. 67
			Precautions When Using Compressed Air................................................................. 67
			Running the Machine During Inspection and Maintenance................................................. 68
			Rules for Refueling the Machine....................................................................... 69
			Cooling System Precautions............................................................................ 69
			Welding Precautions................................................................................... 69
			Battery Precautions................................................................................... 69
				Battery Hazard Prevention......................................................................... 70
				Using Jumper Cables............................................................................... 71
			Starting the Machine.................................................................................. 71
			High-Pressure Hoses................................................................................... 72
				Safe Handling of High-Pressure Hoses.............................................................. 72
			Precautions for High-Pressure Liquids................................................................. 73
				Precautions for High-Pressure Fuel................................................................ 73
				Precautions for High-Pressure Oil................................................................. 73
			Precautions for High-Temperature Liquids.............................................................. 74
				Precautions for High-Temperature Coolant.......................................................... 74
				Precautions for High-Temperature Oil.............................................................. 74
			Critical Parts........................................................................................ 74
			Handling Accumulator and Gas Spring................................................................... 75
			Disposal of Waste Materials........................................................................... 75
			Inflating Tires....................................................................................... 76
			High Voltage.......................................................................................... 76
			Maintenance of Air Conditioner........................................................................ 76
		TRANSPORTATION............................................................................................ 77
			Safety Rules for Loading and Unloading................................................................ 77
	OPERATION - Section 2......................................................................................... 79
		GENERAL VIEW.............................................................................................. 80
			General View of Machine............................................................................... 80
			General View of Controls and Gauges................................................................... 82
			Switch Panel.......................................................................................... 83
			Machine Monitor....................................................................................... 84
				General View...................................................................................... 84
				Display of Liquid Crystal Unit.................................................................... 86
		EXPLANATION OF COMPONENTS................................................................................. 88
			Machine Monitor....................................................................................... 88
			Basic Operation Of Machine Monitor.................................................................... 89
				Starting Engine When Situation Is Normal.......................................................... 89
				Start Engine While Engine Shutdown Secondary Switch Is On......................................... 90
				Stopping Engine When Situation is Normal.......................................................... 91
				If Problem was Found When Starting Machine........................................................ 92
				If Trouble Occurs while Operating Machine......................................................... 93
			Warning Display....................................................................................... 94
				Action Level...................................................................................... 95
				Occurred Failure Code Display..................................................................... 97
				Engine Coolant Temperature Caution Lamp...........................................................100
				Torque Converter Oil Caution Lamp.................................................................100
				Hydraulic Oil Temperature Caution Lamp............................................................100
				Fuel Level Caution Lamp...........................................................................100
				Brake Oil Pressure Caution Lamp...................................................................101
				Seat Belt Caution Lamp............................................................................101
			Caution Display.......................................................................................102
				Engine System Caution Lamp........................................................................102
				Engine Oil Pressure Caution Lamp..................................................................102
				Engine Oil Level Caution Lamp.....................................................................103
				Engine Overrun Caution Lamp.......................................................................103
				Water Separator Caution Lamp......................................................................103
				Radiator Coolant Level Caution Lamp...............................................................103
				Air Cleaner Clogging Caution Lamp.................................................................104
				Fan Control System Caution Lamp...................................................................104
				KDPF System Caution Lamp..........................................................................105
				KDPF Soot Accumulation Caution Lamp...............................................................105
				Transmission System Caution Lamp..................................................................106
				Work Equipment System Caution Lamp................................................................106
				Brake Oil Temperature Caution Lamp................................................................106
				Directional Switch Caution Lamp (If Equipped).....................................................107
				Steering System Caution Lamp......................................................................107
				Steering Oil Pressure Caution Lamp................................................................107
				Emergency Steering System Caution Lamp (If Equipped)..............................................108
				Emergency Steering Motor Caution Lamp (If Equipped)...............................................108
				System Caution Lamp...............................................................................108
				Air Conditioner System Caution Lamp...............................................................109
				Maintenance Time Caution Lamp.....................................................................109
			Centralized Warning Lamp..............................................................................110
			Pilot Display.........................................................................................112
				Pop Up Display....................................................................................113
				Parking Brake Pilot Lamp..........................................................................113
				Turn Signal Lamp Pilot Lamp.......................................................................114
				Head Lamp (High Beam) Pilot Lamp..................................................................114
