CEAM017200
Operation and Maintenance Manual
WA380-6 WHEE WHEEL L L OADER
SERIAL NUMBERS
WA380-6
A53001
and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
May 2006
Copyright 2006 Komatsu Published in USA Komatsu America Corp.
0INTRODUCTION
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INTRODUCTION
FOREWORD 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. Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual. Consult your local KOMATSU distributor or for the latest available information on your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult your local KOMATSU Distributor or for those items that you may require.
Improper operation and maintenance of this machine can be hazardous and could result in serious injury or death. • Opera Operators tors and and maintena maintenance nce personne personnell must read read this manual manual thoroughly before before opera operating ting or maintaining this machine. • This manual manual should be kept near near or with the machine machine for refere reference nce and periodically periodically reviewed reviewed by all personnel who op erate it. • Some actions involved involved in operation operation and and maintenance maintenance can cause a serious accident, accident, if they are are not performed in the manner described in this manual. • The procedures procedures and and precautions precautions given in this manual manual apply apply only to the intended intended uses uses of this machine. machine. If you use your machine for any unintended uses that that are not specifi cally prohi bited, you must be sure that it is safe for you and others. In In no event should you or oth ers engage engage in prohibi ted uses or action action s as describ describ ed in this manual. •
•
KOMA KOMATSU TSU delivers delivers machines machines that that comply with all all applicable applicable regulations regulations and and standards standards of the country to whi ch it has been shipped. If this machine has been been purch ased ased in another coun try or purchased from s omeone in another countr y, it may lack certain safety features features and specific ations that are necessary necessary for us e in your countr y. If there is any question about whether your pr oduct co mplies with the applicable standards standards and regulations of you r countr y, consul t your loc al distrib utor or K OMATS OMATSU U before operating the machine. The safety safety description is given in SAFET SAFETY Y INF INFOR ORMA MATI TION ON and in the SAFE SAFETY TY section 1 ❉
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Storage location for Operation and Maintenance Manual is in the pocket (1) at rear of operators seat back rest.
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INTRODUCTION
SAFETY INFORMATION Most accidents are caused by failure to follow fundamental safety rules for the operation and maintenance of the machine. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the machine before performing maintenance and machine operations. To identify safety messages in this manual and on machine product graphics, the following signal words are used: DANGER! - This word is used on safety messages and product graphics where there is a high probability of serious injury or
death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may result in serious damage to the machine, injury or even death.
WARNING! - This word is used on safety messages and product graphics where there is a potentially dangerous situation,
which could result in serious injury or possibly death if the hazard is not avoided. These safety messages and product graphics usually describe precautions that mus t be taken to avoid the hazard. Failure to avoid this hazard may result in serious damage to the machine or possible injury.
CAUTION! - This word is used on safety messages and product graphics for hazards, which could result in minor or moderate
injury if the hazard is not avoided. These safety messages messages and product graphics might also use this word for hazards where the only result could be damage to the machine.
Remark
This word is used for precautions that must be taken to avoid actions, which could shorten the life or damage the machine.
Safety precautions are described in SAFETY section (01-1) KOMATSU cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety message in this manual and on the machine may not include all possible safety precautions. If any procedures or actions not specifically recommended or allowed in this manual are used, you must be sure that you and others can do such procedures and actions safely and without damaging the machine or causing injury. If you are unsure about the safety of some procedures, contact your local KOMATSU Distributor.
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APPROVED A PPROVED AND NON-APPROVED NON-A PPROVED USES The Komatsu WHEEL LOADER described in this manual has been designed and constructed to be used mainly for the following functions, any non-approved used may void the warranty, damage the machine or possibly injure the operator.
APPROVED A PPROVED Loading operations. Excavating. • Grading. • • Pushing Installation of optional equipment can also be used in the following applications, use only KOMATSU approved equipment. Handling of materials (bucket - pallet forks). • •
NON-APPROVED This paragraph describes some of the improper or unauthorized uses of the machine; since it is impossible to predict all the possible improper uses, if the machine happens to be used for any particular application other than those approved above, it is important to contact your Authorized Komatsu Dealer before carrying out the work operations. • • • • • • •
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Use of machine for lifting or transporting personnel in any manner. Transportation of flammable liquids. Lifting, moving or transporting other machines with the front end equipment. Towing other equipment with the tractor unit or work equipment. Using the loader as a hammer or for striking or driving objects. Towing the machine at high speeds Traveling at high speeds.
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PRODUCT IDENTIFICATION The serial numbers and model numbers on the components are the only numbers that your dealer will need when requiring assistance or ordering replacement parts. It is a good idea to record this information in this manual on page 0-7 (Serial Number And Dealer Information). All views indicated below are viewed from the operators sitting position.
MACHINE SERIAL NUMBER The machine serial number is stamped on the right side center of the front frame.
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INTRODUCTION
ENGINE SERIAL NUMBER AND EMISSION LABEL The engine serial number is on a plate located on the left side of the machine.
SERVICE METER LOCATION The service meter is located in the center bottom of the machines monitor bezel.
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SERIAL NUMBERS AND DEALER DEA LER INFORMATION INFORMATION Model: WA400-5L Machine # Engine #
Dealer:
Address:
Phone # Contacts:
NOTES:
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INTRODUCTION
CONTENTS INTRODUCTION
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPROVED AND NON-APPROVED USes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NON-APPROVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MACHINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE SERIAL NUMBER AND EMISSION LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE METER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERIAL NUMBERS AND DEALER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0-2 0-3 0-4 0-4 0-5 0-5 0-6 0-6 0-7 0-8
SAFETY
SAFETY AND WARNING DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCATION OF THE SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 LOCATION OF SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 SAFETY LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 GENERAL SAFETY RULES AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 GENERAL SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 UNAUTHORIZED MODIFICATIONS MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 GENERAL SAFETY AT JOB SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 WORKING ON LOOSE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 PERSONAL PROTECTIVE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 FIRE AND EXPLOSION PREVENTION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 FIRE CAUSED BY FUEL OR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL . . . . . . . . . . . . . 1-14 FIRE COMING FROM ELECTRIC WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 FIRE COMING FROM HYDRAULIC LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 WINDSHIELD WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 ACTION IF FIRE OCCURS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 FIRE EXTINGUISHER AND FIRST AID KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 MOUNTING AND DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 INSIDE OPERATOR’S COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT . . . . . . . . . . . . . . . . . . 1-17 PRECAUTIONS WHEN USING ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 EMERGENCY ESCAPE FROM OPERATOR'S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 LEAVING OPERATOR’S COMPARTMENT COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 KEEP OPERATOR'S COMPARTMENT CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 DUST HAZARD PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 ASBESTOS HAZARD ALERT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 CRUSH OR PINCH POINT DANGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 PRECAUTIONS BEFORE STARTING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 STARTING YOUR WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 0- 8
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WORK SITE HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 AVOIDING DANGEROUS SITUATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 WORKING CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 RULES FOR ROAD TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 TRAVELING IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 TRAVELING ON ICY OR SNOW-COVERED SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 WORKING ON LOOSE OR UNSTABLE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 TRAVEL ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 PRECAUTIONS DURING MAINTENANCE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 WARNING TAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 EQUIPMENT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 WORKING UNDER THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 USING DROP LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 KEEPING THE MACHINE CLEAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 RUNNING THE MACHINE DURING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 RULES FOR REFUELING THE MACHINE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 COOLING SYSTEM PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 BATTERY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 STARTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 HIGH PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 SAFETY HANDLING HIGH-PRESSURE HIGH-PRESSURE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 PRECAUTION FOR HIGH FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 HIGH TEMPERATURES AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32 DISPOSAL OF WASTE MATERIALS MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 INFLATING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 DISPOSAL OF WASTE MATERIALS MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 HIGH VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 OPERATION
GENERAL VIEW OF MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 OUTSIDE VIEW OF THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 INSIDE VIEW OF THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS . . . . . . . . . . . . . . . . . . . . . . 2-4 INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 SWITCH PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2-6 INSTRUMENT BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 TYPES OF WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 MACHINE ELECTRONIC MONITORING MONITORING DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 MONITOR MODE SELECTOR SWITCHES SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 MODE SELECTOR SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 MODE SELECTOR SWITCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 MONITOR DISPLAY INFORMATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 SERVICE METER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 ACTION CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 WA380-6
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FAILURE CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 SERVICE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 SELECTING LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 EMERGENCY STOP WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 BRAKE PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 ENGINE OIL PRESSURE WARNING WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 BATTERY CHARGE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 STEERING OIL PRESSURE WARNING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 CAUTION ALERT WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 AXLE OIL TEMPERATURE CAUTION CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 TORQUE CONVERTER CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 COOLANT TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 HYDRAULIC OIL TEMPERATURE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 FUEL LEVEL CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 INSPECTION AND MAINTENANCE MAINTENANCE ALERT WARNING SYSTEM . . . . . . . . . . . . . . . . . . . 2-20 RADIATOR COOLANT LEVEL CAUTION CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 ENGINE OIL LEVEL CAUTION CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 BATTERY ELECTROLYTE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 MAINTENANCE CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 AIR CLEANER CLOGGING CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 WATER SEPARATOR CAUTION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 TRANSMISSION FILTER CLOGGING CLOGGING LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 MODE ALERT LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 PARKING BRAKE PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 COOLING FAN REVERSE ROTATION ROTATION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 EMERGENCY STEERING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 OUTPUT MODE PILOT LAMP LAMP (POWER MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 PREHEATING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 SEMI AUTO DIGGING PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 AUTO-GREASING PILOT LAMP LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 JOYSTICK PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 ECONOMY OPERATION DISPLAY DISPLAY LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 SHIFT INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 AUTO-SHIFT PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 LOCKUP PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 SHIFT HOLD PILOT LAMP LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 SHIFT LEVER POSITION PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 TURN SIGNAL PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 HEAD LAMP HIGH BEAM PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 GAUGE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 TORQUE CONVERTER OIL TEMPERATURE TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 ENGINE TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 HYDRAULIC TEMPERATURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 METER DISPLAY PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 DISPLAYING ODOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 RESET FOR FILTER, OIL REPLACEMENT REPLACEMENT TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 0-10
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ENTERING A TELEPHONE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 SELECTING A LANGUAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 ADJUSTING MONITOR BRIGHTNESS BRIGHTNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 MACHINE SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 SWITCH LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 POWER MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 TRANSMISSION MODE SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 TRANSMISSION CUT-OFF SWITCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 TRANSMISSION CUT-OFF SET SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 TURN SIGNAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 DIMMER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 HORN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 HAZARD LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 FRONT WORKING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 REAR WORKING LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 MONITOR PANEL MODE SELECTOR SWITCH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 MONITOR PANEL MODE SELECTOR SWITCH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 KICKDOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 FRONT WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 REAR WIPER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 CIGARETTE LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 CAB LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 REAR DEFROSTER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 E.C.S.S. SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 EMERGENCY STEERING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 COOLING FAN REVERSE ROTATION ROTATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 TORQUE CONVERTER LOCK-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 OPTIONAL SOUND SYSTEM AND AND AIR CONDITIONING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2-45 SOUND SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 POWER SWITCH/VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 AUTO-STORE/PRESET SCAN BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 BASS CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 TREBLE CONTROL KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 LOUDNESS BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 TIME/RADIO DISPLAY SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 TAPE EJECT BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 CASSETTE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 FAST-FORWARD, REWIND BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 METAL TAPE BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 MANUAL TUNING BUTTONS BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 SEEK TUNING BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48 BAND SELECTOR BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 SETTING PRESET BUTTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 WA380-6
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AUTO PRESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 MANUAL PRESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 LISTENING TO RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 LISTENING TO CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 REVERSING TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 PRECAUTIONS WHEN USING USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 HANDLING CASSETTE TAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51 AIR CONDITIONER SYSTEM CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 MAIN POWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 FAN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 AIR CONDITIONER SWITCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 TEMPERATURE CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 FRESH/RECIRC SELECTOR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 COOLING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 HEATING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 DRYING-HEATING AND DEMISTING DEMISTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 PRECAUTIONS WHEN USING USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 PRECAUTIONS FOR INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 2-55 CONTROL LEVERS, PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 GEAR SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 DIRECTIONAL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 GEAR SHIFT LEVER STOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 SAFETY LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 BUCKET CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59 LIFT ARM CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 STEERING TILT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61 SECURITY AND LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 IGNITION KEY LOCKED AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 CAB DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 ENGINE ACCESS DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-62 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 FUEL CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 LOCKING LOCATIONS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63 SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 PASSIVE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 ROLL-OVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 CAB FRONTAL GUARD (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 BACKUP ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-65 ACTIVE SAFETY FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 SAFETY BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66 EQUIPMENT LOCK LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67 MACHINE FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 CAB DOOR OPEN LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68 CAB WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 0-12
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CAB LEFT WINDOW OPEN LOCK RESET KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 CAB RIGHT WINDOW OPEN LOCK RESET KNOB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 RESET RIGHT WINDOW OPEN LOCK FOR ESCAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 FUSE CAPACITY AND NAME OF CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71 MACHINE CAB AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 SEAT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 LUMBAR SUPPORT TYPE SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73 REMOVAL AND INSTALLATION INSTALLATION OF HEADREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74 HANDLING CAB WIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 GREASE PUMP (IF EQUIPPED) EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75 PRECAUTIONS BEFORE STARTING WORK OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 PRE-OPERATIONAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76 PERFORM A WALK AROUND AROUND CHECK OF YOUR MACHINE MACHINE . . . . . . . . . . . . . . . . . . . . 2-76 UNDER THE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 CHECK COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78 CHECK WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79 CHECK AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 CHECK ELECTRIC WIRING WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-80 CHECK ENGINE OIL LEVEL, ADD OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 REAR-VIEW MIRROR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81 IN THE OPERATOR’S CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 SEAT BELT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-83 ADJUST LEVER STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84 START-UP PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 CHECK FUEL LEVEL, ADD FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85 CHECK THE BRAKE PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 CHECK THE PARKING BRAKE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-86 FINAL CHECKS BEFORE STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89 OPERATIONS AND CHECKS AFTER STARTING STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 BREAKING IN THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 NORMAL START-UP AND WARM-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94 TRAVELING, STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 TRAVELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-95 TURNING ON SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 CHANGING GEAR SPEED RANGES RANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98 CHANGING DIRECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99 WHEN USING AUTO-SHIFT AUTO-SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 WHEN USING AUTO-SHIFT AUTO-SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100 STOPPING AND PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-101 TRANSMISSION CUT-OFF SWITCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103 ADJUSTING THE TRANSMISSION CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 STOPPING WHEN TRANSMISSION CUT-OFF IS ON . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104 TURNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-105 EMERGENCY STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 USING THE EMERGENCY STEERING STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-106 WA380-6
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EMERGENCY STEERING SELF-CHECK FUNCTION FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-107 STARTING YOUR WORK OPERATIONS OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 LIFT ARM LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108 BUCKET LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-109 SCOOPING A LOAD OR CUTTING A GRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 LOADING PILED SOIL OR BLASTED ROCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110 CUTTING A GRADE ON LEVEL GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112 LEVELING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 PUSHING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 LOAD AND CARRY OPERATIONS OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113 LOADING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 CROSS DRIVE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 V-SHAPE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 PRECAUTIONS WHEN PILING PILING UP LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-114 LOADING TRUCKS OR HOPPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-115 PRECAUTIONS DURING OPERATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 PERMISSIBLE WATER DEPTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 IF WHEEL BRAKE DOES NOT WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 PRECAUTIONS WHEN DRIVING DRIVING UP OR DOWN SLOPES . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 BRAKING ON DOWNHILL SLOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 IF THE ENGINE STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-116 PRECAUTIONS FOR USING LOAD LOAD AND CARRY METHOD . . . . . . . . . . . . . . . . . . . . 2-116 PRECAUTIONS WHEN DRIVING THE MACHINE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117 PRECAUTIONS REGARDING BRAKE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-117 WORK EQUIPMENT AND MACHINE POSTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 ADJUSTING BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 BOOM KICKOUT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-118 BUCKET POSITIONER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119 BUCKET LEVEL INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-119 TRANSPORTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 LOADING AND SECURING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-120 UNLOADING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121 LIFTING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122 LIFTING LOCATIONS AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-122 USING WIRE ROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123 PRE LIFTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-123 LIFTING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-125 TOWING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-126 COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127 FUEL AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127 PRECAUTIONS AFTER COMPLETION OF OF WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127 AFTER COLD WEATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-127 BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128 WHEN MACHINE RUNS OUT OF FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128 TOWING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-128 WHEN ENGINE CAN BE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 WHEN ENGINE CANNOT BE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 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RELEASING PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-129 METHOD OF RELEASING WITH WITH ADJUSTMENT SCREW . . . . . . . . . . . . . . . . . . . . . . 2-132 EMERGENCY TRAVEL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132 IF BATTERY IS DISCHARGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133 REMOVAL AND INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-133 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 PRECAUTIONS FOR CHARGING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-134 STARTING ENGINE WITH BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-135 CONNECTING THE BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136 STARTING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136 DISCONNECTING THE BOOSTER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-136 ELECTRICAL CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-137 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-138 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-140 LONG-TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141 BEFORE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141 DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141 AFTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-141 MAINTENANCE
GUIDES TO MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 CHECK SERVICE METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 KOMATSU GENUINE REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 KOMATSU GENUINE OILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ALWAYS USE CLEAN WASHER FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ALWAYS USE CLEAN OIL AND GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 CHECKING FOR FOREIGN MATERIALS IN DRAINED DRAINED OIL AND ON FILTERS . . . . . . . . . 3-2 FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 WELDING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 DO NOT DROP THINGS INSIDE THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 DUSTY WORKSITES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 AVOID MIXING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 LOCKING INSPECTION COVERS COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 BLEEDING AIR FROM HYDRAULIC HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 CHECKS AFTER INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 HANDLING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 SERVICE LIMITS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 OUTLINES OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC . . . . . . . . . . . . . . . . 3-6 OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 PERFORMING KOWA (Komatsu Oil Wear Analysis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 KOWA ANALYSIS ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 OIL SAMPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 WA380-6
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STORING OIL AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 OUTLINE OF ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 WEAR PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 PROPER SELECTION OF FUEL, COOLANT COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . 3-11 RECOMMENDED BRANDS, OTHER THAN KOMATSU GENUINE OIL . . . . . . . . . . . . . . 3-12 STANDARD TIGHTENING TORQUES FOR FASTENERS AND HOSES . . . . . . . . . . . . . . . . . . 3-13 TORQUE LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 MAINTENANCE SCHEDULE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 GENERAL MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 INITIAL 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 EVERY 50 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 EVERY 100 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 EVERY 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 EVERY 500 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 EVERY 1000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 EVERY 2000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 EVERY 4000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 EVERY 8000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 GENERAL MAINTENANCE AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 INITIAL 250 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 INITIAL 1000 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 WHEN REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 CLEANING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 CHECK AXLE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 WINDOW WASHING FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 CLEAN RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 CLEAN FINS WITH COMPRESSED COMPRESSED AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 CHECK ELECTRICAL INTAKE AIR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 AIR CONDITIONING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31 REPLACE BOLT-ON CUTTING EDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 REPLACE BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 REPLACING SLOW-BLOW FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 INSPECTION OF TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 CHECKING FUNCTION OF ACCUMULATOR ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 ACCUMULATOR FOR TRAVEL DAMPER DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 ACCUMULATOR FOR BRAKE DAMPER DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 EVERY SPECIFIC HOURS OF SERVICE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 EVERY 50 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 DRAIN SEDIMENT FROM FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . 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EVERY 100 HOURS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 LUBRICATE THE REAR AXLE PIVOT PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 CHECKING THE HYDRAULIC HYDRAULIC TANK OIL LEVEL AND ADDING OIL . . . . . . . . . . . . 3-36 CLEANING THE AIR CONDITIONER FRESH AIR FILTER FILTER ELEMENT . . . . . . . . . . . . 3-37 EVERY 250 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 CHECK BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 CHECK PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 CHECK AIR CONDITIONER CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . 3-40 WHEEL HUB NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 AIR CONDITIONER RECIRCULATION RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 CHECKING FUNCTION OF ACCUMULATOR ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 LUBRICATING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 EVERY 500 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE . . . 3-43 REPLACING PRIMARY FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 EVERY 1000 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 REPLACING PRIMARY AND SECONDARY FUEL FILTER . . . . . . . . . . . . . . . . . . . . . . 3-46 CHANGE TRANSMISSION OIL OIL AND FILTER CARTRIDGE, CLEAN STRAINER . . . . 3-48 CLEAN THE TRANSMISSION CASE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 LUBRICATING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 CHECKING PARTS OF TURBOCHARGER TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 CHECK AND REPLACEMENT OF OF SERPENTINE BELT . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 EVERY 2000 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 CHANGE HYDRAULIC HYDRAULIC OIL, REPLACE HYDRAULIC HYDRAULIC OIL FILTER ELEMENT . . . . . 3-51 REPLACE HYDRAULIC TANK BREATHER BREATHER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 CHANGE THE AXLE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 AIR CONDITIONER RECIRCULATION RECIRCULATION FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 CHECKING BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 CHECKING FUNCTION OF ACCUMULATOR ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 CHECK ALTERNATOR, STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 CHECK ENGINE VALVE CLEARANCE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 CHECK INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 CHECK VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 EVERY 4000 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 LUBRICATING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 CHECK WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 CHECK AIR CONDITIONER CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 REPLACE INJECTOR NOZZLE TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59 CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER 3-59 CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 3-60 EVERY 8000 HOURS OF SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 REPLACE HIGH-PRESSURE PIPING CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 REPLACE FUEL SPRAY PREVENTION CAP CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 CHECK, REPLACE INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 SPECIFICATIONS WA380-6
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INTRODUCTION
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 MACHINE DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 MACHINE SYSTEMS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 OPTIONS, ATTACHMENTS
TORQUE CONVERTER LOCK-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE CONVERTER LOCK-UP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE CONVERTER LOCK-UP PILOT LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METHOD OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARNING/LIMIT FUNCTIONS FUNCTIONS FOR TRAVEL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAVEL SPEED WARNING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRAVEL SPEED LIMIT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SELECTING BUCKET AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . USING MACHINES EQUIPPED WITH KOMTRAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BASIC PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5-2 5-2 5-3 5-3 5-3 5-4 5-4 5-4 5-5 5-6 5-6
WA380-6
SAFETY
1
WARNING! Read and follow all safety precautions. Failure to do so may result in serious injury or death.
This safety section also contains precautions for optional equipment and attachments.
WA380-6
1-1
SAFETY
SAFETY AND WARNING DECALS It is important that all safety and warning decals are in place, not damaged, covered up or removed. It is also important for the operator to be aware of the decal content and location.
LOCATION OF THE SAFETY SAFETY DECAL S • • •
1- 2
Your Komatsu Dealer can supply you with new replacement decals if the ones on the machine are damaged or missing. When replacing replacing damaged damaged or missing missing decals, decals, be sure sure they they are placed placed in the proper proper location. location. Additio Additional nal safety safety or or warning warning decal decalss may be adde addedd to your your machine machine if desir desired. ed.
WA380-6
SAFETY
LOCATION LOCATION OF SAFETY LAB ELS The rear full fender is available as an option only; item 14 indicates that the machine is equipped with full fender.
SAFETY LABELS (1) Precaution before starting (09651-A0481). Warning! Read the manual before operation, maintenance, disassembly, assembly and transportation.
(2) Precautions for safety lock lever (09654-C0481). Sign indicates a hazard of unexpected moving of stopped machine.
Lower the working device to the ground, move the safety lever to the look position and take the engine key with you before leaving the machine.
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SAFETY (3) Precautions when travelling in reverse (423-93-41150). To prevent SEVERE INJURY or DEATH, DEATH, do the following fol lowing before moving the machine or its attachments: • • •
Honk Honk horn horn to to ale alert rt peo peopl plee nea nearb rbyy. Be sure sure no no on on is is on on or or nea nearr the the mach machine ine.. Use Use a spo spott tter er if vie view w is is obs obstr truc ucte ted. d.
Follow the above even if the machine is equipped with back-up alarm and mirrors.
(4) Precautions for going close to electric cables (09801-C0481). Sign indicates an electrocution hazard if the machine is brought too near the electric power lines.
Keep a safe distance from the electric power lines.
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WA380-6
SAFETY (5) Do not enter (09162-23000). Sign indicates a crush hazard between the articulating parts of the vehicle.
(6) Precautions for safety bar (09161-2300). Sign indicates a crush hazard between articulating parts of the vehicle.
(7) Caution when canceling parking brake emergency (423-93-41311) Sign indicates if the release valve is set to RELEASE, a serious accident may occur, as this operation releases the parking brake and the machine may suddenly start to roll.
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SAFETY (8) Precautions when coolant is at high temperature (09653-03001). Sign indicates a burn hazard from spurting hot water or oil if the radiator or hydraulic tank is uncapped while hot.
Allow the radiator or hydraulic tank to cool before removing the cap.
(9) Precautions when handling battery cables (09808-03000). Sign indicates an electrical hazard from handling the cable. Read the the manual for safe and proper handling.