				Clearance Lamp Pilot Lamp.........................................................................114
				Semi Auto-Digging Pilot Lamp (If Equipped)........................................................114
				Auto-Greasing Pilot Lamp (If Equipped)............................................................115
				Directional Selector Pilot Lamp (If Equipped).....................................................115
				E.C.S.S. Pilot Lamp...............................................................................115
				2-Stage Low Idle Pilot Lamp (If Equipped).........................................................115
				Work Equipment Lock Pilot Lamp....................................................................116
				Remote Positioner Pilot Lamp......................................................................116
				KDPF Regeneration Pilot Lamp......................................................................116
				Emergency Steering Pilot Lamp (If Equipped).......................................................117
				Power Mode Pilot Lamp.............................................................................117
				Shift Hold Pilot Lamp.............................................................................117
				Torque Converter Lock-Up Pilot Lamp...............................................................117
				Auto-Shift Pilot Lamp.............................................................................118
				Fan Reverse Pilot Lamp............................................................................118
				Engine Pre-Heating Pilot Lamp.....................................................................118
				Transmission Cut-Off Pilot Lamp...................................................................118
				Air Conditioner Display...........................................................................119
				Shift Indicator...................................................................................119
				Shift Lever Position Pilot Lamp...................................................................119
				Message Pilot Lamp................................................................................119
				Clock.............................................................................................120
			ECO Guidance..........................................................................................121
				Excessive Idling Stop Guidance....................................................................121
				Guidance to Avoid Hydraulic Relief................................................................121
				Brake Dragging Prevention Guidance................................................................121
				Guidance of Accelerator Pedal Depressing Limit....................................................122
				Guidance to Recommend Shifting Up Gear to 4th.....................................................122
				Lock-Up Recommendation Guidance...................................................................122
				Long-Time Digging Prevention Guidance.............................................................122
			Meter Display.........................................................................................123
				Speedometer.......................................................................................123
				Engine Tachometer.................................................................................124
				Engine Coolant Temperature Gauge..................................................................124
				Torque Converter Oil Temperature Gauge............................................................124
				Hydraulic Oil Temperature Gauge...................................................................124
				Fuel Gauge........................................................................................125
				ECO Gauge.........................................................................................125
				L.H. and R.H. Meter...............................................................................125
				Service Meter Display.............................................................................126
				Odometer Display..................................................................................126
				Clock Display.....................................................................................126
				Fuel Consumption Gauge Display....................................................................127
			Monitor Switch Portion................................................................................128
				Menu Switch.......................................................................................128
				Enter Switch......................................................................................129
				Return Switch.....................................................................................129
				Up Switch.........................................................................................129
				Down Switch.......................................................................................129
				Air Conditioner Switches/Numeral Key..............................................................130
			User Menu.............................................................................................131
				ECO Guidance......................................................................................132
				Operating Record..................................................................................133
				ECO Guidance Record...............................................................................134
				Fuel Consumption Record...........................................................................136
				Display Setting...................................................................................137
				Setting Display of Fuel Consumption Gauge.........................................................137
				Switching Display/Non-Display of ECO Gauge........................................................138
				Setting the Target Fuel Consumption Value Displayed in ECO Gauge..................................139
				Switching Display/Non-Display of ECO Guidance.....................................................140
				Switching Display/Non-Display of Guidance when Key is OFF.........................................141
				Machine Setting / Information.....................................................................142
				Manual Fan Reverse Mode...........................................................................143
				Automatic Fan Reverse Mode........................................................................145
				Select Semi Auto-Digging Mode (If Equipped).......................................................147
					Semi-Auto Digging Function....................................................................147
					Operation of Semi-Auto Digging System.........................................................147
					Finishing of Semi-Auto Digging System.........................................................148
				Select Bucket Level Position......................................................................149
					Bucket Flat Level Adjustment..................................................................150
					Bucket Flat Level Initialize..................................................................151
				Auto Kick Down Setting............................................................................152
				Trip Meter........................................................................................152
				Auto Idle Stop Timer Setting......................................................................153
				KDPF Regeneration.................................................................................154
				Maintenance.......................................................................................155
				Reset Remaining Time for Maintenance..............................................................156
			Monitor Setting.......................................................................................157
				Rear View Monitor Setting.........................................................................157
				Reference Line Display............................................................................157
				Reverse-Interlock Enabled Mode....................................................................158
			Meter Display Selection...............................................................................159
				Select L.H. Meter Display.........................................................................159
				Select R.H. Meter Display.........................................................................160
			Screen Adjustment.....................................................................................161
			Clock Adjustment......................................................................................162
				GPS Synchronization...............................................................................162
				Calendar Setting..................................................................................163
				Time Setting......................................................................................164
				12H/24H Display Mode..............................................................................165
				Daylight Saving Time (Summer Time)................................................................165
			Language Selection....................................................................................166
			Message Display.......................................................................................167
				Confirming Method of a Message....................................................................168
				Replying Method to a Message......................................................................168
			Other Functions of Machine Monitor....................................................................169
				Confirm the Service Meter or Odometer when the Starting Switch Key is Set to the OFF Position.....169
			Switches..............................................................................................170
				Starting Switch...................................................................................171
				Power Mode Selector Switch........................................................................172
				Transmission Shift Mode Selector Switch...........................................................172
				Transmission Cut-Off Switch.......................................................................173
				Transmission Cut-Off Set Switch...................................................................173
				Lamp Switch.......................................................................................174
				Turn Signal Lever.................................................................................174
				Dimmer Switch.....................................................................................174
				Horn Switch.......................................................................................175
				Hazard Lamp Switch................................................................................175
				Parking Brake Switch..............................................................................176
				Front Working Lamp Switch.........................................................................177
				Rear Working Lamp Switch..........................................................................177
				Kick-Down Switch..................................................................................178
				Hold Switch.......................................................................................179
				Front Wiper Switch................................................................................179
				Rear Wiper Switch.................................................................................179
				Cigarette Lighter.................................................................................180
				Room Lamp Switch..................................................................................180
				Heated Wire Rear Glass Switch.....................................................................180
				E.C.S.S. Switch...................................................................................181
				Emergency Steering Switch (If Equipped)...........................................................181
				Torque Converter Lock-Up Switch...................................................................182
				Beacon Lamp Switch (If Equipped)..................................................................182
				Directional Selector Enable Switch on R.H. Switch Panel (If Equipped).............................182
				Directional Selector Switch (If Equipped).........................................................183
				Remote Positioner Switch..........................................................................183
				2-Stage Low Idle Switch (If Equipped).............................................................183
				Engine Shutdown Secondary Switch..................................................................184
				Rear View Monitor Brightness Adjustment Switch....................................................185
				Monitor Brightness Selector Switch................................................................185
				Quick Coupler Attachment Switch (if equipped).....................................................185
			Control Levers and Pedals.............................................................................186
				Gear Speed Switch.................................................................................186
					Manual Shift..................................................................................186
					Auto-Shift....................................................................................187
				Directional Lever.................................................................................188
				Work Equipment Lock Switch........................................................................188
				Bucket Control Lever..............................................................................189
				Boom Control Lever................................................................................190
				Brake Pedal.......................................................................................191
				R.H. Brake Pedal..................................................................................191
				L.H. Brake Pedal..................................................................................191
				Accelerator Pedal.................................................................................192
				Steering Tilt Lock Lever..........................................................................192
			Ashtray...............................................................................................192
			Cap with Lock.........................................................................................193
				Fuel Filler Port..................................................................................193
				Hydraulic Tank Oil Filler Cap.....................................................................193
			Frame Lock Bar........................................................................................194
			Towing Pin............................................................................................194
			Grease Pump Holder (If Equipped)......................................................................195
			Back-Up Alarm.........................................................................................195
			Battery Disconnect Switch.............................................................................196
			System Operating Lamp.................................................................................197
			Open and Close Cab Door...............................................................................198
				Cab Door Handle...................................................................................198
				Open Handle for Cab L.H. Door.....................................................................198
				Open Lock for Cab L.H. Door.......................................................................199
				Unlock Knob for Slide Window of Cab...............................................................199