(10) High-pressure warning (09659-5300). There is the hazard of explosion causing injury. Do not disassemble the accumulator, make holes in it, weld it, cut it, hit it, roll it or bring it near the flame. (11) Do not climb on fender (09805-03000) (machines equipped with full rear fender) Sign indicates a hazard of falling. Do not stand on this place.
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WA380-6
SAFETY (12) Do not open when the engine is running (09667-03001). Sign indicates a hazard of rotating parts, such as a belt. Turn off before inspection and maintenance. maint enance.
(13) Do not open when the engine is running (09667-03001). Sign indicates a hazard of rotating parts, such as a belt. Turn off before inspection and maintenance. maint enance.
(14) Do not come near the machine (09812-13000). Sign indicates a hazard of being run over by a moving vehicle.
Keep a safe distance from the vehicle when it is moving.
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SAFETY (15) Do not work on equipment (09807-C0883). Sign indicates a crush hazard from falling off of the working device.
Keep away when the working device is raised.
(16) Do not modify ROPS (09620-A2000) Do not drill, cut, bend or modify ROPS in any way. If damaged, replace the ROPS, do not repair.
(17) Jump start prohibited (09842-A0481) Start the engine only after sitting in the operators seat Do not attempt to start the engine by short circulating the starter motor circuit, serious injury may result.
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WA380-6
SAFETY (18) Precautions for high temperature turbocharger (09817-A0753). Sign indicates a burn hazard from touching heated parts, such as the engine, motor or muffler during or right after operation.
Allow the hydraulic tank to cool before removing the cap.
(19) Precautions for high temperature exhaust (09817-A0753). Sign indicates a burn hazard from touching heated parts, such as the engine, motor or muffler during or right after operation.
Allow the hydraulic tank to cool before removing the cap.
(20) Caution for common rail high pressure (6217-71-93310) Sign indicated extremely high fuel pressure in the system, never loosen the injector lines when the engine is running.
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SAFETY (21) Parking brake emergency cancel switch s witch (423-93-41311) Sign indicates proper procedure for releasing the parking brake during an emergency situation.
(22) Escape (425093-51110) (425093-51110) Sign indicates the areas to escape from the machine in an emergency.
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WA380-6
SAFETY
GENERAL SAFETY RULES AND PRECAUTIONS GENERAL SAFETY RULES Only trained and authorized personnel shall be allowed to operate and service this machine. Before operating this machine it is important to study the operator’s manual thoroughly and become familiar with all controls and safety decals. Keep this manual with your machine at all times for easy and quick reference. Safety must always be the operator’s most important concern. Never operate a machine that is unsafe or in poor operating condition. Always perform a pre-operational check on your machine before operating it. If the machine is equipped with a seat s eat belt and rollover protective structure, OSHA law requires the operator remain within w ithin the confines of the rollover protective structure, with wit h the seat belt fastened snugly around their waist before operating the machine. OSHA law states if your equipment is designed for operation by one person, it is for one person only, never allow other
personnel to ride on your machine in any manor. Never leave your machine running and unattended. Always park the machine in a level area, lower any any work equipment to the ground, set the parking brake, lock the controls and turn the engine off before exiting the operator’s compartment. Be sure that all personnel are at least 12 m (40 ft) away from any point on the machine before moving or operating the machine. Never allow anyone to stand near the machine while in operation. Remember, the larger the machine the more restricted your visibility will be. If pedestrians are in i n the area proceed slowly and sound your horn. hor n. Keep in mind, pedestrians have the right away, and a loaded or smaller machine has the right away over an unloaded machine. Never use your machine for tasks it was not designed for, damage to the machine or injury to the operator may resul t. Follow all safety rules, precautions, and instructions when operating or performing maintenance on the machine. It is the owner and /or operator’s responsibility to replace any safety or warning decals if they are defaced or removed from t he machine. Think before you act, study the job carefully. Careful operator’s and service personnel are the best insurance against accidents. The operator of this machine must be alert, physically fit, and free from the influences of alcohol, drugs or medications that might affect there eyesight, hearing, or reactions. When working with another person on a work site, or during traffic control, be sure all personnel involved understand all hand signals that are to be used. When leaving a job site for long periods of time always lower all work equipment to the ground, neutralize work equipment controls and lock and secure your machine properly to avoid tampering by other personnel. Never drive up to anyone standing in your path of t ravel. Always be sure all personnel are standing s tanding to the side when you approach them and acknowledge your approach. Follow all rules relating to safety as outlined in this manual and by your company, never get involved in horseplay.
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SAFETY UNAUTHORIZED MODIFICATIONS MODIFICATIONS If this machine is modified without permission from Komatsu, there is a danger that problems may occur with safety that may lead to serious personal injury. Modifications may have an adverse effect on items such as machine strength and visibility. Before making any modifications, please consult your Komatsu distributor. Komatsu cannot take any responsibility for accidents, failures, or damage caused by modifications not authorized by Komatsu.
GENERAL SAFETY AT JOB SITE • • • • • • • • • • • • •
Before starting operations, operations, thorough thoroughly ly check check the area for for any unusua unusuall conditions conditions that that could could be danger dangerous. ous. Know your your location location to report report an accident accident or fire. fire. In case of an an emergency emergency,, have a local local emergen emergency cy phone phone number number available. Be caref careful ul when when opera operating ting around around or or near near open open burnin burningg operati operations ons.. Maintai Maintainn the fire fire extin extingui guishe sherr on the the machi machine ne and and a second second one one at the the job job site Keep the machine machine clean, especially especially from from flammable flammable materials materials such as trash, trash, grease, grease, oil or fuel. Keep Keep all all safe safety ty equipme equipment nt in in good good working working condit condition. ion. Check the terrain terrain and and condition condition of the ground at the worksite worksite,, and determine determine the safest method method of operation. operation. Do not not opera operate te wher wheree there there is a hazard hazard of of landsli landslides des or fallin fallingg rocks. rocks. If water water lines, gas lines, lines, or high-volta high-voltage ge electrical electrical lines may may be buried under the worksite, worksite, contact contact each utility compan companyy and have them identify their locations. Take actio actionn to preven preventt unauth unauthoriz orized ed peopl peoplee from from approac approaching hing the the job site site.. When working working on on public public roads, roads, position position flagmen flagmen and and erect erect barriers barriers to ensure ensure the the safety safety of passing passing traffic traffic and and pedestrian pedestrians. s. When traveling traveling or operating operating in shallow shallow water water or on on soft ground, ground, check check the the shape and condition condition of the bedrock, bedrock, and and the depth and speed of flow of the water before starting operations. Conduct Conduct periodic periodic safety training training and and familiarize familiarize all personnel personnel with emergency emergency procedures. procedures.
WORKING ON LOOSE GROUND Avoid traveling or operating your machine too close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse under the weight or vibration of the machine, there is a hazard that the machine may fall or tip over. Remember that the soil is loose after heavy rain or blasting or after earthquakes When working on embankments or near excavated ditches, there is a hazard that the weight and vibration of the machine will cause the soil to collapse. Before starting operations, take steps to ensure that the ground is safe and to prevent the machine from rolling over or falling.
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WA380-6
SAFETY
SAFETY FEATURES Be sure all guards and covers are in place especially after servicing the machine. Have guards or covers repaired immediately if they are damaged. See “STARTING “STARTING THE ENGINE” on page 2-89 Use safety equipment such as safety locks and seat belt properly. Never remove any safety features. Always keep them i n good operating condition. Always secure the machine in a safe position: See “STOPPING AND PARKING THE MACHINE” on page 2-101 Seat belt: See “INSIDE OPERATOR’S OPERATOR’S COMPARTMENT” COMPARTMENT” on page 1-17 Improper use of safety features could result in serious bodily injury or death. Be sure the machine has the correct equipment required by local rules and regulations.
PERSONAL PROTECTIVE PROTECTIVE EQUIPMENT If your machine is equipped with safety equipment OSHA law requires this equipment to be used when operating your machine. Avoid loose fitting clothing, jewelry and loose long hair. These can catch on controls or in moving parts and cause serious injury. Wear a hard hat, safety glasses, safety shoes, mask or gloves when operating or maintaining the machine. Always wear safety goggles, hard hat and heavy gloves, if your job involves driving pins with a hammer or cleaning the air cleaner element with compressed air. Check to be sure no one is near your work area. Check to be sure all personal protective equipment are in good condition before using. If you will be subject to loud noise always wear ear protection.
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SAFETY
FIRE AND EXPLOSION PREVENTION Fuel and oil are flammable. Fuel is particularly flammable and can be hazardous. Always observe the following: • Keep Keep any any open open flame flames, s, airbo airborne rne sparks sparks or or burnin burningg ember emberss away away from flammable fluids. • Stop Stop the the eng engin inee and and do not not smok smokee when when ref refue uelin ling. g. • Tigh Tighte tenn all all fue fuell and and oil oil cap capss secu secure rely ly.. • Refueli Refueling ng or or adding adding oil oil shoul shouldd be made made in well well ventil ventilate atedd areas areas.. • Cle Clean up any any flu fluid id spil spills ls..
FIRE CAUSED BY FUEL OR OIL Fuel and oils are particularly flammable and can be hazardous. To prevent fire, always observe the following: • • • • • • • • • • • • • • •
Do not not smok smokee or or use use any any flame flame near near fue fuell or oil. oil. Stop top the the eng engin inee bef befor oree refu refuel elin ing. g. Do not not leav leavee the the mach machin inee while while add addin ingg fuel fuel or or oil. oil. Tigh Tighte tenn all all fue fuell and and oil oil cap capss secu secure rely ly.. Always Always inspe inspect ct aroun aroundd the entire entire fuel fuel tank tank for leak leakss and clean clean or or repair if needed. Inspect Inspect fuel fuel syste system m for leak leak or seepag seepage, e, this this inclu includes des fuel fuel line lines, s, filfilters and injection system, clean or repair if required. Do not not spill spill fuel fuel on overhe overheate atedd surfac surfaces es or or on parts parts of the the electr electrica icall system. Use well-ve well-ventil ntilate atedd areas areas for adding adding or storin storingg oil oil and and fuel. fuel. Keep oil and and fuel in the determined determined place place and do not not allow allow unauthoriz unauthorized ed persons persons to enter. enter. After After addi adding ng fuel or oil, oil, wipe up any spilled spilled fuel fuel or oil. When carrying carrying out grinding grinding or or welding welding work on the chassis, move any any flammable flammable materials materials to a safe place place before before starting. starting. When When washi washing ng par parts ts with with oil, oil, use use a nonnon-fla flamm mmab able le oil. oil. Diesel Diesel oil oil and and gasoli gasoline ne may may catc catchh fire, fire, so do do not not use use them. them. Put greasy greasy rags rags and and other other flammable flammable materials materials into a safe container container to maintain maintain safety safety at the work work place. place. Do not not weld or or use a cuttin cuttingg torch torch to cut cut any pipes pipes or tube tubess that conta contain in flamma flammable ble liquid liquids. s.
FIRE CAUSED BY ACCUMULATION ACCUMULATION OF FLAMMABL FL AMMABL E MATERIAL MATERIAL • • • •
.
Remove any dry dry leaves, leaves, wood chips, pieces pieces of of paper, paper, wood wood dust, dust, or any other flammable flammable materials materials accumulate accumulatedd or affixed affixed around the engine, exhaust manifold, muffler, air cleaner or battery, or inside the undercovers. Be aware aware that operations operations such such as logging, logging, mulching, mulching, clearing, clearing, and and landfill landfill work work may cause cause trash trash and debris to accumulate accumulate on the machine. Always remove accumulated trash and debris on a daily basis. Clean Clean the mach machine ine after after servic servicing ing the the hydrau hydraulic lic system system,, engine engine or or fuel system system.. Operations Operations near near burn piles or or other open open burning burning may may cause cause airborne airborne sparks sparks or glowing glowing embers embers to cause a fire on on the machine.
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WA380-6
SAFETY FIRE COMING FROM ELECTRIC WIRING 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 to the wire insulation. • • •
Tigh Tighte tenn any any loos loosee conn connec ecto tors rs or wiri wiring ng clam clamps ps.. Repair Repair or repl replace ace any damage damaged, d, pinc pinched hed or chaf chaffed fed wiring. wiring. After market market radios radios or other electrica electricall operated operated equipment equipment in in the cab cab must must be fused fused close close to the the power power supply
FIRE COMING FROM HYDRAULIC LINE • • •
Check that all all the hose and and tube tube clamps, clamps, guards, guards, and cushions cushions are securely securely fixed in position. position. If they are loose, loose, they they may vibrate vibrate during operation operation and rub against against other other parts. parts. This may lead lead to damage damage to the hoses, and and cause high-pressure oil to spurt out, leading to fire damage or serious injury. Check Check for oil leaks leaks dail dailyy and and repair repair them them immed immediat iately ely..
WINDSHIELD WASHER FLUID • •
Use an an automo automotive tive type type washe washerr fluid fluid in the windshi windshield eld wash washer er system system.. Never Never use flammab flammable le fluid fluidss in the windshi windshield eld washer washer system system
ACTION A CTION IF FIRE OCCURS • • • • • • •
If a fire fire occu occurs, rs, esc escap apee from from the the mac machi hine ne as as follow follows: s: Do not not atte attempt mpt to move move the the machine machine or cont continu inuee opera operation tions. s. Turn Turn the the sta start rt swit switch ch OFF OFF to stop stop the the engi engine ne.. Use the the hand handra rails ils and and ste steps ps to to get get off off the the mach machin ine. e. Imme Immedi diat atel elyy ca call for for hel help. p. When When using using a fire extin extingui guishe sher, r, alway alwayss aim the the exting extinguish uisher er at the the base base of the fire fire If an optional optional fire extinguishing extinguishing system is is in place place be be finality finality with with it’s it’s operating operating procedures. procedures.
FIRE EXTINGUISHE EXTINGUISHER R AND A ND FIRST AID K IT As a precaution if a fire or an injury should occur, always keep a fire extinguisher and first aid kit on your machine and do as follows: Be sure that fire extinguisher is in good condition and read the label • on it to ensure you know how to use it. Keep a first aid kit in the storage area. Check the kit periodically • and make any additions if i f necessary. • Keep a list of emergency phone numbers in case of an accident.
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SAFETY
MOUNTING AND DISMOUNTING When mounting or dismounting this machine, always be sure the work equipment is fully lowered to the ground and the engine is OFF. Use all hand holds and step plates on your machine. Never jump off or on to the machine. Before getting on the machine, if there is any oil, grease, or mud on your shoes, rails, steps or platforms, wipe it off immediately, always keep these areas clean, and in good condition. Never get on or off a moving machine. These actions may lead to serious injury. Always bring the machine to a full stop. Be sure machine is at a full stop, equipment lowered and parking brake set before entering or exiting machine.
When getting on or off the machine, always face the machine and maintain a Three Point Contact (both feet and one hand or one foot and both hands) with the handrails, steps and platforms to ensure that you support yourself properly.
When entering the cab and opening the cab door, push the door open until it is securely into the door klatch (1) and held in position. Use the hand rails on the inside of the door while entering or exiting the cab. Never hold any control levers or the steering st eering wheel when getting on or off the machine.
1-16
WA380-6
SAFETY
INSIDE OPERATOR’S COMPARTMENT When entering the operator’s compartment, always remove mud and oil from the soles of your shoes. If you operate the brake pedal with mud or oil on your shoes, your foot may slip and may cause an accident. After using the ashtray, make sure matches or cigarettes are properly extinguished and be sure to close the lid. If the ashtray is left open, there is danger of fire. Do not leave lighters or aerosol cans lying around the operator’s compartment. If the temperature inside the operator’s compartment get’s too high, there is danger that the lighter may explode. Do not stick suction pads to the window glass. Suction pads may act as a lens and could cause fire. Do not use cellular telephones inside the operator’s compartment when driving or operating the machine. After market radios or other electrically operated equipment in the cab must be fused close to the power supply Never bring any dangerous objects such as flammable or explosive items into the operator ’s cab. To To ensure safety, do not use the radio or music headphones when operating the machine. Keep the operator’s compartment clean, never allow trash or tools to accumulate, these may hinder the operation of the controls or pedals. When operating the machine, do not put your hands or head out of the window or beyond the protection of the ROPS. Always use the seat belt equipped with your machine. Be sure the seat belt is fastened snugly around your waist before operating the machine.
PRECAUTIONS WHEN STANDING UP FROM OPERATOR'S SEAT When standing up from the operator's seat, lower the work equipment, set work equipment lock lever (1) to Lock position (L), parking brake switch (2) to ON position (Heathen stop the engine. If you touch the control lever, the machine may suddenly move and cause serious personal injury or death.
PRECAUTIONS WHEN USING ROPS The ROPS (Roll Over Protective Structure) must never be removed from the machine. The ROPS is installed to protect the operator if the machine should roll over. It is designed not only to support the load if the machine should roll over, but also to absorb the impact of the energy. energy. The ROPS fulfills all the regulations and standards for all countries, but if it is modified without authorization or is damaged, the strength may be reduced and it may not able to fulfill its function properly. Never drill, cut or modify the ROPS structure, if the ROPS structure should become damaged in any way, replace it immediately. Do not make repairs to the ROPS structure its self.
EMERGENCY ESCAPE FROM OPERATOR'S CAB If the door of the cab does not open or it is dangerous to get off the machine from the side where the door is, release the open lock of the right window and use the right window as an emergency escape route. See “CAB WINDOW” WINDOW” on page page 2-69
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SAFETY
LEAVING OPERATOR’S COMPARTMENT Below are listed procedures that must be followed when exiting the operator’s cab. 1. Park the the machine machine in a level area, lower all work work equipmen equipmentt to the the ground. 2. Enga Engage ge the the par parki king ng bra brake ke in in the the (LOCKED) position.
3. Place Place safety safety lock lock lever lever for load loader er contro controll in the the (LOCKED) position. 4. Turn the engine engine OFF, OFF, remove remove ignition ignition key key and keep keep the the key with you. 5. Use the the key to lock lock and and secur securee all the the equipm equipment ent locks locks.. This will will prevent other unauthorized personnel from tampering with your machine. Keep in mind you are responsible for securing your machine.
Remark
Never leave your machine running and unattended, even for a moment.
Work equipment posture: See “STOPPING AND PARKING THE MACHINE” on page 2-101 Lock: See “WORK EQUIPMENT” EQUIPMENT” on page 2-108
KEEP OPERATOR'S OPERATOR'S COMPARTMENT COMPARTMENT CL EAN • • • •
When entering entering the operator's operator's compart compartment, ment, always always remove remove all mud and oil from the the soles of of your shoes. shoes. If you you operate operate the pedal with mud or oil on your shoes, your foot may slip and this may cause an accident. Do not not leave leave parts parts or or tools tools lying lying arou around nd the the operato operator's r's comp compartm artment ent.. Do not not use cellular cellular telephone telephoness inside the operato operator's r's compartme compartment nt when when driving driving or operating operating the the machine. machine. Never bring any danger dangerous ous objects objects such as as flammable flammable or explosive explosive items into into the the operator's operator's cab.
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WA380-6
SAFETY
DUST HAZARD PRECAUTIONS Dust can be hazardous to your health if inhaled. Komatsu does not use asbestos in its products. There is a danger imitation products may contain asbestos. If you have to handle materials containing asbestos fibers or other dust materials during demolition operations, always do as follows. • Neve Neverr use use comp compres ressed sed air air for for clean cleaning ing.. • Use water water to to keep keep dow downn the the dust dust whe whenn clea cleanin ning. g. • If there there is is a dange dangerr there there may may be asbe asbestos stos dust in the the air, air, oper operate ate the the machine with the wind to your back whenever possible. • Use Use an appr approv oved ed resp respir irat ator or.. • Do not not allow allow any other other perso personn into into the the area area during during operat operation. ion.
ASBESTOS ASB ESTOS HAZA HAZARD RD ALERT AL ERT Asbestos dust in the air can cause lung cancer if they are inhaled. There is danger of inhaling asbestos materials when working on jobsites doing demolition work or handling industrial waste. Always observe the following. • •
• •
Spray Spray wate waterr to keep keep down down the the dust dust when when clean cleaning ing.. Do not use compressed air for cleaning. If there there is dange dangerr that that there there may may be asbesto asbestoss dust dust in the the air air,, always always operate the machine from an upwind position. All workers should use an approved respirator. Do not not allow allow other other person personss to approa approach ch durin duringg the the opera operation tion.. Always Always obse observe rve the rules rules and and regul regulatio ations ns for for the work site and environmental standards.
CRUSH OR PINCH POINT DANGERS Never stand in or place any part of your body between the movable components such as the articulating portions of the machine or between the machines work equipment. Keep in mind, when the machine is operated, the clearance will change, this may lead to serious personal injury or death. Never drive up to any one standing in front of a solid object or your path of travel. The brakes could fail or the machine could slide on a slippery surface causing injury or even death.
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SAFETY
PRECAUTIONS BEFORE STARTING OPERATIONS As an operator of the machine, you are responsible for the safe operation of the machine at all times regardless of the situation. Although KOMATSU cannot cover all operating conditions that pose a major hazard here are a few basic situations to avoid when using the excavator during work or travel operations. It is advised to study these and always be aware of them before starting your work operations. Failure to do so may result in damage to the machine or injury to the operator and other personnel.
PRE-OPERATI PRE-OPERATIONAL ONAL CHECKS Before starting your work operations it is important to perform a Pre-operational Check to be sure your equipment is in safe operating condition. If any problems are found during your Pre-operational Check, have them repaired immediately. Never operate a machine that is unsafe, unsaf e, damaged or in need of repair. Failure to perform a pre-operational check before starting work w ork operations may result in damage to the machine or injury to the operator and other personnel. Remark
It is important that a pre-operational check be performed at the beginning of your work shift, even if you are taking the machine operations over from another operator, always perform a pre-operational check before you start work.
STARTING YOUR WORK OPERATIONS • • • • • • • • • • • • •
Before Before oper operatin atingg the machin machine, e, walk walk arou around nd it and check check for for peopl peoplee or objects that might be in the way. Do not not start start the the engin enginee if warn warning ing tags tags have have been been attac attached hed to the the steering wheel or control levers. Sound Sound your your horn horn to warn warn other otherss in the area before before starting starting the engine or moving the machine. Operate Operate the machine machine in a seat seated ed posit position ion only only,, with the seat seat belt belt fastened snugly around your waist. Do not not allow allow anyone anyone in the the cab cab or on the the mach machine ine during during operaoperations. Be sure sure all all person personnel nel are are clea clearr from your your work work site site before before startin startingg any work operations. Inspect Inspect for damage damagedd hoses hoses which which may leak or spray spray fluid fluids. s. Before operating operating the machine, machine, walk around it and check for people people or objects objects that might might be in the way. way. Make Make sur suree the the safe safety ty bar bar (1) (1) is is secu secure rely ly in in plac place. e. Do not not start the engine engine if warning warning tags tags have have been been attached attached to the steering steering wheel wheel or control control levers. levers. Sound your horn to warn others in the area before starting the engine engine or moving moving the machine machine.. Operate Operate the machine machine in a seated seated position position only, only, with the the seat seat belt fastened fastened snugly around your waist. waist. Do not not allow allow anyo anyone ne in the cab cab or or on the the mach machine ine during during oper operati ations. ons.
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SAFETY
WORK SITE HAZARDS Before proceeding with any excavating or grading operations it is important to be aware of the hazards involved with this operation. Below is a list outlining what to do to avoid some of these hazards. • Before Before starting starting any excava excavating ting or grad grading ing operati operations, ons, contact all utility departments in your area and have them identify and mark any underground system locations, (gas lines, water lines, electrical lines, sewer lines, etc.). • Check Check your your work work area area for any unusua unusuall groun groundd cond conditio itions. ns. • Make Make sure sure your your work work area area is as as level level as possi possible ble and you will be able to maneuver your work equipment or machine easily. • If you you will will be be workin workingg near near a high traffic traffic area, area, (pede (pedestri strians ans or cars) have a dedicated worker available to direct traffic or install safety fencing around your work site. • Alway Alwayss be awar awaree of all all you yourr work work site site dang danger erss or distractions. • Operations Operations such such as logging, logging, mulching, mulching, land clearin clearingg or landfill landfill operation operationss may cause cause trash trash and debris to accumulate accumulate on on the machine. Remove debris or trash on a daily or more frequent basis as necessary to prevent fire. • Always clean clean trash trash from the exhaust exhaust system system compartm compartments. ents. The The hot exhaust exhaust compartments compartments may may cause cause fire from contact contact with flammable material. • Remove any leaves, leaves, wood wood chips, chips, paper, paper, wood dust dust or anything anything that that could catch catch fire fire accumulate accumulatedd around around the engine. engine.
AVOIDING DANGEROUS DANGEROU S SITUATIONS Avoid traveling with the bucket raised. Rasing the bucket raises the center of gravity on the machine. Traveling with a raised bucket, especially a loaded bucket may result in loss of control or a rollover situation. Never raise the bucket unless the machine is stopped.
When the bucket is raised and loaded, never make sharp turns or stop the machine suddenly, this may cause the machine to tip forward.