				Open Lock Knob for Emergency Escape Door from Cab.................................................200
				Emergency Escape Door Closed Fully or Locked Half Open............................................200
			Unlock in Emergency...................................................................................200
		FUSES.....................................................................................................202
			Inside Rear Console Box...............................................................................202
			Fuse Capacities and Circuit Names.....................................................................202
				Fuse Box A........................................................................................202
				Fuse Box B........................................................................................203
			Slow Blow Fuse........................................................................................204
		AUXILIARY ELECTRIC POWER..................................................................................205
			24V Power Source......................................................................................205
			12V Power Source......................................................................................205
		RADIO.....................................................................................................206
			Rules for Using Radio.................................................................................206
			Explanation of Components.............................................................................206
				Power Button......................................................................................206
				Band/Aux Selector Button..........................................................................206
				Volume Control Button.............................................................................207
				Tuning/Time Adjust Button.........................................................................207
				Preset Button.....................................................................................207
				Display Selector Button...........................................................................207
				Sound Adjust Button...............................................................................207
				Display...........................................................................................207
			AUX...................................................................................................208
			Operation Method......................................................................................208
				Frequency Adjustment..............................................................................208
				Auto Presetting...................................................................................208
				Preset Call.......................................................................................208
				Preset Memory.....................................................................................209
				Sound Control (Balance)...........................................................................209
				Sound Control (Treble)............................................................................209
				Sound Control (Bass)..............................................................................209
				Time Adjustment Button............................................................................209
		AUTO AIR CONDITIONER......................................................................................210
			Air Conditioner Control Panel.........................................................................210
				OFF Switch........................................................................................210
				Auto Switch.......................................................................................211
				Air Conditioner Switch............................................................................211
				Fan Switch........................................................................................212
				Temperature Control Switch........................................................................212
				FRESH/RECIRC Air Selector Switch..................................................................213
				Vent Selector Switch..............................................................................214
				Defroster Switch..................................................................................215
				Display Monitor...................................................................................215
			Sunlight Sensor.......................................................................................215
			Operation Method......................................................................................216
				Automatic Operation...............................................................................216
				Stop Automatic Operation..........................................................................217
				Manual Operation..................................................................................218
				Stop Manual Operation.............................................................................219
				Use Defroster.....................................................................................220
				Demist Operation..................................................................................221
			Rules for Using Air Conditioner.......................................................................222
			Checks and Adjustment of Air Conditioner Equipped Machine.............................................222
		COOL BOX..................................................................................................223
		HANDLING FRONT WIPER......................................................................................223
		FIRE EXTINGUISHER (IF EQUIPPED)...........................................................................223
		HANDLING REAR VIEW MONITOR................................................................................224
		HANDLING KOMATSU DIESEL PARTICULATE FILTER (KDPF).........................................................225
			Manual Stationary Regeneration........................................................................229
			Operation Procedure...................................................................................229
			KDPF Regeneration Stop Procedure......................................................................231
			While Regeneration is Not Being Performed: Setting for Regeneration Stop..............................232
			While Regeneration is Being Performed: Stopping Regeneration..........................................233
			Re-enabling KDPF Regeneration.........................................................................233
		HANDLING KOMATSU CLOSED CRANKCASE VENTILATION (KCCV) FILTER...............................................234
		HANDLING MACHINES EQUIPPED WITH KOMTRAX...................................................................235
			Outline of KOMTRAX....................................................................................235
			Basic Precautions.....................................................................................236
			Observance of the Applicable Laws and Regulations, Exemption..........................................236
		MACHINE OPERATIONS AND CONTROLS...........................................................................237
			Checks and Adjustment Before Starting Engine..........................................................237
				Walk-around Checks................................................................................237
			Checks Before Starting................................................................................240
				Check Machine Monitor.............................................................................240
				Check Coolant Level, Add Coolant..................................................................241
				Check Air Cleaner.................................................................................242
				Electric Air Cleaner Clogging Sensor..............................................................242