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SAFETY Always handle unstable loads carefully, avoid tipping the bucket back or raising the load too high. Be sure sur e to operate the work equipment carefully and keep the load as close to the ground as possible.
Do not use the bucket or lift arms as a crane. The object you are lifting may swing or shift causing the machine to tip, sway or possibly rollover.
Never work under overhangs or excavated bank areas. These could collapse and damage the machine or injure the operator.
WORKING CLEARANCES It is always a good idea to be aware of your clearances around, in front, behind and especially above your work area or travel rout. .Some basic safety precautions to prevent risk are: • When When workin workingg or travelin travelingg in an area area where where clea clearan rances ces are a problem, travel at a slow cautious cauti ous speed. • If you you are are not sure of your your clea clearan rances ces,, reques requestt the aid of anoth another er person who can guide or warn you if you get too close to objects.
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SAFETY •
•
•
Be aware aware of of the the dang dangers ers when when work working ing around around overhe overhead ad electrical lines, high humidity may pose an electrical hazard even if your machine clears the overhead power lines. If your your machin machinee shoul shouldd come come in contac contactt with with overh overhead ead electri electrical cal lines, stop the machine and remain on the machine until the power company clears the lines and it is safe to get off or move the machine. If low low power power lines lines pose pose a greate greaterr hazar hazard, d, ask ask the power power compa company ny to remove the lines until your work is finished.
Cable Voltage
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Min. Safe Distance
6.6kV
3m
10 ft.
66.0kV
5m
16 ft.
275kV
10 m
33 ft.
500kV
11 m
36 ft.
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SAFETY
RULES FOR ROAD ROA D TRAVEL TRAVEL Traveling with your machine may pose some hazards. When traveling, always travel in a safe manor and remain alert at all times A safety conscious operator is the most important insurance when traveling with the machine. Below are several situations and information the operator should be aware of: 1. Raise Raise the load loader er bucke buckett to a safe safe travel travel height height of of 40-50 40-50 cm (16-20 in) from the ground, lock the loader control levers using the safety lock equipped with the machine. 2. Obey all traffic rules when traveling traveling on local and state roads. Always travel at a safe controllable speed. 3. Never Never turn the the ignition ignition key key off off when trave traveling ling.. If the engine engine should stop, apply the brakes and stop the machine immediately. 4. Always Always be awar awaree of your your clearanc clearances es and road road surfac surface. e. Some Some areas may not support the weight of your machine. Plan your rout in advance. If necessary, obtain the aid of an escort to lead or prepare your travel rout. 5. Never travel at high high speeds, speeds, loss loss of control control or tire damage damage may result. result.
TRAVELING IN REVERSE Traveling in reverse may pose several hazards. Below is a list if some basic rules to follow when traveling in reverse: • Be sure sure the area area behin behindd you you is clear clear of of people people or obje objects cts that that might be in the way • Before Before moving moving your your machi machine, ne, sound sound the the horn horn to warn warn others others in your area you are moving. • When When opera operating ting in area areass that that may may pose pose a hazar hazardd or has poor poor visibility, designate a person to direct your movements. • Do not not rely rely totall totallyy on you you machi machines nes mirrors, mirrors, keep keep in mind mind ther theree are blind spot when using the mirrors.
TRAVELING ON ICY OR SNOW-COVERED SURFACES If the ground is icy or covered with snow, the response of the machine to the movements of the steering wheel may not be as precise as expected. To limit the risk resulting from reduced maneuverability, proceed as follows: • Trave Travell at a slow slow safe safe speed speed.. Avoi Avoidd rapped rapped acce accelera leration tionss or breaki breaking. ng. • Rememb Remember er your your stoppi stopping ng distan distances ces are are reduc reduced ed during during slippe slippery ry condi condition tions. s.
WORKING ON LOOSE L OOSE OR UNST UNSTAB ABL L E GROUND To limit the risk when working in these areas: • Avoid operating operating the machine machine too close too too the edge edge of a cliff, cliff, open open trenches trenches or ditch ditch lines. These These areas areas may collapse collapse under the weight of your machine causing serious damage to the machine or injury to the operator. • Keep in mind mind after after a heavy heavy rain or or thaw, thaw, the surface conditions conditions become become worse and less less stable. stable.
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SAFETY
TRAVEL TRAVEL ON SLOPES Traveling on slopes may pose a hazard. In order to prevent tipping the machine or losing control it is important to follow some basic simple rules: . Never turn the ignition key off when traveling up or down a slope. If the engine should stop, apply the brakes and stop the machine immediately. When traveling over rough ground travel at a slow controllable speed. When traveling up or down slopes with an empty bucket it is important to travel at a safe controllable speed with the bucket set in position “A” 20 to 30 cm (8 to 12 in) above the ground.
When traveling up or down a slope with a load, always keep the bucket 20 to 30 cm (8 to 12 in) above the ground and the load facing the top of the hill.
Never travel up or down a slope with the t he load facing the bottom of the hill. Loss of control may result when the brakes are applied.
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SAFETY Always travel straight up or straight down a slope, traveling at an angle on a slope may cause the machine to tip or possibly rollover.
PARK ING THE MACHINE When parking the machine it is important to follow several basic safety rules. Keep in mind you are responsible for the security of the machine when it is parked. Below is a list if some basic rules to follow when parking your machine. 1. Always Always park park the mach machine ine on on a flat level level locat location ion away away from from moving equipment, pedestrians or traffic. 2. Lower Lower all all work equi equipme pment nt on to the the ground ground and and neutra neutraliz lizee all controls. 3. Remove Remove the the igniti ignition on key key, set the the parking parking brake brake in in the “PARK” mode and lock the controls. See “LEAVING “LEAVING OPERATOR’S OPERATOR’S COMPARTMENT” COMPARTMENT” on page 1-18 Be sure all access panels, cab, fuel and oil tanks are locked and secure to prevent tampering with the machine while unattended. 4. Avoid parking parking the machine machine on a slope slope of any kind. If you must park on a slope, park with the bucket facing down the s lope and the wheels blocked to prevent any movement of the machine.
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SAFETY
PRECAUTIONS DURING MAINTENANCE OPERATIONS All maintenance performed on this machine must only be performed by trained and authorized personnel. When performing maintenance it is important import ant to follow the outlined maintenance procedures and safety i nformation outlined in this manual and in the Shop Manual for this machine.
WARNING TAGS For machines equipped with the Electronically Controlled Suspension System (ECSS) be sure the system is off before proceeding with any maintenance procedures. Before performing any maintenance operations on this machine, position the machine on level and firm surface.
Lock the equipment controls, remove the ignition key and tag the steering wheel. Alert all personnel in your area that the machine is down for maintenance. If necessary, tag the machine around specific points to warn others that this t his machine is down for maintenance. If the machine will be down for maintenance for a long period of time, be sure to check and see if the warning tags are still in place before you start your repair procedures the next day.
EQUIPMENT STORAGE Always store optional or extra work equipment in a safe and secure location. Do not store flammable liquids or materials for any length of time.
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SAFETY Store equipment in such a way that it cannot fall or cause injury to others.
WORKING UNDER THE MACHINE Always use approved jack stands to support the machine when performing maintenance under the chassis. Never rely on hydraulic jacks or the machines work wor k equipment to support the machine when working under or on the machine. Always lower the work equipment to the ground after raising the machine for repairs.
When carrying out maintenance or repairs with the bucket raised, always support the bucket safely with the proper support (1) as shown in the illustration.
USING DROP LA MPS Use only approved anti-explosion proof lamps when checking fuel, oil, or batteries. Non-approved lamps can cause an explosion or fire.
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SAFETY
KEEPING THE MACHINE CLEAN Never use flammable liquids to clean your machine. Use only approved non-flammable cleaning solvents to clean parts or the machine itself. Avoid using high pressure steam cleaners or caustic soaps to wash the machine if possible. Steam cleaning or using caustic soaps may damage paint, wiring or sensitive electrical components. Never use high pressure water or flood f lood the inside of the operator ’s cab. Doing so may damage sensitive electrical components. When pressure washing, use high pressure hot water and mild grease cutting soaps. Always grease the machine after cleaning to push any water out of the pivot point connections. Remove trash daily or more often as necessary. Never allow trash to accumulate on the machine.
RUNNING THE MACHINE DURING MAINTENANCE If during maintenance the engine must be run have someone remain in the operator’s seat while the engine is running. This is if the engine must be shut down quickly. Be sure all work equipment is “LOCKED” and the ECSS system is off. For machines equipped with the Electronically Controlled Suspension System (ECSS) be sure the system is off before proceeding with any maintenance procedures.
Set the parking brake in the “ LOCK” mode and instruct the person sitting in the t he cab not to operate any controls unless instructed to.
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SAFETY Always lock the front and rear frames with the safety bar (1).
Be aware of rotating parts while the engine is running.
RULES FOR REFUELING THE MACHINE Always clean up any spills. Grease, fuel, oil or coolant spills can pose a trip hazard if not moped up immediately. Be sure you are adding the correct fluids to the proper location. Mixing fluids can cause damage to internal components. When refueling or adding any fluids, be sure you are in a well ventilated area. Never smoke or allow open flames near you while you are refueling the machine. Never mix gasoline with diesel fuel. f uel. Gasoline is extremely flammable and could cause an explosion. Do not fill the fuel tank completely, leave room for the fuel to expand.
COOLING SYSTEM PRECAUTIONS Never add coolant to a hot or warm engine. Always allow the engine time to cool down completely before opening the radiator cap. Never dump used coolant on the ground, in a lake, stream or in a sewer system. EPA Law requires these fluids to be captured and recycled properly. Failure to do so is in violation of the law.
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SAFETY
BATTERY PRECAUTIONS When working on the electrical system, disconnect the negative (-) battery cable first then the positive posi tive (+) battery cable last. On completion of work, reconnect the positive (+) cable first then the negative (-) cable last. When using jumper cables to start the machine as shown below, hook the positive (+) jumper up first, then the negative (-) jumper last to a remote location on the chassis.
STARTING THE MACHINE Never try to start the m achine by tampering or shorting the starter terminals. Accidental movements of the machine could cause injury or even death. Always start the machine seated in the operators cab using the ignition switch. See “ELECTRICAL “ELECTRICAL CIRCUITS” CIRCUITS” on page 2-137
Never Never use a welder or a machine with a hig her voltage system to j ump s tart the machine. Using Using a higher vo ltage to jump-start a machine may damage the machines machines electrical sys tem or cause an unexpected explosion or fire. Always jump-start a machine with equal voltages and never allow the machines to touch each other when jump starting a machine.
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SAFETY
HIGH PRESSURE HOSES The hydraulic system is always under internal pressure. When inspecting or replacing piping or hoses, always check that the pressure in the hydraulic circuit has been released. If the circuit is still under pressure, it will lead to serious injury, so always do as follows. Do not carry out any inspection or replacement work when the hydraulic system is under pressure. If there is any leakage from the piping or hoses, the surrounding area will be wet, so check for cracks in the piping and hoses and for swelling in the hoses. When carry out inspection, wear safety glasses and leather gloves. There is a hazard that high-pressure oil leaking from small holes may penetrate your skin or cause blindness if it contacts your eyes directly. If you are hit by a jet of high-pressure oil and suffer injury to your skin or eyes, wash the place with clean water, and consult a doctor immediately for medical attention.
SAFETY HANDLING HIGH-PRESSURE HOSES If oil or fuel leaks from high-pressure hoses, it may cause fire or defective operation, which may lead to serious injury. If any loose bolts are found, stop work and tighten to the specified torque. If any damaged hoses are found, stop operations immediately and contact your Komatsu distributor. • • • • • •
Replac Replacee the the hose hose if if any any of the followi following ng probl problems ems are found. found. Dama Damage gedd or or lea leaki king ng hydra hydrauli ulicc fittin fitting. g. Frayed Frayed or cut cut cover covering ing or or expos exposed ed reinf reinforc orceme ement nt wire wire layer layer.. Cove Coveri ring ng swo swolle llen in in pla place ces. s. Twiste wistedd or crush crushed ed mova movabl blee porti portion on.. Fore Foreig ignn mat mater erial ial embe embedd dded ed in cove coverin ring. g.
PRECAUTION FOR HIGH FUEL PRESSURE PRESSURE High pressure is generated inside the engine fuel piping when the engine is running. When carrying out inspection or maintenance of the fuel piping system, wait for at least 30 seconds after stopping the engine to let the internal pressure go down before starting inspection or maintenance. Never loosen a fuel injector line while engine is running severe injury may result from the high pressure fuel spray.
HIGH TEMPERATURES TEMPERATURES AREAS AREA S When you stop the machine at the end of a job, remember the engine coolant, oil, all engine parts, exhaust stack and the hydraulic system is still hot and under pressure. If you attempt to drain engine coolant, hydraulic fluid, or engine oil under these conditions, you expose yourself to various dangers, including the risk of serious burns. Carry out maintenance procedures described in this manual only when the machine has had time to cool down.
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SAFETY
DISPOSAL DISPOSAL OF WASTE WASTE MATERIAL MATERIAL S Never dump waste fluids in a sewer s ewer system, on the ground in rivers, ri vers, etc. Always drain fluids from your machine into the appropriate containers.Never drain fluids directly onto the ground. Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, filters, batteries, coolant, brake fluid and hydraulic oil.
INFLATING TIRES Always bear in mind that tires can burst while being inflated, causing serious accidents. Before servicing the tires, observe the following precautions: • Before Before inflatin inflatingg tires, tires, always always check check the wheel wheel rims, rims, tire tire walls walls and tread for cuts, broken cords, or other damage. • Have Have a tire expert expert perform perform checks checks and tire mainte maintenan nance. ce. • When When inflati inflating ng tires tires,, use a prote protectiv ctivee cage, cage, and a compre compressed ssed air gun with extension hose and pressure gauge. • Make Make sure sure ther theree is nobody nobody in the the vicin vicinity ity before before startin startingg to inflate a tire. Stand at the tread side of the tire to inflate it.
DISPOSAL DISPOSAL OF WASTE WASTE MATERIAL MATERIAL S Never dump waste fluids in a sewer s ewer system, on the ground in rivers, ri vers, etc. Always drain fluids from your machine into the appropriate containers.Never drain fluids directly onto the ground.
Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, filters, batteries, coolant, brake fluid and hydraulic oil. Recycle when ever possible.
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SAFETY
ACCUMUL A CCUMULATOR ATOR This machine is equipped with an accumulator charged with high-pressure nitrogen gas. Before servicing the accumulator, observe the following precautions: • Do not not dis disse semb mble le the the acc accum umul ulat ator or.. • Do not not expo expose se the the accum accumula ulator tor to to high high heat heat or an an open open flam flame. e. • Do not not wel weldd on on the the accu accumu mula lato torr. • Do not not dril drilll or cut cut the the acc accum umul ulat ator or.. • Do not not strik strikee or or cru crush sh the the acc accum umula ulator tor.. • When When repla replacin cingg or dispo disposing sing of the the accum accumula ulator tor,, always always release release the nitrogen pressure from the chamber.
CRITICAL PARTS Periodically some parts must be replaced due to safety purpose. Even if these parts seem to be in good condition and operating properly they may fail at some point causing possible injury to the operator or pedestrian. Listed are some of the systems containing these components that may fail under extended use: • Seat belts. • Fuel Fuel supp supply ly and and del deliv iver eryy hos hoses es.. • Hydra Hydraul ulic ic syste system: m: main main del delive ivery ry hose hosess and and tubin tubing. g. • Hydrau Hydraulic lic hose hoses: s: all all the hoses hoses that that feed feed and and return return the hydrau hydraulic lic fluid to and from the work equipment. For additional information: See “PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS” PARTS” on page 3-15
HIGH VOLTA VOLTA GE When the engine is running or immediately after it has stopped, high voltage is generated at the injector terminal and inside the engine controller, so there is danger of electrocution. Never touch the injector terminal or the inside of the engine controller. If it is necessary to touch the injector terminal or the inside of the engine controller, please contact your Komatsu distributor.
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OPERATION
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2
2-1
OPERATION
GENERAL GENERAL VIEW OF MACHINE OUTSIDE VIEW OF THE MACHINE
1. 2. 3. 4. 5. 6. 7.
2- 2
Bucket Tilt le lever Front wheel Buck Bucket et cylin ylinde der r Fron Frontt wo workin rkingg lam lampp ROPS cab Rear wheel
8. 9. 10. 10. 11. 12. 13.
Turn sig signal nal lamp lamp Head lamp Lift Lift cyl cylind inder er Lift Lift arm arm Rear Rear work working ing lamp lamp Rear Rear combin combinatio ationn lamp lamp
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OPERATION
INSIDE VIEW OF THE CAB
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 10. 11. 11. 12. 13. 14.
Direc Directio tiona nall leve leverr stopp stopper er Rea Rear wip wiper er swit switch ch Fron Frontt wip wiper er swit switcch Gear Gear shif shiftt leve lever r Front ront swit switcch pa panel nel Dire Direcctio tional nal leve lever r E.C. E.C.S. S.S. S. swit switch ch Horn switch Mach Machin inee moni monito tor r Stee Steerin ringg wheel wheel Hazard Hazard lamp lamp switc switchh Lamp switch, switch, Turn Turn signal signal lever, lever, Dimmer switch switch Parkin Parkingg brake brake switch switch Cigare Cigarette tte lighter lighter
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15. 15. 16. 17. 17. 18. 19. 19. 20. 21. 22. 23. 24. 24. 25.
Kickd Kickdow ownn switch switch Lift arm cont control rol leve lever r Hold Hold swit switch ch Bucket Bucket cont control rol leve lever r Igniti Ignition on switc switchh Right Right switc switchh pane panell Accele Accelerat rator or pedal pedal Right Right brak brakee peda pedall Steerin Steeringg tilt lock lock lever lever Left Left brak brakee pedal pedal Safety Safety lock lock leve lever r
2-3
OPERATION
DESCRIPTION OF ALERTS, GAUGES AND SWITCHED SYSTEMS Before operating the machine it is important to understand all the functions equipped with your machines monitor. Operating the machine without knowledge of all the alert systems may damage the machine, property or possibly cause injury to the operator. Below is a description of all monitoring functions.
INSTRUMENT BEZEL
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
2- 4
Cent Centra rall warn warnin ingg lam lampp Brak Brakee oil oil pres pressu sure re cau cauti tion on lam lampp Engi Engine ne oil oil pres pressu sure re cau cauti tion on lam lampp Water ater sep separ arat ator or cau cauti tion on lam lampp Radiat Radiator or cool coolant ant level level cautio cautionn lamp lamp Engi Engine ne oil oil leve levell caut cautio ionn lamp lamp Trans Transmis missio sionn filter filter clog cloggin gingg cautio cautionn lamp lamp Air cleane cleanerr clog cloggin gingg caut caution ion lamp lamp Park Parkin ingg brak brakee pilo pilott lamp lamp Axle oil temper temperature ature caution caution lamp lamp Cooling Cooling fan fan reverse reverse rotati rotation on pilot pilot lamp lamp Mainte Maintenan nance ce cauti caution on lamp lamp Battery Battery electroly electrolyte te level level caution caution lamp (if equipped) equipped) Batte Battery ry charg chargee caution caution lamp lamp Steering Steering oil pressu pressure re caution caution lamp Emergency Emergency steering steering pilot lamp Charac Character ter disp display lay port portion ion Power Power mode mode pilot pilot lamp lamp (P (P mode) mode) Pre-he Pre-heat at pilot pilot lamp lamp Semi auto diggin diggingg pilot pilot lamp lamp (if equipped) equipped) Lockup Lockup pilot pilot lamp lamp (if (if equipp equipped) ed)
22. 23. 24. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 33. 34. 35. 36. 37. 38. 39. 40. 40. 41.
Joysti Joystick ck pilot pilot lamp lamp pilot pilot lamp Directiona Directionall select selector or pilot pilot lamp Shif Shiftt ind indic icat ator or Auto-s Auto-shif hiftt pilot pilot lamp lamp Auto-greas Auto-greasing ing pilot pilot lamp lamp (if (if equippe equipped) d) Shift Shift hold hold pilot pilot lam lampp Shift lever lever positio positionn pilot pilot lamp Torque convert converter er oil temper temperatur aturee gauge Torque converte converterr oil tempera temperature ture caution caution lamp lamp Engine Engine coolant coolant temperat temperature ure gauge Engine Engine coolant coolant temper temperature ature caution caution lamp lamp Spee Speedom domet eter er Turn Turn signa signall pilot pilot lamp lamp Head Head lamp lamp high high beam beam pilot pilot lamp lamp Meter Meter displ display ay pilot pilot lamp lamp Hydraulic Hydraulic oil oil tempera temperature ture caution caution lamp lamp Hydrau Hydraulic lic tempe temperat rature ure gauge gauge Fuel Fuel level level cautio cautionn lamp lamp Fuel Fuel gaug gaugee Economy Economy operation operation display display lamp
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OPERATION
SWITCH PANEL PANELS S These switches are used to control various functions relating to the machines operating system, it is important the operator become familiar with the switch swi tch function and what system they control Without knowledge of all the sw itch controlled systems damage the machine, property or possibly cause injury to the operator may result.
RIGHT SWITCH PANEL
FRONT SWITCH PANEL
1. 2. 3. 4. 5.
10. 11. 12. 13.
6. 7. 8. 9.
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Trans Transmiss mission ion shift shift mode mode selector selector switch switch Transm ransmiss issio ionn cut cut-of -offf switc switchh Tran Transmi smissi ssion on cut cut-of -offf set set switc switchh Directio Directional nal selecto selectorr switch switch actuat actuation ion switc switchh Emer Em erge genc ncyy stee steerin ringg swit switch ch (machines equipped with emergency steering) Powe Powerr mod modee selec selector tor switc switchh Torque orque conv converte erterr lock-up lock-up switc switchh (if equip equipped ped)) Cool Cooling ing fan fan reve reverse rse rot rotati ation on switc switchh Igni Igniti tioon swit switch ch
Monitor panel mode selector selector switch switch 1 Monitor panel mode selector selector switch switch 2 Front Front working working lamp lamp switc switchh Rear Rear working working lamp lamp switc switchh
2-5
OPERATION
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM Before operating the machine it is important to understand all the functions equipped with your machines monitor. Operating the machine without knowledge of all the alert systems may damage the machine, property or possibly cause injury to the operator. Below is a description of all monitoring functions.
INSTRUMENT BEZEL
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 ❉
2- 6
When turning the ignition switch to the “ON” position before starting the engine, the central warning lamp, caution lamps, and pilot lamps light up for 2 seconds to check the system. • After After the alarm alarm buzz buzzer er sounds sounds for for 2 seconds seconds,, it goes goes off if the the conditi condition on is normal normal.. • The shift shift indic indicato atorr displ display ay shows shows “88” “88” for for 2 seco seconds nds.. • The indicator indicator gauges gauges and meters are actuate actuatedd after after the above system check is completed completed.. • The charac character ter display display shows shows “KOMA “KOMATSU TSU”” for for 3 second seconds. s. • If the lamps lamps do not light light up, there there is probab probably ly a failure failure or disconnectio disconnection. n. Contact Contact your your Komatsu Komatsu distributor distributor for inspection.
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OPERATION TYPES OF WARNING If an abnormality occurs on the machine, or if any switch or lever is operated mistakenly, the monitor display and buzzer alert the operator. These are the following types of warnings depending on the level of warning.
EMERGENCY STOP
This warning is given if there is a serious failure that affects the normal operation of the machine or if a setting is incorrect. The central warning lamp on the monitor and the caution lamp for the location of the abnormality will light up. At the same time, the alarm buzzer sounds and action code “E03” is displayed on the character display (1).
CAUTION
This warning is given if the engine coolant or lubricating oil overheats. The central warning lamp on the monitor and the individual caution lamps light up also. At the same time, the alarm buzzer sounds and action code “E02” is displayed on the alert display (1).
MISTAKEN OPERATION
This warning is given if any switch or lever is operated mistakenly. The central warning lamp on the monitor lights up and the alarm buzzer sounds at the same time. In addition, in the following case, action code “E00” is displayed on character display (1). • •
When When the the machin machinee has has exce exceede ededd the the trave travell speed speed limit. limit. When the the work equipment equipment lock lock lever lever is at the the LOCK position position and the EPC EPC control control lever lever is at any any position position other other than than neutral. (Machines equipped with EPC)
INSPECTION INSPECTION AND MAINTENANCE
This warning is given if it is necessary to perform inspection and maintenance of wear parts, or if it is necessary to check the oil or engine coolant level. The individual caution lamp on the monitor lights up. At the same time, action code “E01” is displayed on the character display (1). In the case of this warning, the central warning lamp does not light up and the alarm buzzer does not sound
CENTRAL WARNING LAMP
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 perform the specified action for the item.
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2-7
OPERATION
MACHINE ELECTRONIC MONITORING DISPLAY This display system electronically monitors several major functions, these functions include the amount of operating hours on the machine, all operating alert and failure information and service intervals. These functions can be accessed by using the mode selector switches (1) and (2). It is important for the operator of this machine to know how to access this information and understand what this information contains
1. Service meter ter 2. Acti Action on code code disp displa layy
3. Fail Failur uree cod codee dis displ play ay 4. Filter Filter,, oil oil replac replaceme ement nt time display display
MONITOR MODE SELECTOR SWITCHES In order to access information on the monitor, the mode selector switches must be used in conjunction with each other. These switches are located on the right hand side of the instrument panel as shown in the illustration. They allow you to enter or exit a mode as well as navigate within the mode. There operating function is listed below:
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OPERATION MODE SELECTOR SWITCH 1 Mode selector switch (1) is used to switch the function of the character display on the monitor screen. The basic operation is as follows. Position: To select, confirm or enter a mode or operation. Position: To exit or cancel mode or operation.
MODE SELECTOR SWITCH 2 Mode selector switch (2) is used to navigate within the chosen display on the monitor screen. The basic operation is as follows. Position: To go on to the next screen or function, move the cursor forward, or to increase the number when entering numerals Position: To go back to the previous screen or function, or to move the cursor back, or to reduce the number when entering numerals
MONITOR DISPLAY INFORMATION Once you know the operating functions of the mode selector switches (1) and (2) it is important to be able to access this information and navigate within the mode you have selected, below is a list of these mode and how to access and navigate within them.
SERVICE METER DISPLAY An hour meter reading or an odometer reading can be displayed in this mode if desired. Hour Meter Display
During normal operation display (1) shows the total time in hours that the machine has been operating. While the engine is running, the hour meter advances even if the machine is not moving. The hour meter advances by 1 hour of operation, regardless of the engine speed. You can also access the hours on the machine with the ignition switch in the “OFF” position simply by pressing the () button. Remark
When the starting switch is at the OFF position, if the service meter is displayed even though the top ( ) of machine monitor mode selector switch 1 is not being pressed, there is probably a failure in the machine, so please contact your Komatsu distributor for inspection.
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OPERATION ACTION CODE DISPLAY If an inspection or maintenance procedure must be performed, if there is a failure on the machine, or if it should become necessary to change your operating methods, An action code E00, E01, E02, or E03 will be displayed on the monitor display portion (3). If different failures should occur at the same time, the action code for the most serious problem is displayed. The action code will be displayed first, then the system with the failure will be displayed at 3 second intervals. The level of seriousness in the action code order is as follows, starting with the most serious: E03, E02, E01, E00. In the case of action codes E00, E02, and E03, the alarm buzzer sounds intermittently and the central warning lamp lights up. Ac ti on Cod e (E03)
This code is the most serious of all the codes, it usually indicates an oil pressure loss or a malfunction in a safety related system. If this code should appear on the monitor, stop and shut the machine down immediately. Contact your Komatsu Dealer and do not operate the machine until the problem is repaired. Remark
“E03” is displayed on the top line of the character display and “CHECK RIGHT NOW” and “CALL” are displayed in turn on the bottom line for 3 seconds each. The telephone number is displayed to the right of “CALL”. If no telephone number has been set, the display is blank. For details of the method of inputting the telephone number, see “ENTERING “ENTERING A TELEPHONE NUMBER” NUMBER” on page 2-31. 2-31. Ac ti on Cod e (E02)
This code warns the operator of a potential failure if action is not taken immediately. This would be an over heat condition or an engine over speed. If this code should appear while operating the machine, stop the machine and allow the system to cool down or contact your komatsu distributor for repairs. Remark
The top line of the character display displays “E02” and the bottom line displays the condition of the machine related to overheating.
Ac ti on Cod e (E01)
This code alerts the operator of a problem in the system. This would be low coolant level or a maintenance due item. If this code should appear while operating the machine, take the machine to a maintenance area so servicing can be carried out or the problem can be checked. Remark
“E01” is displayed on the top line of the character display and “MAINTENANCE” or the part of the machine requiring inspection, filling of fluid, or replacement is displayed on the bottom line.
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OPERATION Ac ti on Cod e (E00)
This code will appear if the parking brake is not fully released or the machine is traveling at an excessive road speed or down hill at an excessive speed. If this should occur, slow the machine down immediately to a safe speed. Never N ever over speed the engine, damage to the engine will occur. If an item related to the work equipment control lever is displayed, return the lever to the HOLD position. (Machines equipped with EPC) Remark
Action codes cannot be erased or canceled, after repairs have been made the system will automatically reset its self and the code will disappear.
FAILURE CODE DISPLAY If an action code is displayed, check the failure code using the failure code display method given below.When contacting your Komatsu distributor to request repairs, please inform your distributor of the failure code. Method Method Of Displaying Failur Failur e Code
If an action code is displayed on the monitor display portion (3), press the mode selector switch swit ch (>)button. 1. The action action code code will will chang changee to the the failure failure code. code. • •
•
The failure failure code code is displ displaye ayedd with with the first first 6 digit digitss on the the left left side of the character display. The code code displa displayed yed after after the space space on on the the right right side side of of the the failure code indicates the controller that detected the failure code. The failure failure code code and and the the compo componen nentt causin causingg the failure failure are displayed on the character display for 3 seconds each. Top righ rightt code code
The controller in the system detecting the failure will be indicated.
MON TM WRK
Contr Controll oller er dete detecti cting ng failu failure re code code
Machine monitor Transmission controller Work equipment controller (if equipped)
Press the selector switch (>) button again. If the condition is normal, the service meter is displayed for several seconds, then the display returns to the action code. If more than one failure has occurred at the same time, the next failure code is displayed.
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OPERATION SERVICE DISPLAY After a complete system check when the ignition switch is turned to the “ON” position, if any filter or oil related item is approaching it’s replacement time, this display (4) shows the item for approx. 30 seconds. When this happens, the maintenance caution lamp also flashes or lights up. If this should occur during operation of the machine, have the maintenance performed as soon as possible. After replacing the filter or changing the oil, it is important to reset the time for replacement. Servic Servic e Items Items Li st Item
Service Interval (hrs.)
System Needing Service
System ID Number
Engine oil
500
ENG OIL
01
Engine oil filter
500
ENG FILT
02
Fuel pre-filter
500
FUEL P FILT
41
Fuel filter
500
FUEL FILT
03
Transmission oil
1000
TM OIL
12
Transmission filter
1000
TM FILT
13
Hydraulic filter
2000
HYD FILT
04
Hydraulic tank vent element
2000
HYD BREATH
05
Hydraulic oil
2000
HYD OIL
10
Axle oil
2000
AXLE OIL
15
Service Service Al ert Display
The ID number and item name needing service are displayed on the monitor display, the remaining time to service the item and the number of times a service has been performed are displayed in 3 second intervals. If the service time has already passed, a minus (-) sign appears before the time display. After the display has been on for 30 seconds, it does not appear again until the ignition switch is turned to the “ON” position again. The service information in the illustration is not shown on the monitor display if an action code is being displayed. The top line of the character display shows the ID No. and item name for the item needing replacement; the bottom line shows the time remaining until replacement and the total number of times the replacement has been carried out. If the replacement time has already passed, a minus (-) sign appears before the time. After the display has been given for 30 seconds, it does not appear again until the starting switch is turned to the ON position. The message in the illustration above is not shown on the character display if an action code is being displayed. If there are two or more items to be displayed, the display changes repeatedly every three seconds. If there are more than 10 items, all the items are displayed once each, then the display returns to the normal display. The display appears when there is 30 hours remaining until the filter or oil replacement time. If the replacement time has passed, a minus (-) sign appears before the time tim e for the first 30 hours. When more than 30 hours have passed, the display is no longer given. The maintenance caution lamp flashes as the replacement time approaches, and after the replacement time has passed, it lights up.
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OPERATION Resetting Resetting Service Service Times After Servicin g
Once an item has been serviced and the machine is ready to go back into operation it is necessary to reset the service time interval. It is important to do this in order to keep track of when it will be time to perform service on the machine again. Below is the procedure for resetting the service time interval. 1.
To enter enter reset reset mode the ignition ignition key must be in the “ON” position. position.
2.
Press the () selector switch button and it will display the odometer.
3. Using Using the (>) selec selector tor switch switch button button scroll scroll thoug thought ht the menu menu to the [MAINTENANCE] display. 4.
Once the [MAINTENANCE] display is reached, press the () selector switch button to enter the system.
5. Once Once in the syste system m using using the (< >)sel >)select ector or switch switch butto buttons ns you can scroll through the eight service items listed on page 2-24.
6. When When you have have foun foundd the item item that that was was service serviced, d, using using the the () selector button switch reset the service time interval, a [00: RESET] will appear on the monitor display. 3 seconds later a [YES <> NO ■ ENTER] will appear. 7. To reset reset the service service interv interval, al, select select YES or NO using the (< >) selector switch buttons. Once you have chosen yes or no, use the () selector button to reset the maintenance time interval If yes is selected the service time interval is reset and a beep is heard. If no is selected the service time is not reset.
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OPERATION SELECTING SELECTING LANGUAGE L ANGUAGE To switch the language on the mode display. The following explanation outlines the procedure for changing the language to either English, Japanese, German, French, Italian, Spanish or Swedish. To Select A Language
1.
To enter enter reset reset language language mode the ignition ignition key must must be in the “ON” position.
2.
Press the ()selector switch button and it will display the odometer.
3. Using Using the (>)sel (>)select ector or switch switch button button scroll scroll throu through gh the menu menu to the [LANGUAGE] display. 4.
Once the [LANGUAGE] display is reached, press the () selector switch button to enter the system. The current language is displayed.
5. Once Once in the syste system m using using the(< the(< >)selec >)selector tor switch switch butto buttons ns you you can scroll through the seven languages. 6. After After selec selectin tingg a langua language, ge, press press the the () selector switch button. This confirms the language. To abort, press the () selector switch button. When completing the operation, press the () selector switch button twice or turn the ignition switch “OFF”.
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OPERATION
EMERGENCY STOP WARNING SYSTEM If any abnormality occurs in the (Emergency Stop Warning System), an audible alarm will sound intermittently. The lamp for the location of the abnormality will light up also. If any of these lamps are illuminated during operation of the machine, park the machine in a safe location, lower the work equipment, set the parking brake and shut the engine “OFF”. Contact your local Komatsu Dealer for repairs.Do not operate the machine until repairs have been made.
1. Brake Brake oil oil pre pressu ssure re cau cautio tionn lamp lamp 2. Engi Engine ne oil oil pre pressu ssure re cau cautio tionn lamp lamp
3. Battery Battery charge charge circuit circuit caution caution lamp 4. Stee Steerin ringg oil oil pressu pressure re cau cautio tionn lamp lamp
BRAKE PRESSURE WARNING LAMP This lamp (1) lights up when the brake oil pressure goes below the specified value. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), the brake circuit is not actuated while the engine is stopped, so the brake oil pressure caution lamp and central warning lamp do not light up and the • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the brake oil pressure goes down during operation, the brake oil pressure caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, the top line of the character display displays “E03” and the bottom line displays “CHECK RIGHT NOW” and “CALL” alternately for 3 seconds each, so stop the machine immediately in a safe place, stop the engine, and carry out inspection. If the brake oil pressure caution lamp lights up, the footbrake may not work. Keep the parking brake applied to prevent the machine from moving. In addition, when the accumulator is being charged immediately after starting the engine, the brake oil pressure caution lamp will light up, but the central warning lamp remains OFF and the alarm buzzer does not sound.
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2-15
OPERATION Keep the parking brake applied to prevent the machine from moving until the brake pressure becomes normal and the brake oil pressure caution lamp goes out. alarm buzzer does not sound.
ENGINE OIL PRESSURE WARNING LAMP This lamp (2) lights up to warn the operator that the engine lubricating oil pressure has dropped. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the engine lubricating oil pressure goes down during operation, the engine lubricating oil pressure caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, the top line of the character display displays “E03” and the bottom line displays “CHECK RIGHT NOW” and “CALL” alternately for 3 seconds each, so stop the machine immediately in a safe place, stop the engine, and carry out inspection.
BATTERY CHARGE WARNING LAMP This lamp (3) lights up when the engine is running to warn the operator that an abnormality has occurred in the charging circuit. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If an abnormality occurs in the charging circuit during operation, the battery charge circuit caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, the top line of the character display displays “E03” and the bottom line displays “CHECK RIGHT NOW” and “CALL” alternately for 3 seconds each, so stop the machine immediately in a safe place, stop the engine, and carry out inspection.
STEERING OIL PRESSURE WARNING LAMP (Red) This lamp (4) lights up to warn the operator that the steering oil pressure has dropped. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up. However, it lights up during the self-check of the emergency steering. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the steering oil pressure goes down during operation, the steering oil pressure caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, the top l ine of the character display displays “E03” and the bottom line displays “CHECK RIGHT NOW” and “CALL” alternately for 3 seconds each, so stop the machine immediately in a safe place, stop the engine, and carry out inspection.
If any steering warnings should occur, do not operate the machine until diagnostics or repairs have been made to this system. Operating the machine with a steering alert or warning could lead to loss of control on the machine.
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OPERATION
CAUTION ALERT A LERT WARNING SYSTEM SYSTEM If an operator alert is required the (Caution Lamps), and an audible alarm will sound intermittently. The lamp for the location of the alert as well as the central warning lamp will light up. If any of these lamps are illuminated during operation of the machine, stop the machine in a safe location, lower the work equipment, set the parking brake and run the engine at a low idle until the light goes out or check the system showing the problem. Contact your Komatsu Dealer
1. Axle Axle oil oil temp temper erat ature ure caut caution ion lamp lamp 2. Torque orque conve converter rter oil oil temper temperatu ature re cauti caution on lamp lamp 3. Engine Engine coolan coolantt tempe temperatu rature re caut caution ion lamp lamp
4. Hydraul Hydraulic ic oil temper temperatu ature re caution caution lamp 5. Fuel Fuel lev level el caut cautio ionn lamp lamp
AXLE AXL E OIL TEMPERATURE CAUTION LAMP L AMP This lamp (1) lights up to warn the operator that the brake oil temperature has risen. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) In continuous heavy-duty operations or when traveling long distances downhill where the brake is used frequently, the axle oil temperature becomes high. The axle oil temperature caution lamp and central warning lamp light up and the alarm buzzer sounds intermittently. At the same time, the top line of the character display displays “E02” and the bottom line displays “BRAKE OVERHEAT”, so take the following action. 1. Release Release the accelerator accelerator pedal pedal and move move the gearshift gearshift lever lever down one range range to reduce reduce the travel travel speed. speed. 2. Avoid void usi using ng the the bra brake ke.. A. Do not keep keep the brake pedal pedal depressed depressed continu continuously; ously; use the the brake only only intermittently intermittently..
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2-17
OPERATION B. When using using the left brake brake pedal, pedal, turn the transmission transmission cut-off cut-off switch switch ON to carry out out operations. operations. If use of the the brake is reduced for a short time in the way recommended above, the axle oil temperature will go down and the caution lamp will go out.
TORQUE CONVERTER CAUTION LAMP This lamp (2) lights up to warn the operator that the torque converter oil temperature has risen. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the torque converter oil temperature rises, the torque converter oil temperature caution lamp only will light up. If the oil temperature rises further, the central warning lamp will light up and the alarm buzzer will sound intermittently. At the same time, “E02” is displayed on the top line of the character display and “TC OVERHEAT” is displayed on the bottom line. Stop the machine and run the engine under no load at a mid- range speed until the lamp goes out.
COOLANT TEMPERATURE CAUTION LAMP This lamp (3) warns the operator that the engine coolant temperature has risen. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the engine coolant temperature rises, only the engine coolant temperature caution lamp will light up. If the coolant temperature rises further, the central warning lamp will light up and the alarm buzzer will sound intermittently. At the same time as the central warning lamp lights up, the top line of the character display displays “E02” and the bottom line displays “BRAKE OVERHEAT”, so stop the machine and run the engine under no load at a mid-range speed until the lamp goes out.
HYDRAULIC OIL TEMPERATURE CAUTION LAMP This lamp (4) lights up to warn the operator that the hydraulic oil temperature has risen. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor does not light up. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the hydraulic oil temperature rises, the hydraulic oil temperature caution lamp, the central warning lamp will light up, and the alarm buzzer will sound intermittently. i ntermittently. At the same time, “E02” is i s displayed on the top line li ne of the character dis play and “HYD OVERHEAT” is displayed on the bottom line. Stop the machine and run the engine under no load at a mid-range speed until the lamp goes out
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OPERATION FUEL LEVEL CAUTION LAMP Lamp (5) alerts the operator that the fuel in the tank is below 36 liters (9.19 gal). Add fuel as soon as possible. Remark
If the caution lamp lights up, action code “E02” will not be display on the character display. display.
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2-19
OPERATION
INSPECTION INSPECTION AND MA INTENANCE AL ERT WARNING WARNING SYSTEM If there is need for service or inspection, the lamp for the location needing an inspection or service will light up. If any of these lamps are illuminated during operation of the machine, take the machine to a service location immediately, lower the work equipment, set the parking brake and shut the engine down. These items must be attended to immediately. Failure to do so may result in a system break down. Contact your local Komatsu Dealer for service on these items. Do not continue machine operations
1. Radiato Radiatorr coolan coolantt leve levell caut caution ion lamp lamp 2. Engi Engine ne oil leve levell cauti caution on lamp lamp 3. Battery Battery electr electrolyt olytee leve levell caut caution ion lamp lamp (if equipped)
4. 5. 6. 7.
Main Mainte tena nanc ncee ale alert rt lam lampp Air cleaner cleaner clogging clogging caution caution lamp (machines (machines equipped equipped with KOMTRAX) KOMTRAX) Water ater sep separ arat ator or cau cautio tionn lamp lamp Transmission Transmission filter clogging clogging caution caution lamp (not availabl availablee in North America America))
RADIATOR RADIATOR COOLANT LEVE L EVEL L CAUTION LAMP This lamp (1) lights up to warn the operator that the coolant level in the radiator has gone down. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor lights up if the coolant level in the radiator is low. At the same time, the top line of the character display displays “E01” and the bottom line displays “COOLANT LOW”, so check the water level in the radiator and add water. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the coolant level in the radiator becomes too low, the radiator coolant level caution lamp will light up. At the same time, the top line of the character display displays “E01” and the bottom line displays “COOLANT LOW”, so stop the engine, check the water level in the radiator, and add water.
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WA380-6
OPERATION ENGINE ENGINE OIL LEVE L EVEL L CAUTION CA UTION LAMP This monitor (2) lights up to warn the operator that the oil level in the engine oil level has gone down. During checks before starting (when the ignition switch is turned to the “ON” position but the engine has not started), this monitor lights up if the oil level in the engine oil level is low, and at the same time, the “E01 ENG OIL LEV LOW” is displayed on the character display. Do not start the engine. Check the oil level in the engine and add oil. Remark
During checks before starting, if the engine is started with the engine oil level caution lamp lit up, the lamp will stay lit.
BATTERY ELECTROLYTE CAUTION LAMP (If equipped) This lamp (3) lights up to warn the operator that the battery electrolyte level has gone down. During checks before starting (when the starting switch is turned to the ON position but the engine is not started), this monitor lights up if the battery electrolyte level is low. lo w. At the same time, the top line of the character display displays “E01” and the bottom line displays “COOLANT LOW”, so do not start the engine. Check the battery level. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the battery electrolyte level becomes too low, the battery electrolyte level caution lamp will light up. At the same time, “E01” is displayed on the top line of the character display and “BATTERY LEV LOW” is displayed on the bottom line, so check the electrolyte level l evel and add distilled water.
MAINTENANCE CAUTION CAUTION LA MP
If the caution lamp lights up, repair the problem as soon as possi ble. If If this is l eft as as it is, it wil l lead to failure.
When the time for oil change is reached, this lamp (4) flashes or lights up for approx. 30 seconds after completion of the system check when the starting switch is at the ON position. Remark
The maintenance caution lamp flashes when there are less than 30 hours to the replacement time, and after the replacement time has passed, it stays on.
For details of the items covered by filter and oil replacement, “SERVICE “SERVICE DISPLAY” DISPLAY” on page 2-12. 2-12 . After replacing the filter or changing the oil, reset time for the replacement. For details, “RESET FOR FILTER, FILTER, OIL REPLACEMENT TIME” on page 230. 30.
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2-21
OPERATION AIR CLEANER CL EANER CLOGGING CAUTION CA UTION LAMP LA MP This lamp (5) lights up to warn the operator that the air cleaner is clogged. During checks before starting (when the ignition switch is turned to the “ON” position but the engine is not running), this monitor does not light up. • Duri During ng ope opera rati tion on (en (engi gine ne run runni ning ng)) If the air cleaner becomes clogged, the air cleaner clogging caution lamp will light up, and at the same time, the “E01 AIR FILTER” is dis played on the character display. Stop the engine and clean or replace the element. Remark
Check the dust indicator installed at the side of the air cleaner.
WATER WATER SEPARATOR SEPARATOR CAUTION CA UTION LAMP L AMP This lamp (6) lights up if water accumulates in the water separator installed to the fuel pre-filter. If it lights up, check the pre-filter. For details, see “REPLACING PRIMARY AND SECONDARY SECONDARY FUEL FILTER” FILTER” on page 3-47
TRANSMISSION FILTER CLOGGING LAMP This lamp (7) is not used.
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WA380-6
OPERATION
MODE AL ERT LAMPS These indicators alert the operator that the machine is in a certain operating mode or a function is operating. It is important for the operator of this machine to pay close attention to these indications especially when the machines engine is running or the machine is mobile, failure to do so may shorten the life of a component or inadvertently cause an accident
1. 2. 3. 4. 5. 6. 7. 8. 9. ✸
Park Parkin ingg brak brakee pilo pilott lamp lamp Cooling Cooling fan reverse reverse rotation rotation pilot pilot lamp lamp Emer Em erge genc ncyy stee steerin ringg pilot pilot lamp lamp Outpu Outputt mode mode pilo pilott lamp lamp (powe (powerr mode) mode) Preh Prehea eati ting ng pilo pilott lam lampp Semi Semi auto auto dig dig pilot pilot lamp lamp (if (if equip equippe ped) d) Auto-gr Auto-greas easee pilot pilot lamp (if equipp equipped) ed) Joysti Joystick ck pilo pilott lamp lamp (if (if equi equipp pped ed)) Econ Economy omy oper operat atio ionn pilo pilott lamp lamp
10. 11. 11. 12. 13. 14. 15. 16.
Shift Shift indica indicator tor pilot pilot lamp lamp Auto-shi Auto-shift ft pilot pilot lamp lamp Lock-up Lock-up pilot pilot lamp lamp (if equipped) equipped) Shift Shift hold hold pilot pilot lamp lamp Shift Shift lever lever position position pilot pilot lamp lamp Turn Turn signal signal pilo pilott lamp lamp Head Head lamp high high beam beam pilot pilot lamp
This feature is not used on Waste Handler applications
PARKING BRAK E PILOT LAMP This monitor (1) lights up when the ignition switch is in the “ON” position or when the parking brake is applied.
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2-23
OPERATION COOLING FAN REVERSE ROTATION ROTATION PILOT L AMP This monitor (2) lights up when the when the ignition switch is in the “ON” position or when direction of rotation of the cooling fan is reversed, and at the same time, the “COOLING FAN REVERSE” is displayed on the character display.
EMERGENCY STEERING PILOT LAMP This monitor (3) lights up when the ignition switch is in the “ON” position or when the emergency steering is being actuated. If the engine stops when the machine is traveling or an abnormality occurs in the steering oil pressure circuit, and the machine is traveling at a speed of more than 2 km/h (1.2 mph), the emergency steering is automatically actuated and the lamp lights up. If the lamp lights up, move the machine immediately to a safe place, stop the engine, and check the condition. The lamp flashes, if the emergency steering is actuated continuously for one minute, and at the same time, “E02 EMR S/T OVERRUN” is displayed on the character display. There is an emergency steering self-check function. For details, “EMERGENCY STEERING SELF-CHECK FUNCTION” on page 2-107. 2-107.
OUTPUT MODE PILOT LAMP (POWER MODE) This monitor (4) lights up when the ignition switch is in the “ON” position or when the power mode is selected. s elected. Use the power mode selector switch to select the output P mode.
PREHEATING PILOT LAMP This monitor (5) lights up when the when the ignition switch is in the “ON” position or when engine preheating electric heater is actuated. In cold weather, when the ignition switch is turned to the “ON” position, this lamp lights up. When the preheating is completed, it goes out. The preheating time differs according to the ambient temperature. t emperature.
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WA380-6
OPERATION SEMI AUTO DIGGING PILOT LAMP (If equipped) This lamp (6) is not used.
AUTO-GREASING PILOT L AMP (If equipped) This lamp (7) is not used.
JOYSTICK JOYSTICK PILOT LA MP (If equipped) This lamp (8) is not used.
ECONOMY OPERATION OPERATION DISPLAY LA MP This lamp (10) lights up when the economy mode is used.
SHIFT INDICATOR This monitor (11) indicates the transmission gear range (actual travel speed range).
AUTO-SHIFT PILOT LA MP This monitor (12) lights up when the when the ignition switch is in the “ON” position or the auto-shift function is selected. Use the transmission shift mode selector switch to select the shift mode.