				Check Water Separator, Drain Water................................................................243
				Check Oil Level in Engine Oil Pan, Add Oil........................................................245
				Check Fuel Level, Add Fuel........................................................................246
				Check Electric Wiring.............................................................................247
				Check Tire Pressure...............................................................................247
				Check Window Washer Fluid Spurting Out............................................................247
				Check Wiper Function..............................................................................247
				Check Horn........................................................................................247
				Check Defroster Function..........................................................................247
				Check Locks.......................................................................................247
				Check Emergency Escape............................................................................247
			Adjustments...........................................................................................248
				Seat Adjustment...................................................................................248
			Head Rest.............................................................................................251
				Removal...........................................................................................251
				Installation......................................................................................251
			Seat Belt.............................................................................................252
				Fasten and Unfasten Seat Belt.....................................................................252
			Adjust Lever Stand....................................................................................253
				Adjust Height and Angle of Armrest................................................................253
				Adjust Lever Stand Position.......................................................................253
			Mirrors Adjustment....................................................................................254
			Adjust Rear View Camera...............................................................................255
				Adjusting Rear View Camera Angle..................................................................255
				Checking Reference Line...........................................................................257
			Operations and Checks Before Starting Engine..........................................................258
		STARTING ENGINE...........................................................................................260
			Start in Normal Weather...............................................................................260
			Start in Cold Weather.................................................................................262
			Turbocharger Protection Function......................................................................263
			Automatic Warm-Up Operation...........................................................................264
			Checks After Starting Engine..........................................................................264
				Check Engine Starting and Abnormal Noise..........................................................264
				Check Engine Acceleration and Deceleration........................................................264
				Check Parking Brake...............................................................................265
				Check Brake Performance...........................................................................265
				Check Clearance Between Brake Pedal and Floor.....................................................265
				Check Abnormal Parts Found Previously.............................................................265
				Running-In........................................................................................265
				When Machine is Normal............................................................................266
			Stopping Engine.......................................................................................268
		MACHINE OPERATION.........................................................................................269
			Move Machine..........................................................................................269
			Shifting Gears........................................................................................273
			Shift Between Forward and Reverse.....................................................................275
			Stop Machine..........................................................................................277
			Transmission Cut-Off Function.........................................................................279
				Adjust Transmission Cut-Off Position..............................................................280
				Braking While Activating Transmission Cut-Off Function............................................280
			Steering Machine......................................................................................281
			Emergency Steering (If Equipped)......................................................................282
			Self-Check Function for Emergency Steering............................................................283
			Handling Torque Converter Lock-Up Function............................................................284
			Travel Speed Warning Function.........................................................................285
		WORK EQUIPMENT CONTROLS AND OPERATIONS....................................................................286
			Boom Control Lever....................................................................................286
			Bucket Control Lever..................................................................................287
		RECOMMENDED APPLICATIONS..................................................................................288
			Digging Work..........................................................................................288
			Loading Stock Piles and Blasted Rocks.................................................................288
			Digging or Loading on Level Ground....................................................................290
			Leveling Work.........................................................................................291
			Dozing Work...........................................................................................291
			Load-and-Carry Operation..............................................................................292
			Loading Work..........................................................................................292
				Cross Drive Loading...............................................................................293
				V-Shape Loading...................................................................................293
			Forking Work..........................................................................................293
			Notes on Handling Blasted Rocks.......................................................................294
				Operation Procedure not to Damage the Machine.....................................................294
					Handling Bucket...............................................................................294
					Gear Shifting When Approaching Working Area...................................................294
					Machine Articulation During Excavation........................................................294
					Bucket Dump Angle During Ground Excavation....................................................295
					Bucket Dump Angle During Leveling Work........................................................295
					Loading to Bucket.............................................................................296
					Bucket Dump Operation During Excavation.......................................................296
					Running Front Wheel on Blasted Rocks..........................................................297