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2-25
OPERATION LOCKUP PILOT LAMP (if equipped) This monitor (12) lights up when the when the ignition switch is in the “ON” position or the torque converter lock-up is engaged and the transmission is set to direct drive. For details, “TORQUE CONVERTER CONVERTER CAUTION LAMP” on page 218. 18.
SHIFT HOLD HOLD PILOT LA MP This monitor (14) lights up when the when the ignition switch is in the “ON” position or the shift hold is actuated.
SHIFT LEVER POSITION PILOT LAMP This monitor (15) displays the transmission position of the gearshift lever.
TURN SIGNAL SIGNAL PILOT L AMP This monitor (16) flashes at the same time as the turn signal lamp flashes. If an open circuit exists in the turn signal indicator lamp system, the flashing interval becomes shorter.
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OPERATION HEAD LAMP HIGH BEAM PILOT LAMP This monitor (17) lights up when the head lamps are set to high beam.
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OPERATION
GAUGE DISPLAY These gauges allow the operator of the machine the ability to monitor the operating systems on the machine. It is important for the operator to pay close attention to these gauges especially when the machines engine is running, mobile or the working
1. Torque orque conve converter rter oil temp tempera eratur turee gauge gauge 2. Engin Enginee wate waterr tempe tempera ratur turee gaug gaugee 3. Hydra Hydrauli ulicc temp temper eratu ature re gau gauge ge
4. Fuel ga gauge 5. Speedometer 6. Mete Meterr disp displa layy pilo pilott lamp lamp
TORQUE CONVERTER OIL TEMPERATURE GAUGE This meter (1) indicates the torque converter oil temperature. It should be in white range (A) during operations. If it enters red range (B) during operations, caution lamp (C) inside the torque converter oil temperature gauge will light up. At the same time, the central warning lamp lights up and the alarm buzzer sounds intermittently. In addition, “E02” is displayed on the top line of the character display and “TC OVERHEAT” is displayed on the bottom line. Run the engine under no load at a mid-range speed and wait until the indicator goes down to white range (A).
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OPERATION ENGINE TEMPERATURE TEMPERATURE GAUGE GA UGE This meter (2) indicates the engine coolant temperature. During normal operations, the indicator should be in the white range (A). If the indicator enters red range (B) during operations, caution lamp (C) inside the engine coolant temperature gauge lights up. At the same time, the central warning lamp lights up and the alarm buzzer sounds. In addition, the top line of the character display displays “E02” and the bottom line li ne displays “ENGINE OVERHEA O VERHEAT”. T”. Run the engine at a midrange speed under no load and wait for the indicator to return to the white range (A).
HYDRAULIC TEMPERATURE GAUGE This meter (3) indicates the hydraulic oil temperature. It should be in white range (A) during operations. If it enters red range (B) during operations, caution lamp (C) inside the hydraulic oil temperature gauge will light up. At the same time, the central warning lamp lights up and the alarm buzzer sounds intermittently. In addition, “E02” is displayed on the top line of the character display and “HYD OVERHEAT” is displayed on the bottom line. Run the engine under no load at a mid-range speed and wait until the indicator goes down to white range (A)
FUEL GAUGE This meter (4) indicates the amount of fuel remaining in the fuel tank. F: Full tank E: Fuel level is low
When the amount of remaining fuel goes below 27 liters (7.13 US gal), the caution lamp (A) inside the fuel gauge lights up. If it lights up, check and add fuel.
SPEEDOMETER This meter (5) indicates the travel speed of the machine. The display unit is indicated on meter display pilot lamp (6). It is also possible to display the engine speed by switching meter (5). If you wish to switch between the speedometer and tachometer, please contact your Komatsu distributor to have it switched.
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OPERATION METER DISPLAY PILOT LAMP This lamp (6) displays the unit for the travel speed or engine tachometer.
MACHINE MONITOR The machine monitor (1) also has the following functions: Odometer, filter/oil replacement time reset, telephone number input, language selection, and monitor brightness adjustment.
DISPLAYING ODOMETER Use this when checking the total distance that the machine has traveled. 1. Check that the charact character er display display is showing showing the service service meter meter or the action code. If it is giving any other display, turn the ignition switch “OFF”, then turn the ignition switch to the “ON” position and wait for the above display to be given. 2. Press the () of monitor panel mode selector switch 1. It displays the odometer. 3. When When comp completi leting ng the operati operation, on, press press (■ ) on the monitor panel mode selector switch 1, or turn the ignition switch “OFF”.
RESET FOR FILTER, OIL REPLACEMENT TIME The filter and oil replacement time is displayed on the character display, so if the filter and oil have been replaced, reset the filter and oil change time. 1.
Press the () of monitor panel mode selector switch 1, and display the odometer. 2. Press Press (>) or or (<) of moni monitor tor panel panel mode mode sele selecto ctorr switch switch 2 until until “MAINTENANCE MONITOR” is displayed.
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OPERATION 3.
Press the () of monitor panel mode selector switch 1. It will change to the display in the diagram on the right. The bottom line shows two items: the replacement time on the left and the total number of times the item has been replaced on the right. 4. Press Press the (>) (>) or (<) of monito monitorr panel panel mode sele selecto ctorr switch switch 2 to display the item (filter or oil) which has reached the replacement time.
5.
Press the () of monitor panel mode selector switch 1. It will change to the display in the diagram on the right. The top line shows [Reset] and [Item to be reset] in turn. 6. When When resettin resettingg the repla replacem cement ent time, time, press press (>) or or (<) of machine machine monitor mode selector switch 2, align the cursor with “YES”, then press () of machine monitor mode selector switch 1. It will reset and return to the previous screen. To abort, align the cursor with “NO”, then press () of machine monitor mode selector switch 1. 7. When When resettin resettingg the replac replaceme ement nt time for for another another item, item, use use the procedure in Step 4. After completing, press () of machine monitor mode selector switch 1 twice or turn the starting switch OFF.
ENTERING A TELEPHONE NUMBER It is possible to display the telephone number on the right side of “CALL” displayed on the character display when action code “E03” is generated. 1. 2. 3. 4.
5. 6.
Press the () of monitor panel mode selector switch 1, and display the odometer. Press (>) or (<) of of monitor monitor panel panel mode selector selector switch 2 until “TEL” is displayed. displayed. Press () of monitor panel mode selector switch 1. It will change to the display in the diagram on the right. Once the telephone number is entered, the number will be displayed next time. Up to 12 digits digits can can be displayed displayed for for the telephone telephone number number.. The cursor is displayed at the enter position. Press (>) or (<) of monitor panel mode mo de selector s elector switch 2 to display “0 - 9". To leave a blank, select “*”. When the input value is decided, press ( ) of monitor panel mode selector switch 1. The cursor will move to the next position. Repeat Repeat the proced procedure ure in Step 4 until the last last digit. digit. At the last digit, digit, press press () of monitor panel mode selector switch 1 to return to the previous screen. If there is a mistake in the input or the input is to be stopped, press ( ) of monitor panel mode selector switch 1 to return to the previous screen. When When comp complet leting ing the operat operation ion,, press press () on the monitor panel mode selector switch 2 twice, or turn the ignition switch ignition switch “OFF”.
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OPERATION SELECTING SELECTING A LANGUAGE L ANGUAGE Use this when switching the language displayed on the character display. The following is for when English is set as the language for the character display. 1.
Press the () on the monitor panel mode selector switch 1, and display the odometer. 2. Press Press (>) or or (<) of moni monitor tor panel panel mode mode sele selecto ctorr switch switch 2 until until “LGUAGE” is displayed.
3.
Press the () of machine mode panel selector switch 1. The presently selected language is displayed. 4. Press Press (>) or (<) (<) of monitor monitor pane panell mode mode selecto selectorr switch switch 2 and sele select ct the language.
The available languages are English, Japanese, German, French, Italian, Spanish, and Swedish. 5. After After selec selecting ting the langua language, ge, press press the the () of monitor panel mode selector switch 1. To confirm, set the cursor at “YES”, then press the () of monitor panel mode selector switch 1. The language will be selected and the screen will return to the previous screen. To abort, set the cursor at “NO”, then press the () of monitor panel mode selector switch 1. 6. When When comp completi leting ng the operati operation, on, press press () of monitor panel mode selector switch 2 twice, or turn the ignition switch “OFF”.
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OPERATION ADJ USTING MONITOR MONITOR BRIGHTNESS To adjust the brightness of the t he monitor. 1.
Press the () of monitor panel mode selector switch 1, and display the odometer. 2. Press Press (>) or (<) (<) on the the monitor monitor pane panell mode sele selecto ctorr switch switch 2 until until “BRIGHTNESS ADJUST” is displayed. 3. Press the () of monitor panel mode selector switch 1. “MONITOR PANEL” will be displayed on the bottom line and it will be possible to adjust the brightness of the monitor.
The brightness can be adjusted for the overall monitor or for the liquid crystal display only. To adjust only the brightness of the liquid crystal display, press the (>) or (<) of monitor panel mode selector switch 2 to switch the display to “LCD PANEL”. 4.
Press the () of monitor panel mode selector switch 1. The screen will change to the display shown on the right and it will be possible to adjust the brightness. 5. Press Press the (>) (>) or (<) of the the monitor monitor pane panell mode sele selecto ctorr switch switch 2 to select a level between L and H (available range: 7 stages). 6. After After selec selecting ting the brightne brightness, ss, pres presss the the () of monitor panel mode selector switch 1. The brightness will be selected and the screen will return to the previous screen. 7. When When comp completi leting ng the operati operation, on, press press () of monitor panel mode selector switch 2 twice, or turn the ignition switch “OFF”.
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OPERATION
MACHINE SWITCHES SWITCHES AND A ND CONTROLS CONTROLS Before operating the machine it is also important to understand all the functions of your machines controls and switches. Operating the machine without full knowledge of all control systems may damage the machine, property or possibly cause injury to the operator. Below is a description of all switch and controls functions.
SWITCH LOCATION
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OPERATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 11. 12. 13.
Igni Ignittion ion swit witch Powe Powerr mod modee sel selec ecto torr swi switc tchh Trans Transmis missio sionn shift shift mode mode selec selector tor switch switch Trans ransmi miss ssio ionn cutcut-of offf swit switch ch Trans Transmis missio sionn cut-of cut-offf set switch switch Lamp Lamp switch switch,, Turn Turn signa signall lever lever,, Dimmer Dimmer swit switch ch Horn switch Haza Hazard rd la lamp swi switch tch Park Parkin ingg bra brake ke swit switch ch Front Front worki working ng lamp lamp switc switchh Rear Rear workin workingg lamp lamp switch switch Monitor Monitor panel panel mode mode selector selector switch switch 1 Monitor Monitor panel panel mode mode selector selector switch switch 2
14. 14. 15. 15. 16. 16. 17. 17. 18. 19. 19. 20. 21. 21. 22. 23. 24. 24. 25. 26.
Kick Kickdo down wn swi switc tchh Hold Hold swit switch ch Fron Frontt wipe wiperr switc switchh Rear Rear wip wiper er swi switc tchh Cigare Cigarette tte lighte lighter r Cab Cab lamp lamp swit switch ch Rear Rear defro defroste sterr switc switchh E.C. E.C.S. S.S. S. swit switch ch Emergency Emergency steering steering switch switch (if equippe equipped) d) Cooling Cooling fan fan reverse reverse rotation rotation switc switchh Lock Lock-up -up swit switch ch Air Cond Conditi itioni oning ng contr controls ols Radio Radio (if equipp equipped) ed)
IGNITION SWITCH This switch (1) is used to start or stop the engine. “OFF” position
It is possible to insert and remove the ignition switch key, all the electric system switches are turned off, and the engine stops. In addition, the parking brake is automatically applied. “ON” position
Electric current flows in the charging circuit, lamp circuit, and accessory circuit. Keep the ignition switch key at the “ON” position while the engine is running. “START” position
This is the position to start the engine. Hold the key at this position while cranking. Release the key immediately after the engine has been started. The key will return to the “ON” position when released.
POWER MODE SELECTOR SWITCH This switch (2) can be used to switch the engine output to match the purpose of the operation. When the POWER mode is selected, the output mode pilot lamp (P mode) on the machine monitor lights up. NORMAL position (a): Normal mode (low engine output), operations
where emphasis is on fuel consumption, such as operations on flat ground where high engine output is not needed. POWER position (b): Power mode (high engine output), operations
where emphasis is on production. Remark
For efficient fuel consumption, use the NORMAL mode. The maximum engine speed is set lower than in the P mode, except for hard operations such as heavy-duty digging of rock. Ample power and low fuel consumption can be obtained in the NORMAL mode. Furthermore, by pressing the accelerator pedal lightly, it is possible to reduce fuel consumption. Use the P mode when performing heavy-duty digging operations of rock or operations where speed is required, or when traveling at speed under the machine's own power on flat ground or on slopes.
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OPERATION TRANSMISSION MODE SELECTOR SWITCH This switch (3) is used to change the shift point when the AUTO SHIFT/MANUAL selector switch has been switched to auto shift. At each of the L and H positions, the system switches to auto shift and the auto shift pilot lamp on the machine monitor lights up. Normally, set to auto shift. MANUAL position: System is set to manual shift and speed range is
position selected by gearshift lever L position: Travel speed when shifting up is low (flat ground, normal
travel) H position: Travel speed when shifting up is high (traveling uphill, traveling at high speed) Remark
For details of the manual shift, see “Manual Shift” Shift” on on page 2-56 . For details of the auto-shift, see “AUTOMA “AUTOMATIC SHIFT” on page 2-57 .
TRANSMISSION CUT-OFF SWITCH
When When moving t he machine on an uphill slope, set the transmission transmission cu t-off switch to the “ OFF” OFF” position, depress the accelerator pedal whi le keeping the left b rake pedal pedal depressed, then gradually release release the brake pedal pedal and allow t he machine to move. This way the machine can be prevented from tr aveling backwards.
Turn this switch (4) “ON” and “OFF”. When the switch is pressed, the pilot lamp lights up and the system is turned “ON”. The transmission is shifted to neutral at the adjusted brake depression position. Normally, keep the switch at the “ON” position. For details of the method of adjusting the cut-off position, “ADJUSTING THE TRANSMISSION CUT-OFF” CUT-OFF” on page page 2-104. 2-104 . Position (a): OFF The left brake pedal acts in the same way as the normal brake (right brake pedal). Position (b): ON The left brake pedal acts in the same way as the normal brake, and at the same time, sets the transmission to neutral.
Remark
The brake pedal position can be adjusted when the system is actuated with the transmission cut-off set switch on the right switch panel.
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OPERATION TRANSMISSION CUT-OFF SET SWITCH
Ap pl y t he p ark in g b rak e bef or e adj us ti ng th e tr ans mi ss io n c ut -of f p os it io n.
Turning the switch (5) to the “ON” position sets the transmission to Neutral and sets the transmission cut-off function, which allows the brake pedal applied position to be adjusted. Position (a): ON Cut-off position can be adjusted When the switch is released, it automatically returns to its original position. For details of the method of adjusting the cut-off position, “ADJUSTING THE TRANSMISSION CUT-OFF” CUT-OFF” on page page 2-104. 2-104 .
LAMP LA MP SWITCH SWITCH This (6) is used to light up the head lamps, side clearance lamps, tail lamps, and instrument panel lighting. Position (a): OFF Position (b): Side clearance lamps, tail lamps, and instrument panel lights up Position (c): Head lamps light up in addition to lamps at b position.
Remark
The lamp switch can be operated regardless of the position of the lever.
TURN SIGNAL SIGNAL LEVER This lever (6) operates the turn signal lamps. Position (a): LEFT TURN: (Push lever FORWARD). FORWARD). Position (b): RIGHT TURN (Pull lever BACK).
Remark
When the lever is operated, the turn signal pilot lamp will also light up. When the steering wheel is turned to the neutral position, the turn signal lever will return automatically to “OFF”. If not, return the lever to “OFF” manually.
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OPERATION DIMMER SWITCH This (6) switches the head lamp between high beam and low beam. Position (a): Low beam Position (b): High beam
HORN BUTTON When the button (7) in the center of the steering wheel is pressed, the horn will sound.
HAZARD LAMP L AMP SWITCH SWITCH
Use the hazard hazard lamp o nly i n emergencies. Using the hazard l a m p w h e n t r a v el el i n g c o u l d c o n f u s e t h e d r i v e r s o f o t h e r machines.
This switch (8) is used in emergencies, such as the case of emergency parking on the street when the machine breaks down. “ON”: All turn signal lamps flash.
PARKING BRAKE SWITCH
Alw A lw ays ay s appl ap pl y t he par ki ng br ake ak e w hen he n l eav in g th e m achi ac hi ne or when parking it. Even Even if the parking parking brake switch is t urned “ ON” ON” , there is danger danger unti l the parking brake pilot lamp lights up, so keep the br ake pedal pedal d epressed.
This switch (9) operates the parking brake. Position (a): ON. The parking brake is applied, and the parking brake pilot lamp lights up. Position (b): OFF The parking brake is released.
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OPERATION
Never use the parking brake switch to apply the brakes when traveling, except in an emergency. The parking brake may be damaged damaged and thi s may lead to a serious accident. Apply t he parkin parkin g brake only after the machine has stopped. If the parking br ake has has been used as an emergency emergency brake when traveling at hi gh speed, contact your Komatsu dist ribut or to have the parking parking brake checked for any abnormality. Remark
When the parking brake is applied, the machine will not move even if the directional lever is operated. If the directional lever is placed at the F or R position with the parking brake still applied, the central warning lamp will light up and the buzzer will sound. Before starting the engine, turn the parking brake switch “ON”.
FRONT WORKING LAMP SWITCH
Al way s tu rn th e w or ki ng lam p of f bef or e t rav eli ng on pu bl ic roads.
When turning the front working lamp “ON”, operate the lamp switch to turn the side clearance lamp “ON” or the head lamp “ON”, then operate this switch (10). Position (a): Working lamp lights up Position (b): Working lamp goes out If position (a) is pressed, the pilot lamp will light up and the working lamp circuit will be switched “ON”. If the lamp switch is not at the “ON” position for the side clearance lamp or head lamp, the working lamp will not light up.
REAR WORKING LAMP SWITCH
Al way s tu rn th e w or ki ng lam p of f bef or e t rav eli ng on pu bl ic roads.
When turning the rear working lamp “ON”, operate the lamp switch to turn the side clearance lamp “ON” or the head lamp “ON”, then operate this switch (11). Position (a): Working lamp lights up Position (b): Working lamp goes out If position (a) is pressed, the pilot lamp will light up and the working lamp circuit will be switched “ON”. If the lamp switch is not at the “ON” position for the side clearance lamp or head lamp, the working lamp will not light up.
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OPERATION MONITOR PANEL PANEL MODE SELECTOR SWITCH 1 This switch (12) is used to switch the function of the character display. When the switch is released, it automatically returns to its original position. The basic operation is as follows. Position (): press to select or confirm each mode or operation. Position (): press to cancel each mode or operation.
MONITOR PANEL PANEL MODE SELECTOR SWITCH 2 This switch (13) is used to switch the function of the character display. When the switch is released, it automatically returns to its original position. The basic operation is as follows. Position (>): Press here to go 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
KICKDOWN SWITCH When the gearshift lever is in 2nd, if switch (14) on the head of the left arm control lever is pressed, the transmission will shift down to 1st. This switch is used to increase the drawbar pull in digging operations. If the transmission is in auto-shift, and the travel speed is below 10.5 km/h (6.5 mph) in any speed range when traveling in either forward or in reverse, the kick-down switch is actuated and it is possible to shift down to 1st. This makes it easy to perform load and carry operations. Even if the travel speed is more than 10.5 km/h (6.5 mph), this switch can be used to shift the transmission down. Each time the kick-down switch is pressed, the speed range will shift down one range at a time (F4 → F3 → F2). When the torque converter is in the lock-up condition (if equipped), the lock-up is canceled.
Remark
When canceling the kick-down, operate the directional lever. In manual shift, the kick-down can be canceled by operating the gearshift lever to any position other than 2nd. It is also possible to cancel the kick-down by turning the ignition switch “OFF”. In auto-shift, if the travel speed becomes high after the kick-down, the gear will be shifted up by the auto-shift. In auto-shift, when traveling at more than 18 km/h (11.22 mph) in 3rd or at more than 28 km/h (17.4 mph) in 4th, even if the kick-down switch is pressed, the transmission will not shift down. This is to prevent overrun of the engine.
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OPERATION HOLD SWITCH To set the speed range when traveling in automatic transmission, press switch (15) at the side of the left arm control lever knob. The transmission will be set in the speed range displayed on shift indicator (A) on the machine monitor and shift hold pilot lamp (B) will light up. When the switch is pressed again, the display goes out. Use this function to select the desired speed range when traveling up or down hills or when performing operations such as grading.
Remark
When the torque converter is in the lock-up condition (if equipped), the transmission cannot be set. When canceling the shift hold, operate the directional lever or gearshift lever or operate the transmission shift mode selector switch to MANUAL. It is also possible to cancel the hold shift by turning the ignition switch “OFF”.
FRONT WIPER SWITCH When the rotary switch (A) of this switch (16) is turned, the front wiper will move. If button (B) is kept pressed, washer fluid will be sprayed out on to the front glass. Position (a): (OFF) stop Position (b): (INT) Intermittent wiper Position (c): Low-speed wiper Position (d): High-speed wiper
REAR WIPER SWITCH When lever (C) of this switch (17) is turned, the rear wiper will move. Position (a): Washer liquid is sprayed out Position (b): OFF Position (c): Wiper is operated Position (d): Washer liquid is sprayed out, wiper is operated.
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OPERATION CIGARETTE LIGHTER This is used to light cigarettes. After the cigarette lighter (18) is pushed in, its element will heat up and return to its original position after a few seconds. Pull it out and light your cigarette.
CAB L AMP SWITCH SWITCH The switch (19) is used to turn the cab lamp “ON” and “OFF”. Position (a): OFF Position (b): Lights up when the cab door opens Position (c): Lights up
Remark
The cab lamp lights up even when the main switch is “OFF”, so when leaving the operator's compartment, turn the switch to position (a) (OFF) or (b). When operating with the cab door fully open, set the switch to position (a) (OFF).
REAR DEFROSTER SWITCH When this switch (20) is pressed, electric current flows through the heated wire glass at the rear and the mist is removed from the glass. Position (a): “ON” (removes mist from glass) Position (b): “OFF”
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OPERATION E.C.S.S. SWITCH
If the machine is traveling or th e work equipment is r aised, the moment th e E.C. E.C.S.S S.S.. switch is t urned “ ON” ON” , the work equipment will move. If operations are perform ed with t he E.C.S E.C.S.S. .S. switc h at the “ ON” ON” posit ion, the mom ent the E.C.S E.C.S.S. .S. swit ch is operated, the work equipment may move. Never turn on the E.C.S.S. switch during inspection or maintenance. The work equipment will move and this wi ll create a dangerous situatio n.
• • •
Always stop the machine machine and lower the the work equipment equipment to the ground ground before before operating operating the E.C.S.S. E.C.S.S. switch. switch. When performing performing an inspection inspection and and maintenan maintenance, ce, first lower lower the the work equipme equipment nt to the ground, ground, then turn turn the E.C.S.S. E.C.S.S. switch “OFF” before starting the inspection and maintenance operation. When When carryi carrying ng out out level leveling ing work work,, turn turn the E.C.S.S. E.C.S.S. switch switch “OFF “OFF”. ”.
This switch (21) is used to turn the E.C.S.S. “ON” and “OFF”. Position (a): “ON” The pilot lamp lights up and the E.C.S.S. is actuated. Position (b): “OFF” The E.C.S.S. is not actuated.
Remark
The E.C.S.S. is a device that uses the hydraulic spring effect of an accumulator to absorb the vibration of the chassis during travel and allows the machine to travel smoothly and at high speed. When traveling in 1st, the E.C.S.S. is not actuated. When the speed range is 2nd to 4th, and the travel speed becomes more than 5 km/h (3.1 mph), the E.C.S.S. is automatically actuated; when the travel speed goes below 3 km/h (1.9 mph), it is automatically disengaged.
EMERGENCY STEERING SWITCH This switch (22) is the manual control switch for the emergency steering. Even when the engine has stopped, steering operations are made possible by pressing this switch. Position (a): ON The pilot lamp inside the switch and the emergency steering pilot lamp on the machine monitor light up and it becomes possible to operate the steering. When the switch is released, it automatically returns to its original position. Actuate the emergency steering only in cases of emergency or when checking the function.The maximum operating time for continuous emergency steering is 60 seconds. When using emergency steering, travel at a speed of less than 5 km/h (3.1 mph). For details, see “EMERGENCY “EMERGENCY STEERING” STEERING” on page 2-106. 2-106.
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OPERATION COOLING FAN REVERSE ROTATION SWITCH This switch (23) is used to rotate the cooling fan in the reverse direction when cleaning the radiator. Position (a): Manual reverse rotation switch ON If the switch is pressed once when the fan is rotating in the normal direction, the rotation of the fan is reversed. If the switch is pressed again the fan returns to normal rotation. When the fan is rotating in reverse, the cooling fan reverse rotation pilot lamp on the machine monitor lights up. For details of the procedure for cleaning, see “CLEAN RADIATOR RADIATOR FINS” on page 3-30. 3-30 . Run the engine at idling when operating the switch. Remark
When the direction of rotation of the fan switches, the reverse rotation pilot lamp flashes.
COOLING FAN AUTO REVERSE ROTATION SWITCH (If equipped)
This switch (23) is used to rotate the cooling fan in the reverse direction when cleaning the radiator. Position (a): Auto reverse rotation function ON
The fan automatically rotates in reverse for 2 minutes every 2 hours. The pilot lamp inside the switch and the cooling fan reverse rotation pilot lamp on the machine monitor light li ght up. Position (b): Manual reverse rotation switch ON
If the switch is pressed once when the fan is rotating in the normal direction, the rotation of the fan is reversed. If the switch is pressed again, the fan returns to normal rotation. When the fan is rotating in reverse, the cooling fan reverse rotation pilot lamp on the machine monitor lights up. After the switch is pressed, the fan continues to rotate in the reverse direction for approx. 10 minutes. Position (c): Neutral (OFF)
The cooling fan is constantly set to normal rotation. Run the engine at idling when operating the switch. • • • •
When the directio directionn of rotation rotation of the fan is switched, switched, the reverse rotation pilot lamp lamp flashes. flashes. When the the machine machine is operatin operatingg under under high load load or in in low temperatu temperatures, res, the direction direction of rotation rotation of the fan fan may not not change. change. This is to protect the machine. When When the the engi engine ne is is stoppe stopped, d, the the fan fan retu returns rns to norma normall rotatio rotation. n. When the the switch switch is set to position position (b) (Manual (Manual reverse reverse rotation rotation switch switch ON), ON), if the switch is released, released, it returns to position position (c) (Neutral). Even if the switch is not kept pressed at position (b), the fan will continue to rotate in reverse direction for a certain period, so there is no need to keep the switch pressed at position (b).
TORQUE CONVERTER LOCK-UP SWITCH For details of the torque converter lock-up, see “TORQUE CONVERTER CONVERTER LOCK-UP” on page 5-2. 5-2 .
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OPERATION
OPTIONAL SOUND SYSTEM AND AIR CONDITIONING SYSTEM As an option your machine may be equipped with one of the listed premium sound system for your audio pleasure. Remember safety has priority. Only operate your radio if the operating conditions allow. Familiarize yourself with the units before starting your work operations. When listening to your radio, you should set the volume so you can hear what is going on around you.
SOUND SYSTEM COMPONENTS
1. 2. 3. 4. 5. 6. 7.
Powe Powerr switc switch/ h/V Volum olumee AutoAuto-sto store re/pr /pres eset et scan scan but butto tonn Bass Bass contr ontrol ol knob knob Trebl reblee cont contro roll kno knobb Loud Loudne ness ss butt buttoon Time/r Time/radi adioo display display select selector or button button Tape ape ejec ejectt butt button on
8. 9. 10. 10. 11. 11. 12. 13. 14.
Casse ssette tte door Fast Fast forwa forward, rd, rewin rewindd but button tonss Prese Presett butto buttons ns Metal Metal tape tape button button Manual Manual tunin tuningg button buttonss Seek Seek tuni tuning ng button button Band Band selec selector tor butto buttonn
A. Band display
B. Metal tape display
C. FM stereo reception display
D. Loudness display
E. Tape direction display
F.
Preset channel display
G. Time/fr ime/freq eque uenc ncyy displa displayy
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OPERATION POWER SWITCH/VOLUME When this switch (1) is turned to the right, it clicks and the power is turned on. If it is turned further, the speaker volume is adjusted.
AUTO-STORE/PRESET AUTO-STORE/PRES ET SCAN BUTTON Use this button (2) to actuate the preset scan and auto-store functions. • Auto-store Each time this button is pressed for more than 2 seconds while in radio reception, this auto-store function automatically starts to search for the desired station within a receivable band, and memorize the frequency in the preset memory. During this scanning process, the frequency shown in the right side of display continues to change. This indicates that each frequency is memorized in the auto-store. The auto-store function cannot be used when the channel display is flashing. When the display is flashing, the preset scan function is being used. • Preset scan If this button is pressed for less than 0.5 second while in radio reception, programs from the six preset stations in the same band will be broadcast one after another for 5 seconds s econds each, starting from No. 1 through No. No . 6 stations consecutively. When the desired station is found, press the button again. This stops the preset scan tuning process and switches to ordinary broadcasting. The same process will be repeated r epeated continuously until the button is pressed press ed again.
BASS BA SS CONTROL CONTROL KNOB Turn this button (3) to the left to reduce the low tones; turn it to the right to emphasize the low tones. Direction (a): Low tone reduced Direction (b): Low tone emphasized
TREBLE CONTROL KNOB Turn this button (4) to the left to reduce the low tones; turn it to the right to emphasize the high tones. Direction (a): High tone reduced Direction (b): High tone emphasized
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OPERATION LOUDNESS BUTTON This button (5) is used when playing at low volume. It makes it possible to hear more easily by emphasizing the low tone when the low tones are weak. Push button: Actuated (ON) Push button again: Canceled (OFF)
TIME/RADIO DISPLAY SELECTOR BUTTON This button (6) is used to switch between the “Radio/tape display” and the “Time display”.
Correcting the time press the button to set the time display. (A) Correcting hour: Keep the DISP button pressed and press the bottom (H) of the TUNING button to correct the hour. (B) Correcting minute: Keep the DISP button pressed and press the top (M) of the TUNING button to correct the minute.
TAPE EJECT BUTTON This button (7) is used to stop the tape and to eject the cassette. When this button is pressed, the tape is ejected and the radio plays.
CASSETTE DOOR Set the cassette with the exposed portion por tion of the tape on the right side s ide and insert it through the cassette door (8).
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OPERATION FAST-FORW FAST-FORWARD, ARD, REWIND B UTTONS These buttons (9) are used to fast-forward or rewind the tape. Fast-forward/rewind If you press the button pointing in the same direction as the lighted arrow indicating the direction of play, the tape will be fast-forwarded; if you press the button pointing in the opposite direction, the tape will rewind. To stop the tape, lightly press the button that is not locked. The fast-forward or rewind operation will be canceled. If the fast forward and rewind buttons are pressed at the same time, the tape will change sides.
PRESET BUTTONS These buttons (10) are used to call up the broadcast station frequencies preset in memory for each of buttons No. 1 to No. 6. It is possible to preset 18 stations (FM: 12; AM: 6) with these buttons.
METAL METAL TAPE BUTTON B UTTON (used also for preset button No. 5) This button (11) is used when playing a metal or chrome tape. This button is also used for preset button No. 5. When it is pressed, “MTL” appears on the display.
MANUAL TUNING TUNING BUTTONS These buttons (12) are used for manual tuning. When “TUN Å»” button is pressed, the frequency goes up; when “TUN Å…” button is pressed, the frequency goes down. If the button is pressed down and held, the frequency will change continuously.
SEEK TUNING BUTTONS These buttons (13) are used to seek tuning. When the “SEEK UP” button is pressed, the search automatically goes up; when the “SEEK DOWN” button is pressed, the search automatically goes down. When the next station that can be received is found, it automatically stops.
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OPERATION BAND SELECTOR BUTTON When this button (14) is pressed, the band is switched between FM1, FM2, and MW (AM). The band is shown on the display.
METHOD OF OPERATION SETTING PRESET BUTTONS It is possible to preset 6 MW (AM) stations and 12 FM stations (FM1: 6 stations, FM2: 6 stations). If you are playing the cassette, press the tape eject button to stop the tape.
AUTO PRESET Use band selector button (1) to select MW (AM), FM1 or FM2. A. Press auto-stor auto-store/prese e/presett scan button (2) for less less than than 0.5 second second.. B. The preset preset scan scan tuning tuning function function automatically automatically searches searches for the the desired station within the same band and can memorize as many as 6 stations in the preset memory.
MANUAL PRESET PRESET Use band selector button (1) to select MW (AM), FM1 or FM2. A. Press manual tuning buttons buttons (2) or or seek tuning buttons (3). B. Press preset preset button button (4) (4) of the the number number to be preset preset for 2 seconds seconds while the frequency display is being shown on the C. display. display. (The preset preset channel channel and frequency frequency are displayed displayed and the presetting is completed). D. Repeat Repeat the steps explaine explainedd in Item 2 and 3 above above to preset preset other stations stations to the subsequen subsequentt numbers. E. If you want want to preset a station station in the other other bands, follow follow the steps explaine explainedd in Item 1 through through 4 above. above. Remark
Also, use Steps 2 and 3 when changing the setting of a preset preset switch to another station. When the power is disconnected, such as when the battery is replaced, all the settings are deleted, so preset the stations again.
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OPERATION LISTENING TO RADIO A. Turn Turn the starting switch ON, then then turn turn power power switch switch (1) ON. B. Use band band selector selector button button (2) (2) to select select MW (AM), FM1 or or FM2. C. Select Select the the station station with with the the preset preset button buttonss (3). In case you do not promptly remember the number assigned to a certain preset station, press auto-store/preset scan button (4) for less than 0.5 second. The preset 6 stations will broadcast one after another for 5 seconds each. When the desired station broadcasts, press the button again and scan tuning stops. D. If you want to tune in to a station station that that is not not preset, preset, use either either seek tuning button (5) or manual tuning button (6). E. Adjust Adjust the the volume volume,, balance balance,, and tone tone as desire desired. d. F.
When turning the radio radio OFF OFF,, turn power switch (1) to the left left until it clicks.
Remark
To switch to the radio when listening to a cassette, press the cassette eject button to stop the tape. If you insert a cassette when listening to the radio, the tape will start to play.
LISTENING TO CA SSETTE TAPE TAPE A. Turn Turn the starting switch ON, then then turn turn power power switch switch (1) ON. B. Set the the cassette cassette with with the exposed exposed portion portion of the tape tape on the right side and push it past the cassette door. The tape will automatically start playing.
C. If the arrow indicating indicating the the direction direction of play play is pointin pointingg to the the right, the top side is being played; if the arrow is pointing to the left, the bottom side is being played. D. When the the tape reaches reaches the end, end, it is automati automatically cally reversed reversed and the other side starts to play. E. When finished with the the tape, tape, press press the cassette cassette eject eject button button to eject the tape and automatically switch to the radio.
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OPERATION REVERSING TAPE When listening to the tape, press both FAST FORWARD, REWIND buttons (A) and (B) at the same time lightly. When this is done, the tape direction display will be reversed.
PRECAUTIONS WHEN USING •
• • • • • • •
If a volt voltage age greate greaterr than than the the specifi specified ed volta voltage ge is input, input, itit may cause cause fire, electrocution, or other failure. Never input any voltage other than the specified voltage. Places Places inside inside the the radi radioo are are under under high high volta voltage. ge. Do not not remov removee the the cover. Do not not carry carry out out any any modifi modificat cation ions. s. This This may may cause cause fire, fire, electro electrocucution, or other failure. If the sound sound cannot cannot be heard, nothing nothing is displayed, displayed, or or any other other problem problem occurs, occurs, turn turn off off the power power switch switch and ask ask your Komatsu distributor to make repairs without delay. Stow Stow the anten antenna na when when trave traveling ling in place placess with low over overhea headd cleara clearance nce.. To ensure ensure safety safety during during operations operations,, keep the volume volume at a level level where it is possible possible to hear other other machines machines.. If water water gets inside inside the speaker speaker case or radio (auto tuning), tuning), itit may cause cause a serious problem, problem, take care not not to let water get get in these items. Do not wipe wipe the scales scales or buttons buttons with benzene, benzene, thinner thinner,, or any other other solvent. solvent. Wipe Wipe with a soft dry cloth. cloth. Use a cloth soaked in alcohol if the equipment is extremely dirty.
HANDLING CASSETTE TAPE • • • • •
Clean the tape tape head head approx. approx. once a month month with a commercia commercially lly available available head cleaning cleaning tape. tape. Do not leave leave the tape tape any place place where it is exposed exposed to direct direct sunlight, sunlight, any place that that is excessivel excessivelyy dusty, dusty, or any place place where there is a magnetic field. Do not not use 120-minute 120-minute tapes. tapes. The tape tape is thin and and it easily gets caught caught up inside inside the the machine. machine. If the tape tape is slack, slack, itit easily gets caught caught up up inside the machine machine.. Use a pencil to wind in the tape to remove any slack. slack. Do not use use any cassette cassette tape if the label label has has started to come off. It may cause cause defective defective rotation, rotation, or it may be impossible impossible to get the tape out of the machine.
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2-51
OPERATION
AIR A IR CONDITIONER SYSTEM CONTROL PA NEL By taking fresh air into the cab through a filter, it is possible to raise the pressure inside the cab. This action makes it possible to provide a pleasant working environment, especially on dusty job sites
1. 2. 3.
Main power switch Fan switch Air conditioner switch
4. Temperature control switch 5. FRESH/RECIRC selector switch 6. Display monitor
MAIN POWER SWITCH Use the switch (1) to turn the main power of the air conditioner ON/ OFF.
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OPERATION When the switch is pressed, display monitor (A) lights up. The fan begins operation. When the switch is pressed again, the air conditioner is turned OFF and the display monitor goes out. The fan stops. (When the switch is turned ON, the setting displayed is the same as when the air conditioner was turned OFF.)
FAN SWITCH Use this switch (2) to adjust the air flow from the fan. The air flow can be adjusted to 4 levels. When this switch (A) is pressed, the air flow increases; when switch (B) is pressed, the air flow decreases.
The setting for the air flow is displayed on the display monitor. A: Monitor display B: Air flow a: Air flow “Lo” b: Air flow “M1” c: Air flow “M2” d: Air flow “Hi”
AIR CONDITIONER SWITCH Use this switch (3) to start and stop the cooling or dehumidifying heating function.
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OPERATION When the main power switch is ON, if the air conditioner switch is pressed, the air conditioner is i s turned ON and (A) is displayed on the th e display monitor. If the switch is pressed again, the switch is turned OFF and display monitor (A) goes out.
TEMPERATURE TEMPERATURE CONTROL SWITCH Use this switch (4) to adjust the temperature between low temperature and high temperature.
When switch (A) is pressed, the temperature of the air blowing out becomes higher; when switch swi tch (B) is pressed, pr essed, the t he temperature of the air blowing out becomes lower. The setting (C) for the temperature is displayed on the display monitor.
FRESH/RECIRC SELECTOR SWITCH Use this switch (5) to switch between recirculation of the air inside the cab and intake of fresh air from outside. When this switch is pressed, recirculation of inside air is selected and (A) lights up on the display monitor. If the switch is pressed again, intake of fresh air is selected and (B) lights up on the display monitor. • Reci Recirc rcul ulat atio ionn of of air air insi inside de cab cab Only the air inside the cab is circulated. Use this setting when carrying out quick cooling or heating of the cab or when the outside air is dirty. • Inta Intake ke of fres freshh air air from from outs outsid idee Air from the outside is taken into the cab. Use this setting when taking in fresh air from outside or when removing the mist from the windows.
METHOD OF OPERATION COOLING OPERATION OPERATION 1. Press main main power power switch switch (1) of the air condition conditioner er to turn the the power power ON. 2. Press Press fan fan switch switch (2) and and set set the air flow flow to to “Hi”. “Hi”. 3. Press Press tempera temperature ture cont control rol switch switch (3) (3) and set the the display display monito monitorr to COOL (A). 4. Press air air conditione conditionerr switch switch (4) to turn turn the air condition conditioner er switch switch ON. 5. Press Press RECIRC/ RECIRC/FRE FRESH SH select selector or switch switch (5) (5) to select select RECIRC RECIRC..
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OPERATION 6. When the tempera temperature ture inside inside the cab goes goes down, down, use the temperatu temperature re control control switch and and the fan switch switch to set to the the desired desired temperature. If the temperature control switch is pressed to set the display monitor to COOL (A) and the air conditioner is run with the air flow at “Lo” for a long period, there is a slight risk that the evaporator will freeze. If it freezes and no cold air comes out, turn the air conditioner switch OFF, raise the temperature setting, run the air conditioner with the air flow at “Hi “for a short time, then turn the air conditioner switch ON again.
HEATING OPERATION 1. Press main main power power switch switch (1) of the air condition conditioner er to turn the the power power ON. 2. Press Press fan fan switch switch (2) and and set set the air flow flow to to “Hi”. “Hi”. 3. Press Press RECIRC/ RECIRC/FRE FRESH SH select selector or switch switch (4) (4) to select select FRESH FRESH.. When the temperature inside the cab goes up, use the temperature control switch and the fan switch to set to the desired temperature. Remark
Heating is carried out using the engine cooling water, so it can be carried out when the cooling water temperature is high.
DRYING-HEATING DRYING-HEATING AND DEMISTING OPERATION 1. Press main main power power switch switch (1) of the air condition conditioner er to turn the the power power ON. 2. Press Press fan switch switch (2) (2) and and set the the air flow flow to the the desired desired sett setting. ing. 3. Press Press temper temperatu ature re contro controll switch switch (3) and and set to the the desire desiredd temperature. 4. Press Press RECIRC/ RECIRC/FRE FRESH SH select selector or switch switch (4) (4) to select select FRESH FRESH.. 5. Press Press air condi condition tioner er switch switch (5) (5) to turn the the air air conditio conditioner ner ON. ON. When the outside temperature is below 0 oC (32oF), the air conditioner (compressor) may not operate.
PRECAUTIONS WHEN USING • • •
• • •
To prevent prevent any excessiv excessivee load on on the engine engine or compresso compressor, r, use the air condition conditioner er when the the engine engine is running. running. If the machine machine is used in places places where where there there is dust or or bad smell, smell, recirculate recirculate the the air inside inside the cab cab when using the the air conconditioner. To prevent prevent leakage leakage of refrigera refrigerant nt from the air conditione conditionerr cooling cooling circuit, circuit, run the air air conditioner conditioner for for several several minutes 2 or 3 times a month, even during the off-season. If the machine is left for a long time when the refrigerant is leaking, rust will form on the inside and this will cause failure. To protect protect your health, health, do not make make the inside of the cab cab too cool cool and do not let let the cold cold air flow flow contact contact your your skin directly directly for long periods. Ventil entilat atee the the cab cab fro from m time time to time. time. If the temperat temperature ure inside inside the cab is high, high, open open the door or window to let the the hot air air escape escape and let fresh air in before before startstarting operation of the air conditioner.
PRECAUTIONS FOR INSPECTION AND MAINTENANCE • • •
When carrying carrying out out inspection inspection and and maintenanc maintenancee of the air conditione conditioner, r, follow follow the table table given given in “CHECK “CHECK AIR AIR CONDITIONER (PAGE 4-35)”. To allow the air conditioner conditioner to show its full full performanc performancee and provide provide a comfortable comfortable environment, environment, have inspectio inspectionn and maintenance carried out periodically. When adding adding refrigera refrigerant nt or carrying carrying out out other maintena maintenance, nce, special special tools tools and instruments instruments are needed, needed, ask your your Komatsu Komatsu distributor to carry out inspection and repair.
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OPERATION
CONTROL LEVERS, PEDALS
1. 2. 3. 4.
Gear Gear shif shiftt lev lever Dire Direct ctio iona nall leve lever r Gear Gear shi shift ft lev lever er sto stopp pper er Safe Safety ty lock lock leve leverr
5. 6. 7. 8.
Buck Bucket et cont contro roll lev lever er Lift Lift arm arm con contr trol ol leve lever r Brak rake pedals Acce Accele lera rato torr peda pedall
GEAR SHIFT LEVER This lever (1) controls the travel speed of the machine. Manual Manual Shift
This machine has a 4-FORWARD, 4-FORWARD, 4-REVERSE speed transmission. Place the speed control lever in a suitable position to obtain the desired speed range. 1st and 2nd speeds are used for working. 3rd and 4th speeds are used for traveling. However, when the speed control lever stopper is being used, it is impossible to shift to 3rd or 4th. Disengage the speed control lever stopper before trying to shift gears. Position (a): 1st Position (b): 2nd Position (c): 3rd Position (d): 4th.
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OPERATION Remark
The length of the lever can be adjusted to 3 stages (positions A, B, C). To To adjust the length, remove the screw at the bottom of the lever knob, slide the knob to the desired position, then tighten the screw again. The lever is installed to position B when it is shipped from the factory.
AUTOMATIC SHIFT
Automatic gear shifting can be performed in the 2nd and 4th speed range of the four forward and reverse speeds depending on the travel conditions. Position (a): 1st Position (b): 2nd Position (c): 3rd Position (d): 4th
The range of speeds during automatic gear shifting is determined by the position of the gear shift lever as shown in the chart on the right.
Remark
The 1st position for the gearshift lever sets the transmission in 1st. There is no automatic shifting of the transmission. When shifting down from 2nd to 1st, press the kick-down switch on the lift arm control lever. If the transmission is in auto-shift and the travel speed is below 10.5 km/h (6.5 mph) in any speed range when traveling in either forward or in reverse, the kick-down switch is actuated and makes it possible to shift down to 1st. This makes it easy to perform load and carry operations. Even if the travel speed is more than 10.5 km/h (6.5 mph), this switch can be used to shift the transmission down. Each time the kick-down switch is pressed, the speed range will shift down one range at a time (when in 4th: F4 → F3 → F2; when in 3rd: F3 → F2).
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OPERATION To set to the desired speed range when traveling uphill or downhill, or when grading, do as follows. • • •
When When settin settingg the the speed speed range, range, press press the the HOLD HOLD switc switchh on the lift arm control lever. The speed speed range range is settin settingg at the the spee speedd range range display displayed ed on on the the transmission indicator on the main monitor. When When shiftin shiftingg up or down down from from set set speed speed rang range, e, use use the gear gear shift shift lever to shift gears.
Remark
When downshifting the transmission from 2nd to 1st with the kickdown switch, an upshift from 1st to 2nd occurs when travel speed increases.
DIRECTIONAL LEVER This lever (2) is used to change the direction of travel of the machine. The engine cannot be started if the directional lever is not at N (neutral). In this case, the central warning lamp will light up and the buzzer will sound. At the same time, “E00 SHIFT LEVER NEUT” is displayed on the character display. Return the gearshift lever to the N position and start the engine. Position (a): Forward Position N: Neutral Position (b): Reverse Remark
The length of the lever can be adjusted to 3 stages (positions A, B, C). To To adjust the length, remove the screw at the bottom of the lever knob, slide the knob to the desired position, then tighten the screw again. (The lever is installed to position B when it is shipped from the factory.)
GEAR SHIFT L EVER STOPPER STOPPER This stopper (3) prevents the speed control lever from entering the 3rd and 4th positions when working. Position (a): Stopper actuated. Position (b): Stopper released.
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OPERATION SAFETY LOCK LEVER
Before getting up from the operator's seat, set the safety lock lever securely to the LOCK position. If the safety lock lever is not at the LOCK position, and work equipment control lever (A) is touched by mistake, it may lead to a serious serious acci dent. If the safety lock lever is not placed securely at the LOCK position, the work equipment may move, and this may lead to a serious accident or personal injury. Check that the lever is in the position shown in the diagram. When When pulling up or pushing down the safety safety lock lever, lever, be careful careful not to touch work equipment equipment control lever (A).
This lever (4) is a locking device for the work equipment control lever. Push the safety lock lever down to lock it. Remark
This lever electrically locks the hydraulic circuit for the work equipment, so if it is at the LOCK position, the work equipment will not move even when work equipment control lever (A) is operated. If the work equipment control lever is operated when this lever is at the LOCK position, the central warning lamp lights up and the alarm buzzer sounds. At the same time, “E00 WORK LEVER POSI” is displayed on the character display.
BUCKET CONTROL LEVE L EVER R Lever (5) operates the bucket. Position (a): TIL TILT T When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, positi oner, and the lever is returned to the HOLD position.
Position (b): HOLD The bucket is kept in the same position. Position (c): DUMP
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OPERATION LIFT ARM CONTROL L EVER EVER This lever (6) operates the lift arm. This lever (6) operates the lift arm. Position (a): RAISE When the lift arm control lever is pulled further from the RAISE position, the lever is stopped in this t his position. When the lift li ft arm reaches the preset position of the kick-out, the lever is returned to the HOLD position. Position (b): HOLD The lift arm is kept in the same position. Position (c): LOWER Position (d): FLOAT FLOAT The lift arm moves freely under external force.
Do not use the FLOAT feature when traveling forward, the bucket will dig in and raise the front of the machine. The FLOAT FLOAT feature feature sho uld o nly b e used in r everse. everse.
BRAKE PEDAL
When When traveling downhill, downshift the transmission to use the engine as a brake. When needed, use the right brake pedal. Do not use the brake pedals repeatedly unl ess necessary. necessary. Do not rest your foot on eith er the left or right br ake pedal.
These pedals (7) operate the brakes. Right Brake Pedal
The right brake pedal operates the wheel brakes, and is used for normal braking. Left Br ake Pedal Pedal
The left brake pedal operates the wheel brakes, and if the transmission cut-off switch is at “ON”, it also returns the transmission to neutral. If the transmission cut-off switch is at “OFF”, the left brake pedal acts in the same way as the right brake pedal. Remark
When the accelerator is being used for operating the work equipment, always use the left brake pedal to slow or stop the machine after putting the transmission cut-off switch to the “ON” position.