					Unstable Rocks................................................................................297
				Excavation........................................................................................297
				Work on Wall Surface..............................................................................297
				Switching Between Forward and Reverse.............................................................298
				Stationary Steering of Tires......................................................................298
			Work Procedure for V-Shape Loading to Dump Truck......................................................298
				Preparation for Loading...........................................................................298
				Approaching Working Face..........................................................................299
			Digging...............................................................................................300
			Reversing Machine After Excavation....................................................................301
			Approaching Dump Truck................................................................................302
			Loading to Dump Truck.................................................................................303
			Reverse Travel From Dump Truck........................................................................304
		RULES FOR OPERATION.......................................................................................305
			Permissible Water Depth...............................................................................305
			If Brake Does Not Stop Machine Movement...............................................................305
			Travel On Slopes......................................................................................306
				Lower the Center of Gravity When Turning..........................................................306
				Traveling Down Hill...............................................................................306
				If Engine Stops on Slope..........................................................................306
			Precautions for Travel................................................................................306
			Precautions About Brake Performance...................................................................307
		REMOTE POSITIONER.........................................................................................308
			Remote Bucket Positioner Operation....................................................................308
			Remote Boom Positioner Operation......................................................................309
				Raise Remote Boom Positioner Operation............................................................309
				Reset Raise Remote Boom Positioner................................................................309
				Lower Remote Boom Positioner Operation............................................................310
				Reset Lower Remote Boom Positioner................................................................311
		BUCKET LEVEL INDICATOR....................................................................................312
		PARKING THE MACHINE.......................................................................................313
		CHECK AFTER FINISHING WORK................................................................................315
			Before Stopping Engine................................................................................315
			After Stopping Engine.................................................................................315
		LOCKING...................................................................................................316
		HANDLING TIRES............................................................................................317
			Precautions When Handling Tires.......................................................................317
			Tire Pressure.........................................................................................317
				Precautions for Using Load-and-Carry Method.......................................................318
		TRANSPORTATION............................................................................................319
			Transportation Procedure..............................................................................319
			Loading and Unloading with Trailer....................................................................319
				Loading...........................................................................................319
				Securing Machine..................................................................................320
				Securing Position.................................................................................321
				Unloading.........................................................................................322
			Lifting Machine.......................................................................................323
		COLD WEATHER OPERATION....................................................................................325
			Cold Weather Operation Information....................................................................325
			Fuel and Lubricants...................................................................................325
			Coolant...............................................................................................325
			Battery...............................................................................................325
			After Daily Work Completion...........................................................................326
			After Cold Weather Season.............................................................................326
		LONG-TERM STORAGE.........................................................................................327
			Before Storage........................................................................................327
			During Storage........................................................................................327
			After Storage.........................................................................................327
			Starting Machine after Long-Term Storage..............................................................327
		TROUBLES AND ACTIONS......................................................................................328
			Running Out of Fuel...................................................................................328
			Towing Machine........................................................................................328
			When Engine is Operable...............................................................................329
			When Engine is Not Operable...........................................................................329
			Releasing Parking Brake...............................................................................329
			Releasing Brake by Using Emergency Parking Brake Cancel Valve.........................................330
			Releasing Method with Adjustment Bolt.................................................................332
			Emergency Travel Operation............................................................................332
			Discharged Battery....................................................................................333
				Remove and Install Battery........................................................................333
				Charging the Battery..............................................................................334
			Start Engine with Booster Cables......................................................................335
				Connect and Disconnect Booster Cables.............................................................335
				Connect Booster Cables............................................................................336
				Starting Engine...................................................................................336
				Disconnect Booster Cables.........................................................................336
			Lowering Work Equipment When Engine is Stopped........................................................337
		OTHER TROUBLE.............................................................................................339
			Electrical System.....................................................................................339
			Chassis...............................................................................................341
			Engine................................................................................................343
			Electronic Control System.............................................................................345
	MAINTENANCE - Section 3.......................................................................................347
		GUIDES TO MAINTENANCE.....................................................................................348
			Check Service Meter...................................................................................348
			Komatsu Genuine Replacement Parts.....................................................................348
			Komatsu Genuine Oils..................................................................................348
			Always Use Clean Washer Fluid.........................................................................348
			Always Use Clean Oil and Grease.......................................................................348
			Checking for Foreign Materials in Drained Oil and on Filters..........................................348
			Oil and Fuel Strainers (If Equipped)..................................................................348
			Welding Instructions..................................................................................349
			Do Not Drop Things Inside Machine.....................................................................349
			Precautions for KDPF..................................................................................349
			Dusty Work Sites......................................................................................349
			Avoid Mixing Oil......................................................................................349
			Locking Inspection Covers.............................................................................349
			Bleeding Air from Hydraulic Circuit...................................................................350
			Precautions When Installing Hydraulic Hoses...........................................................350
			Checks After Inspection and Maintenance...............................................................350
			Fuel and Lubricants to Match the Ambient Temperature..................................................350
			Close Engine Side Cover Securely......................................................................350
		OUTLINES OF SERVICE.......................................................................................351
			Handling Oil, Fuel, Coolant, and Performing Oil Clinic................................................351
				Oil...............................................................................................351
				Fuel..............................................................................................352
				Coolant and Water for Dilution....................................................................353
				Grease............................................................................................353
			Performing KOWA (Komatsu Oil Wear Analysis)...........................................................354
				KOWA Analysis Items...............................................................................354
				Oil Sampling......................................................................................354
			Storing Oil and Fuel..................................................................................355
			Filters...............................................................................................355
			Handling Electrical Components........................................................................355
		WEAR PARTS................................................................................................356
			Wear Parts List.......................................................................................356
		RECOMMENDED FUEL, COOLANT, AND LUBRICANTS.................................................................357
			Fuel, Coolant, and Lubricant Ambient Temperature Chart................................................358
			Recommended Brands, Other Than Komatsu Genuine Oil....................................................360
		STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS............................................................362
		PERIODIC REPLACEMENT OF SAFETY-CRITICAL PARTS.............................................................364
		MAINTENANCE SCHEDULE CHART................................................................................366
		SERVICE PROCEDURE.........................................................................................368
			EVERY 10 Hours Maintenance (Only for the First 50 Hours)..............................................368
			Initial 250 Hours Maintenance (Only After the First 250 Hours)........................................368
			Initial 1000 Hours Maintenance (Only After the First 1000 Hours)......................................368
			When Required.........................................................................................369
				Clean and Replace Air Cleaner.....................................................................369
					Clean Outer Element...........................................................................369
					Replace Element...............................................................................371
				Clean Inside of Cooling System....................................................................372
				Check Transmission Oil Level, Add Oil.............................................................376
				Check Axle Oil Level, Add Oil.....................................................................378
				Clean Axle Breather...............................................................................379
				Clean Air Conditioner Condenser...................................................................380
				Check Window Washer Fluid Level, Add Fluid........................................................380
				Clean Radiator Fin and Cooler Fin.................................................................381
					Clean By Cooling Fan Reverse Turn.............................................................381
					Manual Fan-Reverse Operation..................................................................381
					Automatic Fan-Reverse Operation...............................................................381
					Clean Fin with Compressed Air.................................................................382
				Replace and Invert Bolt-On Cutting Edge...........................................................383
				Replace Bucket Teeth..............................................................................383
				Check and Maintenance Air Conditioner.............................................................384
					Check Level of Refrigerant (Gas)..............................................................384
					Maintenance and Schedule......................................................................385
				Replace Slow-Blow Fuse............................................................................386
				Check Function of Accumulator.....................................................................387
					E.C.S.S. Accumulator..........................................................................387
				Tire Selection and Check..........................................................................388
					Tire Selection................................................................................388
					Check Tire Pressure, Inflate..................................................................389
				Clean and Replace Fuel Breather Filter............................................................390
			Checks Before Starting................................................................................392
			Every 50 Hours Maintenance............................................................................393
				Drain Water and Sediment From Fuel Tank...........................................................393