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OPERATION ACCELERAT ACCEL ERATOR OR PEDAL This pedal (8) controls the engine speed and output. The engine speed can be freely controlled between low idling and full speed.
STEERING TILT LOCK LEVER
Stop the machine before adjusting the angle of the steering wheel. If If the adjustm ent is made when the machine is moving, serious injury may result.
This lever is used to set the steering wheel to the FREE position when adjusting the position of the steering wheel to the front or rear or up or down. Pull the lever up, set the steering wheel to the desired position, then push the lever down to lock the steering wheel securely in position. The amount of adjustment is as follows. Up-down movement
When at 0 mm (0 in.)
When moved up to 40 mm (1.6 in.)
Tilt amount
0 - 105 mm (0 - 4.1 in.)
0 - 130 mm (0 - 5.1 in.)
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2-61
OPERATION
SECURITY AND LOCKS This machine is equipped with several security, locks and safety features designed to protect the operator, persons performing service, repair or inspections i nspections on the machine as well as the general public when the machine is not in use and unattended. It is important for the operator of the machine to know where these features are located and when to use them. Failure to do so may result in damage to the machine or injury to personnel.
IGNITION KEY LOCKED AREAS These areas require the ignition key to lock and secure them. Whenever you leave the machine unattended for any length of time it is advised to lock and secure the machine safely. Doing so will prevent unauthorized personnel from accessing the machine.
CAB DOOR LOCKS The left cab door is equipped with a key lock. Locking the cab prevents access to the machine operating controls.
ENGINE ACCESS DOORS Both sides of the engine access doors right and left are set up with a security lock to prevent unauthorized access. Always keep these doors locked to avoid the possibility of vandalism.
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OPERATION REAR GRILL To access the fuel tank fill cap, both the rear grill and fuel cap are locked. The lock for the rear grill is located on the lower portion of the grill.
FUEL CAP After refueling the machine lock the fuel tank (1) cap. Insert the ignition key and turn the key to the OPEN position, remove the key and unscrew the cap. To lock, fully install the cap, insert the ignition key and turn the key to the LOCK position.
LOCKING LOCATIONS OVERVIEW Always lock the following parts. 1. 2. 3. 4. 5.
Fuel Fuel tank tank fill filler er cap cap Engi Engine ne side side pan panel el (2 poin points) ts) Cab door Hydraulic tank Rear grille
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OPERATION 6. Air cond conditi ition oner er fre fresh sh air air filt filter er
7.
Tran Transmi smissi ssion on filte filterr cov cover er
Remark
The starting switch key is used also for locks (1) to (7).
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OPERATION
SAFETY FEATURES Before performing any type of operation or maintenance on the machine it is important to know where and how to use the safety features built into the machine. These safety features are of the passive type or active type.
PASSIVE SAFETY FEATURES Passive safety features are built into the machine and need little or no attention. It is important to inspect these safety features for damage or ware occasionally.
ROLL-OVER ROLL -OVER PROTECTIVE PROTECTIVE STRUCTURE (ROPS) This is to protect the operator in a rollover situation or from falling objects. When operating the machine, it is important to remain within the ROPS structure to avoid any contact with falling objects Never modify, cut or drill on any part of this structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation.
CAB FRONTAL FRONTAL GUARD (OPTIONAL) (OPTIONAL) This feature is only available on machines used in severe operations. It is designed to protect the operator from objects falling back onto the cab and entering the operators compartment.
BACKUP ALARM This sounds an alarm when the directional lever is set to the “R” position. It is used to warn people behind the machine that the machine will travel in reverse.
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OPERATION
ACTIVE A CTIVE SAFETY FEATURES Active safety features are safety devices that must be used by the operator in order to be effective. Failure to use these installed features may lead to serious injury or even death.
When perfor perfor ming m aintenance or transpo rtin g the machine, always always lock t he safety safety bar. Al way s r emo ve t he s afet y b ar fo r g ener al t rav el o per ati on s. If it is no t rem ov ed, th e st eeri ng wh eel wi ll no t be able to tur n the machine. This This si tuation is extremely dangerous.
SAFETY BAR The bar locks the front frame and rear frame to prevent the machine from bending during normal travel or when servicing or transporting the machine.
SEAT BELT The seat belt is installed to keep the operator in the seat within the cab of the machine if the machine is ever in a rollover situation. Always use the seat belt when operating the machine. It is important to inspect this component for ware or damage. If the belt is worn or damaged, replace it immediately.
Even if there appears appears to be no abnormalit y with the seat seat belt, replace it once every thr ee years. years.
Remark
The date of manufacture of the seat belt is marked on the belt at the place indicated by the arrow in the diagram on the right.
Check that the bolts that connect the seat belt to the machine are not loose. Tighten if necessary. Tightening torque: 24.5 ± 4.9 N·m (18.1 ± 3.6 lb. ft.)
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OPERATION 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 with a new one.
EQUIPMENT LOCK LEVER Lever (4) is used to lock the equipment controls. By locking the controls they cannot be operated inadvertently. When leaving the operators cab or working within the cab always lock the controls
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2-67
OPERATION
MACHINE FEATURES These features are important for the operator to know about. Although not safety related these features offer operator comfort and convenience as well as easy care for the machine.
CAB DOOR
• • • • • •
Always Always che check that that the cab cab door door is locke locked, d, both both whe when it is open and when it is closed. Always Always stop stop the machin machine e on le level vel ground ground before before opening opening or closing the door. Avoid Avoid ope openin ning g or closing closing the the door door on a slop slope e. The There re is is danger that the operating effort may sudd enly change. Whe When opening opening or closing closing the door door, alwa always ys use use door door handle and knob. Be care careful ful not not to get get your your hands hands ca caught ught by the the fron frontt pill ar or center pillar. When When there there is is any any person person inside inside the cab, cab, alway always s call call out a warning warning b efore opening or closin g the door.
CAB DOOR OPEN OPEN LOCK When getting in or out of the operator's compartment, or when operating with the door open, use this lock to hold the door in position. 1. Push the door door again against st catch catch (1) (1) to lock lock itit in positi position. on. 2. When attaching attaching the the door door in position, position, lock it firmly to the catch. catch. 3. When getting on or off the the machine, machine, hold the the handrail handrail on the inside.
4. When When closing closing the the door door from from the opera operator' tor'ss seat, seat, push knob knob (2) (2) to release the catch. 5. When closing the door door after after getting getting off the the machine, machine, pull knob knob (3) (3) to release the catch.
2-68
WA380-6
OPERATION
CAB WINDOW WINDOW CAB LEFT WINDOW OPEN OPEN LOCK RESET KNOB Use this when raising or lowering the glass in the window of the left door. Grip lock release knob (1), release the lock, then remove the glass down to the lower lock position. Release lock release knob (1). When moving the glass down, there are 2 stages for lock position (A).
CAB RIGHT WINDOW OPEN LOCK RESET KNOB Use this to keep the right window glass at the open or closed position. Pull open lock knob (1) towards the inside of the machine to release the lock, push open-lock knob (1) up along the rail to move to the lock position, then release the knob. There are 2 lock positions: open and closed.
RESET RIGHT WINDOW OPEN LOCK FOR ESCAPE If the door of the cab does not open or it is dangerous to get off the machine from the side where the door is, release the open lock of the right window, open the right window fully, and use the right window as an emergency escape route. 1. Grip open open lock lock knob knob (1) and pull pull it towards towards the the rear of the machine. machine.
2. Remove Remove the the open open lock guid guidee rail from from the wind window ow pillar pillar guide guide to free the right window lock.
WA380-6
2-69
OPERATION 3. Open Open the right right window window fully fully and and escape escape throug throughh the window window.. When returning the open lock knob to its original position, pull the window to a position where it is possible to lock it, align the open lock guide rail with the guide, then push in the open lock knob to the front. Check that the rail is completely fitted into the guide, then secure at the LOCK position.
It is dangerous to carry out operations with the emergency escape window lock released. The right window wil l extend beyond beyond the outermos t wheel. There is also danger that the window m ay close suddenly when the brake is applied. Al way s ch eck th at th e o pen -lo ck kn ob fo r th e r ig ht wi nd ow gl ass is lo ck ed at th e o pen or cl os ed po si ti on before driving the machine.
2-70
WA380-6
OPERATION
ELECTRICAL FUSE The fuses protect the electrical equipment and wiring from burning out. If the fuse becomes corroded, or white powder can be seen, or the fuse fus e is loose in the fuse holder, replace the fuse. Replace the fuse with another of the same capacity. Loosen the knob (1) at two places, then remove cover (2). The fuse boxes are A and B.
FUSE CAPACITY AND NAME OF CIRCUIT FUSE BOX A
No.
Fuse Capacity
Name Of Circuit
1.
10A
Left head lamp
2.
10A
Right head lamp
3.
10A
Left side clearance lamp
4.
10A
Right side clearance lamp
5.
20A
Main lamp circuit
6.
10A
Machine monitor A Load meter (if equipped)
7.
5A
Air conditioner B
8.
20A
Air conditioner A
9.
20A
Wiper/washer
10.
20A
Backup lamp, brake lamp
11.
10A
Work equipment positioner posi tioner Work equipment controller (if equipped)
12.
5A
Emergency steering (if equipped)
13.
5A
Parking brake
14.
10A
Transmission control A
15.
10A
Horn
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2-71
OPERATION FUSE BOX B
No.
Fuse Capacity
Name Of Circuit
1.
5A
Engine control B
2.
10A
Rear heater glass
3.
10A
KOMTRAX (if equipped)
4.
20A
Rotating beckon (if equipped)
5.
10A
Turn signal indicator
6.
20A
Radio, cigarette lighter, 12V power source and air suspension seat (if equipped)
7.
10A
Rear work lamp
8.
10A
Front working lamp
9.
10A
Front working lamp
10.
30A
Engine controller A
11.
5A
Transmission control B, work equipment control B (if equipped)
12.
10A
Cab lamp
13.
10A
Monitor B, A KOMTRAX (if equipped)
14.
10A
Hazard lamp
15.
20A
Ignition switch
If the power does not come on when the ignition switch is turned “ON”, the slow-blow fuse may be blown. Check and replace it, if it is blown. The slow-blow fuse is beside the engine on the left side of the machine. 1. 2. 3. 4.
50 A: Perma Permane nent nt powe powerr sourc sourcee 50 A: Main Main power ower A 50 A: Main Main power ower B 120 A: A: Heater Heater relay relay (ele (electr ctrica icall intake intake air air heater) heater)
2-72
WA380-6
OPERATION
MACHINE CAB CAB AND CHASSIS SEAT ADJUSTMENT
When adjust adjust ing t he operator's seat, stop the machine in a safe place before starting starting the operation. Ad ju st th e seat bef or e st art in g o per ati on s f or th e day or wh en c han gi ng op erat or s. When adjusti adjusti ng the posi tion o f the operator's seat, always set the work equipment lo ck lever to the LOCK position to prevent any accidental contact with the control levers.
Adjustments (E), (J), and (K) use the air compressor built into the seat, turn the engine ignition switch to the “ON” position when carrying out the adjustment.
LUMBAR SUPPORT TYPE SEAT • •
When pulling pulling up up levers levers (2) and and (3), be careful careful not to pull pull up the the switch switch box at at the front front by mistake. mistake. There is is danger danger that the the switch box may be damaged. When the the left armrest armrest is at the raised position, position, do not not push down on on the tip tip of the the armrest armrest with your your hand hand to support support your weight. There is danger that the armrest mount may be damaged. A. Fore-and-aft Fore-and-aft adjustment: adjustment: Pull Pull lever lever (1) up, set set the seat to to the desired position, then release the lever.Amount of adjustment: 180 mm (7.1 in.) (10 mm (0.4 in.) x 18 stages) B. Seat angle adjustment: adjustment: Move Move lever lever (2) up and apply apply your weight to the rear of the seat. The seat will tilt to the rear. Move lever (3) up and apply your weight to the front of the seat. The seat will tilt to the front. Amount of adjustment: 24 degrees (front and rear tilt: 3 stages each) C. Seat height adjustment: adjustment: Move Move levers levers (2) (2) and (3) up and move move the seat up or down to desired position. These levers are also used for adjusting the seat angle, so adjust the seat angle to set the seat to the desired height. Amount of adjustment: 65 mm (2.6 in.) D. Adjusting Adjusting fore-and-a fore-and-aft ft position position of seat cushion: cushion: Push lever lever (4) (4) in, set the seat cushion to the desired position, then release lever. Amount of adjustment: 65 mm (2.6 in.) E. Adjusting Adjusting weight weight setting setting for seat: seat: Sit Sit on the seat, raise your body slightly, sli ghtly, then operate switch swi tch (5) ( 5) to t o adjust the strength s trength of the suspension. Amount of adjustment: 50 - 130 kg (110 - 287 lb.)
F.
l When When + is presse pressed: d: Sus Suspe pens nsio ionn beco become mess stro strong nger er l When When - is is press pressed ed:: Susp Suspen ensio sionn bec becom omes es wea weake ker r Reclining Reclining angle adjustmen adjustment: t: Move lever lever (6) up and move the the seat backrest backrest to the front or rear. rear. Push Push your back back against the backrest when carrying out this adjustment. If your back is not pressing against the backrest, the backrest may suddenly spring forward.
l Amount Amount of adjust adjustmen ment: t: Front Front tilt: tilt: Free Free Rear Rear tilt:40 tilt:40 degre degrees es (2 degre degrees es x 20 stage stages) s) G. Head rest angle angle adjustment adjustment (if equipped equipped): ): Rotate the headrest headrest to the front or rear. rear.
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2-73
OPERATION l Amount Amount of adjustm adjustment ent:: Front Front tilt: tilt: 13 13 degr degrees ees Rear Rear tilt: tilt: 13 degree degreess H. Head rest height height adjustment adjustment Move Move the head rest rest up or down. Amount Amount of adjustment: adjustment: 80 80 mm (3.2 in.) I.
Arm rest angle angle adjustmen adjustment: t: Rotate the knob knob (7) and adjust the angle angle of the the arm rest. rest. (Left side side only) Amount Amount of of adjustment: 73 degrees (front: 54 degrees; rear: 19 degrees) If the arm rest is turned, it will spring up. (Both left and right sides)
J.
Lumbar Lumbar support support Operate switch (8) (8) to give a suitable tension to the lower lower lumbar lumbar region. region. Operate Operate switch (9) to give give a suitable tension to the upper lumbar region.
• When When + is pres pressed sed:: Ten Tensio sionn beco become mess stron stronge ger r • When When - is presse pressed: d: Ten Tensio sionn bec becom omes es wea weake ker r K. Side support: support: Operate Operate switch (10) (10) to give a suitable suitable tension tension to the left left and right lumbar lumbar region. region. • •
When When + is pres pressed sed:: Ten Tensio sionn beco become mess stron stronge ger r When When - is presse pressed: d: Ten Tensio sionn bec becom omes es wea weake ker r
REMOVAL AND INSTALLATION OF HEADREST REMOVAL
If the headrest is not needed, remove it as follows. 1. Pull Pull up the the headr headrest est to the posit position ion where where it stops. stops. 2. From the the top of the seat back, back, turn stopper stopper (1) (under (under the the material material at the top of the seat) of the headrest bar on one side in the direction of the arrow, and pull up the headrest. When stopper (1) is turned, it will come out of groove (2). 3. Turn stopper (1) on the other other side side in the the direction direction of the arrow, arrow, and pull up the headrest. When both stoppers (1) come out of groove (2), the headrest can be removed. INSTALLATION
Insert the bars into the holes in the top of the seat and push down.
2-74
WA380-6
OPERATION HANDLING CAB WIPER WIPER Remark
When angling the wiper arm (1) to the front, check that the wiper blade is hanging free.
When angling the wiper arm (1) to the front, such as when wiping the glass clean, if the wiper arm (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.
GREASE PUMP (IF EQUIPPED) The grease pump is installed in the holder on the left radiator side of the engine bulkhead at the rear of the machine. After using it, wipe off the grease from its outside and install it in position. Insert the grease pump in the holder and fix it with the rubber band. Hitch the tail chain of the grease pump to the hook at the bottom of the holder.
WA380-6
2-75
OPERATION
PRECAUTIONS BEFORE STARTING WORK OPERATIONS Before starting your work operations it is important to perform several procedures to be sure your equipment is in a safe operating condition. It is also important to be aware of the hazards involved when operating your machine.
PRE-OPERATI PRE-OPERATIONAL ONAL CHECKS Before starting your machine and preceding with any work operations it is important to be sure your machine is safe to operate. Below is a list of some basic items to check before any work is to begin. If any problems are found during your Pre-operational Check, have them repaired immediately. Never operate a machine that is unsafe, damaged or in need of repair.
PERFORM A WALK AROUND CHECK OF YOUR MACHINE A. Look Look for any any obviou obviouss missing missing or dama damaged ged items items.. B. Check the the condition condition of the loading loading bucket, bucket, look look for loose or missing missing attachment attachment pins, damaged damaged surfaces surfaces or missing parts. C. Check the conditio conditionn of all visible hydraulic hydraulic hoses, hoses, look for worn or leaking leaking fittings, cut, scuffed scuffed or cracked cracked hose surfaces. If any hose is found to be worn, cracked or leaking have it repaired or replaced immediately. D. Check for leaking leaking or damaged damaged hydraulic hydraulic cylinders. cylinders. If any cylinder cylinder is damaged damaged or leaking have have it repaired immediately. E. Inspect the the mechanical mechanical lift, lift, dump and and pivot pivot points. Look Look for any any loose or missing parts, parts, cracked, cracked, bent or damaged areas. F.
Be sure all safety safety decals decals are in place and and are not damaged damaged.. Be sure they are are clean and and visible for for all personnel personnel to see.
G. Check the the condition condition of the front front and rear tires. tires. Look for excess excess wear or cut cut surfaces, objects objects imbedded imbedded in the tire tire or under inflation.
If worn or damaged damaged tires are used, they may burst and cause serious inj ury or death. death. To ensure safety, safety, do not u se the follow ing ti res. • Wear : Tires with a tread grooves of less than 15% of th at of a new tire Tires with extreme uneven uneven wear or w ith stepped-type wear wear • Dam ag e: Tires with damage that has reached reached the cord s (1), (1), or wit h cracks i n the rubb er Tires with cut or pul led cords (1) Tires with peeled peeled (separated) (separated) surface Tires with damaged damaged bead (2) Leaking or impro perly repaired tubeless tubeless tires Deterior Deterior ated, deformed or abnorm ally damaged damaged tir es, which do not seem usable
2-76
WA380-6
OPERATION H. Insp Inspeect tire tiress
I.
Inspect rims.
Check the rims (wheels) and and ring s for deform ation, corrosi on and cracks. In partic partic ular, check the side rings, lock ring s and rim flanges thorou ghly.
J.
Check Check under the machine machine for for any build-up build-up of debris, debris, trash or leaks. leaks. Remove Remove any debris debris that is found found and have have the leak leak checked by authorized personnel.
K. Inspect Inspect the fuel and hydraul hydraulic ic tanks for damage damage or leaks. leaks. Be sure the the fill caps are installe installedd and locked locked in place. L. Be sure sure the step stepss are not not damaged damaged or or covere coveredd with mud. mud. M. Check the conditio conditionn of the cab. inspect inspect the windows, mirrors, mirrors, hand holds, holds, work lights, directional directional and and canopy for any damage or missing parts. Be sure all locks are functional. N. Check the exhaust stack, be sure it is not damaged, kinked or restricted in any way. Be sure the exhaust outlet is facing away from the cab and is not restricted.
WA380-6
2-77
OPERATION
UNDER THE HOOD A. Open the hood hood and check check all fluid levels. be sure they they are at the specified specified level outlined outlined in the maintenance maintenance section. section. B. Check the the engine engine and radiator radiator for any build build up of trash, trash, wood chips, chips, rubbish, leaves leaves or other other flammable flammable materials. materials. If flammable materials are found as well as excess build up of oil or dust, remove the flammable material or have the engine cleaned. C. Be sure the the hood closes closes properly properly and and will lock lock securely securely to prevent prevent tampering tampering by by others.
CHECK COOLANT LEVE L EVEL L
Do not open the radiator cap unless necessary. When checking the coolant, always wait for the engine to cool do wn and check the sub tank. tank. Immediately after after the engine is stop ped, the coolant is at a high temperature and and the radiator i s under high internal pressure. If the cap is removed to check the coolant level in this condition, there is a hazard of burns. After waiting for the temperature to decrease, turn the cap slowly before removing it. This action allows t he pressure insid e the radiator to release gradually. gradually.
When adding adding coolant, use the step and and handrail to s upport yours elf securely.
1. Open Open the side side door door of the the engin enginee hood hood on the the right right side of of the machine. 2. Check Check that that the cool coolant ant level level is betw between een the the FULL FULL and LOW LOW range range on sub-tank (1). If the coolant level is low, add coolant through the water filler port of sub-tank (1) to the FULL line. 3. After After adding adding cool coolant ant,, tighten tighten the the cap secu securely rely.. 4. If sub tank (1) is empty, empty, check check for for water water leakage, leakage, then check the water level in the radiator. If the water level is low, add coolant to the radiator, then add coolant to sub tank (1).
If the volume of coolant added is more than usual, check for possible leakage. Confirm that there is no oil in the coolant.
2-78
WA380-6
OPERATION CHECK WATER SEPARATOR
Each part of the engine is still highly heated immediately after the engine is stopped. Do not attempt to drain cool ing water or remove the filter element element cup. High pressure is generated inside the engine fuel piping, whi le the engine engine is ru nning . Wait Wait for mo re than 30 seconds after the engine stop for the engine to sufficiently cool down. Then start with draining cooling water or removing the filt er element element cup. Do not bring fire close.
Check water separator, drain water and sediment. 1. Open Open the engi engine ne side side cover cover on the the right right side side of the mach machine ine.. The water separator forms one unit with the fuel pre-filter, and is at the bottom.
2. It is possible possible to judge the condition condition of water and sediment sediment through through transparent cap (3). If water or sediment is accumulated, set a container under drain hose (4) to collect the discharged water. 3. Loosen Loosen plug (2) and drain drain the the water. water. 4. Tighten Tighten plug plug (2) as soon as fuel starts to to be dischar discharged ged from from drain drain hose (4). Tightening torque: 0.2 - 0.45 Nm (2 to 4 in/lbs) 5. On this this machine machine,, sensor sensor (5) is is installe installedd to detect detect if wate waterr is accumulated at the bottom of the fuel pre-filter. If water separator caution lamp (6) on the machine monitor lights up, carry out the above Steps 1 - 4 to drain the water. If plug (2) is stiff, coat O-ring (5) of plug (2) with grease. 6. Set a fuel fuel cont contain ainer er unde underr drain drain hose hose (4). (4). 7. Loosen plug (2), then then drain drain all all the sediment sediment together together with the the fuel fuel from drain hose (4). 8. Check Check that that nothing nothing comes comes out out from drain drain hose hose (4), (4), then remov removee plug (2). 9. Coat Coat O-ring O-ring portion portion (5) (5) with a suita suitable ble amoun amountt of grease grease.. 10. When doing doing this, be careful careful not not to let the grease grease get on the the drain valve water drain port (a) or the plug thread. 11. Screw in plug (2) by by hand until it contacts contacts the the bottom. bottom. 12. Remove the fuel container container.. • If trans transpar parent ent cap cap (3) (3) is dirty dirty and the cont content entss canno cannott be easily easily seen, clean transparent cap (3) when replacing the filter. • When washing washing,, if plug plug (2) is removed removed,, coat the O-ring O-ring with grease, grease, then tighten by hand hand until it contacts contacts the the bottom. bottom.
WA380-6
2-79
OPERATION CHECK AIR CLEANER ELEMENT
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and damage it. Al way s s to p t he en gi ne b efo re c arr yi ng ou t t hes e op erat io ns . When using comp ressed air, air, there is danger that dirt may be blown around and cause serious inju ry. Al way s u se p ro tec ti ve g las ses , du st mas k, an d o th er p ro tec ti ve eq ui pm ent .
1. Open Open the engi engine ne side side cover cover on the the right right side side of the chas chassis. sis. 2. If the yellow yellow pisto pistonn in the displa displayy portion portion of dust dust indicat indicator or (1) installed to the air cleaner enters the red range (7.5 kPa), clean the element. 3. After After cleanin cleaning, g, press press the button button of of the dust dust indicat indicator or to reset reset it. 4. If the yello yellow w piston piston enters enters the the red range range (7.5 (7.5 kPa) kPa) soon after after the the dust indicator is reset, it is necessary to replace the element. 5. For deta details ils of the the proced procedure ure for for replaci replacing ng the the elemen element, t, See “ENGINE AIR FILTER” FILTER” on page page 3-19. 3-19.
ELECTRIC AIR CLEA NER CLOGGING SENSOR SENSOR
(Machines equipped with KOMTRAX) If the yellow piston in the display portion of dust indicator (1) enters the red range (7.5 kPa), or air cleaner clogging caution lamp (2) on the machine monitor lights up, clean the air cleaner element. Remark
Do not clean at the element until the air cleaner clogging caution lamp lights up. If the element is cleaned frequently before the air cleaner becomes clogged, the air cleaner will not be able to provide its expected performance and the cleaning efficiency will become poor. In addition, dirt stuck to the element will drop inside the inner element more frequently during the cleaning operation.