			Every 100 Hours Maintenance...........................................................................394
				Lubricate Rear Axle Pivot Pin (Three Places)......................................................394
				Check Oil Level in Hydraulic Tank, Add Oil........................................................394
				Clean Air Conditioner Fresh Air Filters...........................................................395
			Every 250 Hours Maintenance...........................................................................396
				Check Level of Battery Electrolyte................................................................396
					Check Electrolyte Level From Side of Battery..................................................396
					When it is Impossible to Check Electrolyte Level From Side of Battery.........................397
					When it is Possible to Use Indicator to Check Electrolyte Level...............................397
				Check Parking Brake...............................................................................398
				Check Air Conditioner Compressor Belt Tension, Adjust.............................................398
					Check.........................................................................................398
					Checks when Replacing V-Belt..................................................................398
					Adjustment....................................................................................399
				Check Looseness of Wheel Hub Bolts, Retighten.....................................................400
				Clean Air Conditioner Recirculation Air Filters...................................................400
				Check Function of Accumulator.....................................................................401
					Brake Accumulator.............................................................................401
				Lubricate Work Equipment..........................................................................401
			Every 500 Hours Maintenance...........................................................................403
				Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge.................................403
				Replace Fuel Pre-Filter Cartridge.................................................................405
			Every 1000 Hours Maintenance..........................................................................407
				Replace Fuel Main Filter Cartridge................................................................407
				Change Oil in Transmission Case, Clean Transmission Strainer......................................409
				Replace Transmission Oil Filter Cartridge.........................................................410
				Clean Transmission Breather.......................................................................410
				Lubricate Center Hinge Pin........................................................................411
				Lubricate Drive Shaft Center Support..............................................................411
				Check for Looseness of Engine Intake Pipe Clamp...................................................412
				Check Alternator Drive Belt Tension, Replace......................................................412
			Every 2000 Hours Maintenance..........................................................................413
				Change Oil in Hydraulic Tank and Clean Hydraulic Tank Strainer....................................413
				Replace Hydraulic Tank Filter Element.............................................................415
				Replace Breather Element in Hydraulic Tank........................................................417
				Change Axle Oil...................................................................................418
				Clean Air Conditioner Recirculation and Fresh Air Filters.........................................418
				Check Brake Disc Wear Amount......................................................................419
				Check Function of Accumulator.....................................................................420
					PPC Accumulator...............................................................................420
				Check Alternator..................................................................................420
				Check Engine Valve Clearance, Adjust..............................................................420
				Check Vibration Damper............................................................................420
				Replace KCCV Filter Element.......................................................................421
			Every 4000 Hours Maintenance..........................................................................425
				Lubricate Drive Shaft.............................................................................425
				Check Water Pump..................................................................................426
				Check Starting Motor..............................................................................426
				Check Air Conditioner Compressor, Adjust..........................................................426
				Check for Looseness of High-Pressure Piping Clamp, Hardening of Rubber............................427
				Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber..................................428
			Every 4500 Hours Maintenance..........................................................................429
				Clean KDPF........................................................................................429
			Every 8000 Hours Maintenance..........................................................................429
				Replace Starting Motor............................................................................429
				Replace Fuel Spray Prevention Cap.................................................................429
	SPECIFICATIONS - Section 4....................................................................................431
		SPECIFICATIONS............................................................................................432
	OPTIONS, ATTACHMENTS - Section 5..............................................................................435
		SELECTING BUCKET AND TIRES................................................................................436
		MULTI-FUNCTION LEVER WITH PCS.............................................................................437
			Name of Each Part.....................................................................................437
			Explanation of Components and Switches................................................................437
				Multi-Function Mono Lever with PCS................................................................437
				Kick-Down Switch..................................................................................439
				HOLD SWITCH.......................................................................................440
				Directional Selector Switch.......................................................................441
				PCS (Proportional Control Switch).................................................................442
			Display of Liquid Crystal Unit........................................................................443
				Flow Control Mode Display Lamp (Continuous Mode)..................................................443
				Flow Control Mode Display Lamp (Proportional Mode)................................................443
				Detent Operation Pilot Lamp.......................................................................443
				Attachment Oil Flow Level.........................................................................444
			Setting Method of PCS.................................................................................445
		HYDRAULIC QUICK COUPLER...................................................................................447
			Removing Attachment...................................................................................447
			Installing Attachment.................................................................................449
			Ground Testing........................................................................................451

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