CHECK ELECTRIC WIRING
If the fuses frequently blow or if there are traces of short circuits in the electrical wiring, locate the cause and immediately perform repairs, or contact your Komatsu distributor for repairs. Keep the top surface of the battery clean and check the breather hole in the battery cap. If it is clogged with d irt o r dust, wash the battery cap to clean the breather breather hole.
Check for damage, wrong fuse capacity, and any sign of disconnection or short circuit in the electric wiring. Also, check and tighten any loose terminals. Particularly, check the wiring of the “battery”, “starting motor” and “alternator” carefully.
2-80
WA380-6
OPERATION When checking around the battery, make sure there is no accumulation of flammable material. Remove all flammable material. Please contact your Komatsu distributor for investigation and correction of the cause.
CHECK ENGINE OIL LEVEL, ADD OIL
The parts parts and oil are at at hig h temperature immediately after the engine is stop ped, and and may cause serious burns . Wait Wait for th e temperature temperature to go dow n before starting the operation.
1. Open Open the insp inspect ection ion cove coverr of the right right side side at at the rear rear of the the machine. 2. Take out out the dipst dipstick ick (G) (G) and wipe wipe off off the oil oil with cloth cloth.. 3. Insert dipstick (G) fully fully in the oil oil filler filler pipe, pipe, then take it out again. 4. The oil oil level level should should be be betwee betweenn the H and and L marks marks on dipstic dipstickk (G). 5. If the oil level level is below below the the L mark, mark, add add engine engine oil oil through through oil oil filler (F). 6. If the oil is above above the H mark, drain the excess excess engine engine oil from drain drain plug (P), and check the oil level again. 7. If the oil level level is correct, correct, tighten tighten oil oil filler filler cap cap (F) securely securely and and close close the inspection cover. Remark
When checking the oil level after the engine has been operated, wait for at least 15 minutes after stopping the engine before checking. If the machine is at an angle, make it horizontal before checking.
REAR-VIEW MIRROR ADJUSTMENT
Be sure to adjust adjust t he mirror s before startin startin g work. If they are are not adjusted properly, you cannot secure the visibility and may be injured or may inj ure someone seriously.
• Mirrors A, B Loosen bolt (1) of the mirror, then adjust the mirror to a position which gives the best view from the operator's seat of the blind spot at the left and right sides at the rear of the machine. •
When When instal installing ling the mirror mirror,, adjust adjust so that that it is possibl possiblee to see any person (or any object of a height of 1 m (3 ft 3 in) and diameter of 30 cm (11.8 in) at the rear left or right of the machine.
WA380-6
2-81
OPERATION • Mirrors C Adjust so that is possible to see the ground around the machine at a range of 1 m (3 ft 3 in) from the operator's seat. •
If the the movem movement ent of the the mirro mirrorr is stif stifff when when adjust adjusting ing it, loose loosenn bolt (2) of the mirror.
Install the mirrors at the position and dimensions shown in the diagram. The values below are reference values for the range of visibility.
• • •
• Rang Rangee of of vie view w (le (left) ft):: 250 25000 mm mm (8 (8 ft ft 2 in) in) • Rang Rangee of of vie view w (rig (right ht): ): 2500 2500 mm (8 ft 2 in) in) Mirror Mirror A: Must be possibl possiblee to to see see hatche hatchedd porti portion on (A) Mirro Mirrorr B: Must Must be be possi possibl blee to see see hat hatch ched ed por portio tionn (B) (B) Mirro Mirrorr C: Must Must be be possi possibl blee to see see hat hatch ched ed por portio tionn (C) (C)
Tighten the mirror mounting bolts securely that they will not be loosened and the mirrors will not come off. Tightening torque Mirrors A, B: 2.0 to 2.5Nm (18 to 22 in/lbs) Mirrors C: 8.8 to 9.8Nm (78 to 87 in/lbs) If the tightening torque cannot be controlled, ask your Komatsu distributor for tightening the bolts.
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WA380-6
OPERATION
IN THE OPERATOR’S OPERATOR’S CA B A. Check the the condition condition of the cab cab floor. floor. Be sure it is clean clean and free from from tools, objects, objects, excess excess dirt, trash or grease. grease. B. Check to be be sure both doors doors open and and close properly properly.. Be sure the right right door is unlocked unlocked for safety safety purpose. purpose. C. Check the the windows windows for cleanlines cleanliness, s, remove remove any stickers stickers or objects objects pasted pasted to the the windows. windows. D. Make sure sure the fire extingui extinguisher sher is in place place and and in operating operating condition condition.. E. Be sure the operator’ operator’ss manual, safety safety manual manual and all all cab safety decals decals are in place place and and in good condition. condition. F.
Check Check to be sure sure the the seat seat belt belt and seat seat works works prope properly rly..
SEAT BELT ADJUSTMENT ★
Always wear the seat belt.
Before fastening the seat seat belt, check that there is no abnormality in t he belt mounting b racket or bolt. If the belt is wor n or damaged, replace replace it. Fasten Fasten the seat belt before starting op erations. Al way s w ear t he s eat b elt du ri ng op erat io ns . Make sure that the left and rig ht belts are not tw isted when fastening the seat belt.
Fastening Fastening And Removing The Belt Belt
• Fastening Belt Hold grip (2) and pull the belt out from the retractor device (1), check the belt to be sure it is not twisted then insert the tongue (3) into buckle (4) securely. When doing this, pull the belt lightly to check to be sure it is properly locked. • Removing belt Press button (5) in the buckle (4) and remove tongue (3) from buckle (4). The belt is automatically retracted. Hold grip (2) and return the belt slowly into the re-wind device (1) Belt Length Adjustment
To make the belt shorter: Pull the free end if the tether belt.
WA380-6
2-83
OPERATION To make the belt longer: Set the fixed end of the tether belt at 90 degrees to the holder and pull.
ADJ UST LEVER STAND STAND
When adjust adjust ing the lever stand, check that the work equipment l ock lever is securely at the LOCK positio n. If it is not at the LOCK position, and the work equipment control levers are touched by accident when adjustin g the lever stand, stand, the work equipm ent may suddenly move and cause serious serious personal injur y. ADJ UST HEIGHT A ND ANGLE ANG LE OF WRIST WR IST REST
The height of wrist rest (1) can be adjusted by loosening lock lever (2). Amount of adjustment: 30 mm (1.2 in) Angle: 44 degrees Set lock lever (2) to the FREE position (F). The lock lever is loosened. Hold the armrest at the desired position and move the lock lever to the LOCK position (L) to secure the armrest in position.
ADJ UST LEVER STAND FORWARD AND B ACK WARD
Pull lever (1) up with your left hand, grip wrist rest (3) with your right hand and move it to the front or rear, then release lever (1). Amount of adjustment: 180 mm. (7 in)
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WA380-6
OPERATION
STAR START T-UP PROCEDURES
When performin g start-up checks, be sure your machine is in a well ventilated area. area.
1. Turn Turn the the igniti ignition on switc switchh to “ON” “ON” positio position. n.
CHECK MONITOR PANEL PANEL 2. Check that all all the monitor lamps, the gauges gauges and the warning warning lamp light up for about 2 seconds and the alarm buzzer sounds for about 2 second. If the lamps do not light up, there is probably a failure or disconnection, so contact your Komatsu distributor for inspection. Remark
It is important that a pre-operational check be performed at the beginning of your work shift, even if you are taking the machine operations over from another operator, always perform a pre-operational check before you start work.
CHECK FUEL LEVEL, ADD FUEL
When adding adding fuel, never let the fuel overflow. This actio n may cause a fire. If If any fuel i s spil led, wipe it up compl etely. etely. Never Never bring the flames near the fuel because it is highl y flammable and dangerous. Remark
If the engine has run out of fuel and has stopped, it is necessary to operate the priming pump to bleed the air completely from the fuel line before starting the engine again. Take care not to let the engine stop because of lack of fuel. If the engine has run out of fuel, the air bleeding operation can be performed more quickly if the fuel tank is completely filled with fuel.
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2-85
OPERATION 1. Ignition Ignition key key must must be in the the “ON” “ON” positi position on to check check the the fuel fuel level level with fuel level gauge (G).
•
If necess necessary ary add fuel fuel throug throughh fuel fuel filler filler (F) (F) to fill the the tank. tank. For details of the method for opening and closing the cap, see “SECURITY “SECURITY AND LOCKS” LOCKS” on page 2-62. 2-62.
•
Fuel Fuel capa capaci city ty:: 300 300 liter literss (79 (79.2 .255 US US gal gal.) .)
CHECK THE BRAKE PEDALS 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.
CHECK THE PARKING PARKING BRAKE B RAKE Check that the parking brake works properly. If there is any abnormality in the operation of the parking brake or the brake does not provide the proper braking effect, please contact your Komatsu distributor for adjustment.
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OPERATION FINAL CHECKS BEFORE STARTING THE ENGINE
Al way s set th e s afet y lev er sec ur ely to th e L OCK po si ti on bef or e s tar ti ng th e en gi ne. If th e con c on tr ol lev ers are touched by accident at the time of starting the engine, the work equi pment may move suddenly, which may cause serious serious injur y.
1. Check to see if the parking parking brake brake switch switch (1) (1) is in the “A” “A” position. position.
2. Chec Checkk dire direct ctio iona nall leve leverr is in the the N position.When starting the engine, if directional lever (2) is not at the N position, the engine will not start.
3. Be sure sure the work work equipm equipment ent lock lock lever lever is in the the LOCK LOCK position position (L). (L).
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OPERATION 4. Check Check that that the bucke buckett is comple completely tely lowe lowered red to the the groun ground. d. A. If it is not completely completely lowered, lowered, lower lower the bucket bucket to the the ground ground as follows. B. Check that the the work work equipment equipment control control lever lever is at at the HOLD position, then set the work equipment lock lever l ever to the FREE position. C. Operate Operate the work equipme equipment nt control control lever lever to lower the the bucket bucket to the ground. D. Check that the work equipme equipment nt control control lever lever is at the HOLD HOLD position, then set the work equipment lock lever to the LOCK position. 5. Check Check that that work work equipme equipment nt lock lock lever lever (3) is at at the LOCK LOCK positio positionn (L).
6. Insert the key key in in starting starting switch switch (4), turn turn the the key key to the ON ON position position (B), and check that the machine monitor system works. When the starting switch is turned to the ON position before starting the engine, monitors, gauges, and central warning lamp light up for approx. 2 seconds, and the alarm buzzer sounds for approx. 2 sec. If any monitor does not light up, there is probably a failure or disconnection. Contact your Komatsu distributor for inspection. In addition, after all the monitors, gauges, and central warning lamp light up, a self check is carried out to check that the emergency steering function works properly. For details, See “EMERGENCY STEERING SELF-CHECK SELF-CHECK FUNCTION” FUNCTION” on page 2-107. 2-107.
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OPERATION STARTING STARTING THE ENGINE NORMAL STARTING STARTING
Start Start th e engine engine only after sitt ing dow n in the operator’s seat with seat belt fastened around around y our waist. Do not attempt to start the engine engine by short -ciruit ing the engine startin startin g circui t. Doing Doing so may cause serious bodily injury or fire. Check to be sure that there are no persons or obs tacles in the surro undin g area, area, sound th e horn and start the engine. Exhaust gas is toxic. When starting the engine in confined spaces, be particularly careful to ensure good ventilation.
1. With the key key to the “ON” “ON” position. position. Preheating Preheating will automatic automatically ally start and preheating pilot lamp (2) will light up. Remark
Do not accelerate the engine suddenly before completing the warming-up operation. Do not keep the starting motor rotating continuously for more than 20 seconds.
If the engine does not start, wait for at least 2 minutes before trying to start the engine again. This machine is equipped with an engine automatic preheating device that functions to start the engine preheating automatically. If the ambient temperature is low, the preheating monitor will light up when the key in starting switch (1) is turned to the ON position to inform the t he operator that preheating has been started automatically.
1.
Turn the key in starting switch (1) to ON position (B).
If the ambient temperature is low, the preheating pilot lamp (2) lights up and automatic preheating is carried out. Keep the key in starting switch (1) at the ON position until the preheating pilot lamp (2) goes out. The time that the preheating pilot lamp (2) stays lighted up depends on the ambient temperature as shown in the table on the
Ambient temperature
Heating time
-1º C to to -15º -15º C (30º (30º F to 5º 5º F) 0 second secondss to 30 seco seconds nds -15º -15º C or or le less (5º (5º F or less less))
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0 to to 12 12 sec sec..
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OPERATION 2. If the preheating preheating pilot pilot lamp lamp (2) does not not light light up, up, or it lights lights up and then goes out to inform that the engine preheating has been completed, turn the key in starting s tarting switch (1) to the START START position (C). 3. The starting motor will continue continue to turn turn and and the the engine engine will start. start. Keep the key in starting switch (1) at the START position (C) to keep the starting motor running until the engine starts. Remark
In low temperatures, to ensure lubrication of the engine and to improve the durability, no fuel is supplied to the engine for 3 seconds after the key in starting switch (1) is turned to the START position (C), so the engine will not start during this time. Therefore, keep the key in starting switch (1) at the START position (C) to keep the starting motor running until the engine starts.
4. When engine is started, started, release release the key key of ignition ignition switch switch (1) and the key will return automatically to “ON”.
STARTING IN COLD WEATHER
•
Do not not sudde suddenly nly acce accelera lerate te the the engine engine before before the the warmin warming-u g-upp operation is completed. It takes some time to start up the engine when the machine is left unused for more than half a day in the ambient temperature of approx. -20 °C (4°F). In that case, use the engine starting switch in the following manner.
1. Turn Turn the the key in startin startingg switch switch (1) (1) to ON ON positio positionn (B). If the ambient temperature is low, the preheating pilot lamp (2) lights up and automatic preheating is carried out. Keep the key in starting switch (1) at the ON position until the preheating pilot lamp (2) goes out. The time that the preheating pilot lamp (2) stays lighted up depends on the ambient temperature as shown in the table on the right. Ambient temperature
Heating time
-1º C to to -15º -15º C (30º (30º F to 5º 5º F) 0 second secondss to 30 seco seconds nds -15º -15º C or or le less (5º (5º F or less less))
2-90
0 to to 12 12 sec sec..
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OPERATION 2. When When prehea preheating ting pilot pilot lamp lamp (2) goes goes out, out, turn the the key key in starting starting switch (1) to t o the START START position (C). (C) . Keep the key in starting switch (1) at the START position (C) to keep the starting motor running until the engine starts. 3. The start starting ing motor motor will will continu continuee to turn and and the engin enginee will start. start. Remark
In low temperatures, to ensure lubrication of the engine and to improve the durability, no fuel is supplied to the engine for 3 seconds after the key in starting switch (1) is turned to the START position (C), so the engine will not start during this time. Therefore, keep the key in starting switch (1) at the START position (C) to keep the starting motor running until t he engine starts.
4. Method Method of of starting starting engi engine ne in tempe temperat rature uress of approx approx.. -20°C (-4°F). A. Keep the engine engine starting starting motor running running for the the max. 20 seconds, seconds, holding holding the key key of engine starting starting switch switch (1) in the START START position (C), until the engine starts up. B. If the engine engine fails to start up even even after running running the engine engine starting starting motor motor for about 20 seconds, seconds, stop stop the engine engine starting motor once (release the engine starting switch (1) key), and try the same process again after a pause for a minute or so. C. If the engine engine still fails fails to start up after after the second second attempt, attempt, try the same process process for for the third time after after a pause pause for a minute or so. 5. When the engine engine has started started up and and the the engine engine speed rises, release the key of engine starting switch (1). The key will automatically return to the ON position (B).
AUTOMATIC WARMING-UP WARMING- UP OPERATION
When the engine is started, if the engine water temperature is below 30 °C (86°F) the warming-up operation is carried out automatically (engine speed: 1000 rpm). It is cancelled when the engine water temperature goes above 50 °C (122°F). (Engine speed: 850 rpm) (X): Engine speed (rpm) (Y): Water temperature (°C)
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OPERATION
OPERATIONS AND CHECKS AFTER STARTING ENGINE If any problems occur, turn the ignition switch to the “OFF” position. If the work equipment is operated without warming up the machine sufficiently, the response of the work equipment to the movement of the control lever will be slow, and the work equipment may not move as the operator desires, so always perform the warm-up operation. Particularly in cold areas, be sure to perform the warm-up operation fully.
BREAKING IN THE MACHINE 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. • • • • •
Be sure to break-in break-in the machine machine for the the initial initial 100 hours (as (as indicated indicated by the service meter). During During break break-in -in opera operatio tions, ns, follow follow the the preca precautio utions ns describ described ed in this this manual manual.. Idle Idle the the engi engine ne for for 5 minu minute tess afte afterr starti starting ng itit up. up. Avoid void oper operati ation on with heavy heavy loads loads or or at high high speed speeds. s. Avoid sudden sudden starts, sudden sudden accele acceleration, ration, sudden sudden steering and sudden sudden stops stops except except in cases of of emergency emergency..
NORMAL START-UP START-UP AND WARM-UP After starting the engine, do not immediately start operations. First, perform the following operations and checks. Remark
Do not suddenly accelerate the engine before the warm-up operation is completed. Do not run the engine at low or high idle continuously for more than 20 minutes. If it is necessary to run the engine at idle, apply a load from time to time or run the engine at a midrange speed.
1. Depress the accelera accelerator tor pedal pedal (1) (1) lightly lightly and run the the engine engine with with no load at midrange speed for about 5 minutes. Remark
Do not use starting aids such as either to start a cold engine, damage to the engine may result.
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OPERATION To warm up the hydraulic oil in cold areas, do as follows. 2. After carrying carrying out out the warming-up warming-up operation, operation, check check that the the engine engine rotation is smooth, then set the work equipment lock lever to the FREE position (F). 3. Operate Operate the bucket bucket control control lever lever to the TIL TILT T position position (A) and return return it to the HOLD position (B) repeatedly to warm up the hydraulic oil. Relieve the circuit at the TILT position (A) for a maximum of 10 sec. This brings the oil to the relief pressure and makes it quicker warm up the oil. 4. Slowly operate the steering steering wheel to the left and and the right about 10 times to warm up the hydraulic oil inside the steering valve
If the steering wheel is operated and stopped while the oil temperature is low, there may be a time lag before the machine stops turning. In this case, use the frame lock bar to ensure safety, safety, and perform t he warm-up operation in a wide place. Do not relieve relieve the hydraulic hydraulic oil in the circuit conti nuously for more than 5 seconds.
Turn the steering wheel a little and stop in that position. Confirm that the machine turns by an angle equivalent to the amount that the steering wheel is turned. Select the oil from the table of recommended oils below according to the ambient temperature. If Komatsu EO10W30-DH is used in the cold season, replace it with Komatsu EO15W40-DH oil when the cold season finishes. Ambient temperature Reservoir
Hydraulic fluid
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Type of fluid
-22
-4
14
32
50
68
86
104
122oF
-30
-20
-10
0
10
20
30
40
50oC
Engine oil
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OPERATION 5. After carrying carrying out the warmingwarming-up up operatio operation, n, check check that that the the gauges gauges and caution lamps are normal. If there is any abnormality, carry out maintenance or repair. Run the engine under a light load until engine water temperature gauge (2) and torque converter oil temperature gauge (3) are in the green range. 6. Check for abnormal abnormal exhaust exhaust gas color, color, noise, noise, or vibration. vibration. If any problem is found, contact your Komatsu distributor. di stributor. Remark
The rotating speed of the cooling fan differs according to the following conditions, but this does not indicate any abnormality. The cooling fan speed increases when the hydraulic oil temperature, engine coolant temperature, or transmission oil temperature are high. However, when the cooling fan is rotating in reverse, it rotates at a fixed speed proportional to the engine speed, regardless of any oil or coolant temperature.
STOPPING THE ENGINE Remark
If the engine is abruptly stopped before it has cooled down, engine life may be greatly shortened. Consequently, do not abruptly stop the engine apart from an emergency. In particular, if the engine has overheated, do not abruptly stop it but run it at medium speed to allow it to cool gradually, then stop it.
1. Run the the engine engine at low idling for about about 5 minutes to cool cool down down gradgradually. 2. Turn Turn the igni ignition tion switch switch (1) (1) to the “OFF” “OFF” positio positionn to stop stop the engine. 3. Remove Remove the key from from ignit ignition ion switch switch (1).
After Af ter Stopp Sto ppin ing g Th e Engi ne 4.
Walk around around the machine machine and check check the the work work equipment, equipment, body and and undercarriage check for leakage of oil and coolant. 5. Fill Fill the the fue fuell ta tank. nk. 6. Check the engine engine compartment compartment for any debris. Clean out any any debris debris to avoid a fire hazard. 7. Remove Remove any any mud mud attach attached ed to the unde underca rcarria rriage. ge.
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OPERATION
TRAVELING, STOPPING AND PARKING THE MACHINE Before traveling or moving the machine, it is important to know all the control functions and relevant safety regulations for the area you will be traveling or moving the machine in. If you will be traveling on state or local roadways, observe all traffic safety laws. Travel at a safe controllable speed.
TRAVELING 1. Check Check that that the the warnin warningg pilot pilot lamp lamp (1) (1) is not not lit lit up.
2. Set the the safety safety lock lock of bucke buckett contro controll lever lever and and lift lift arm control lever to the FREE (F) position.
3. Raise Raise the work work equipm equipment ent to the the travel travel postu posture re shown shown in the the diagram on the right.
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OPERATION 4. Depress Depress right brake pedal (5) and and turn turn parking parking brake switch (6) to the “OFF” (RELEASE) position to release the parking brake. Keep right brake pedal (5) depressed.
Remark
If the parking brake is still actuated when parking brake switch is at the “OFF” (RELEASE) position (B), turn the parking brake switch “ON” (A) , then turn it “OFF” again (B).
5. Set the the speed speed contro controll lever lever to the desir desired ed speed speed range. range. Position (a): 1st. Position (b): 2nd. Position (c): 3rd. Position (d): 4th.
6. Set the the direc direction tional al lever lever to to the desired desired directio direction. n.
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OPERATION 7. After releasin releasingg the right brake pedal, pedal, depress depress the the accelera accelerator tor pedal pedal to begin moving the machine .
Al way s t rav el at a saf e co nt ro ll abl e sp eed.
Remark
When moving the machine off on a hill, turn transmission cutoff switch (10) OFF, OFF, depress left brake pedal (11), (11), operate the gearshift lever to the low speed range, then depress accelerator pedal (9) and gradually release left brake pedal (11) to let the machine move off. This makes it possible to prevent the machine from rolling back.
When traveling, and turning the machine. Keep in mind the front frame is joined to the rear frame at the center of the machine by the center pin. Therefore, the front and rear frames bend at this point, and the rear wheels follow in the same track as the front wheels when turning. When turning, turn the steering wheel carefully to follow the machine as it turns. Remark
When the steering wheel reaches the end of its stroke, do not try to turn it any further. Check the play it should be 50 to 100 mm (2.0 to 3.9 in) in the steering wheel. If any abnormality is found, contact your Komatsu dealer for inspection.
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OPERATION TURNING ON SLOPES Traveling on slopes is dangerous in general. However, turning on a slope can be fatal. When traveling on a slope never turn the steering wheel. Always travel straight up or straight down a slope. If the machine should start to tip, lower the bucket to the ground immediately to stabilize the machine. Travel at a slow pace in the lower speed ranges, avoid dragging the brakes when traveling down a slope.
Remark
When starting to move the machine on a hill, turn transmission cut-off switch (1) “OFF”, depress left brake pedal (2), operate the gearshift lever to the travel position, then depress accelerator pedal (3) and gradually release left brake pedal (2) to let the machine move. This makes it possible to prevent the machine from rolling back.
CHANGING GEAR SPEED RANGES
When traveling traveling at high speed, do not s hift gears suddenly. Use the brake to reduce the travel speed before shifting gears.
Shift Gears As Follows. Move the gearshift lever (1) to the desired position to shift. ★
When digging or loading, perform the operation in 1st or 2nd. Use the gearshift lever stopper. Position (a): 1st. Position (b): 2nd. Position (c): 3rd. Position (d): 4th.
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OPERATION Remark
If the gearshift lever is operated slowly or is stopped between gear positions, the central warning lamp may light up and the alarm buzzer may sound. In this case, there is no failure, but try to operate the gearshift lever so that the gear shifting is completed within 2 seconds. This machine is equipped with kick down switch (3). When traveling in 2nd, if kick down switch (3) is pressed, the transmission shifts down to 1st. For operations carried out in 1st and 2nd, such as digging and loading, we recommend the use of the kick down switch. For details of the method of use, see “KICKDOWN SWITCH” on page page 2-40 2-40 . This machine is equipped with an auto-shift system that automatically shifts the gear. For details of the method of use, see “TRANSMISSION “TRANSMISSION MODE SELECTOR SELECTOR SWITCH” on page 2-36 and see “WHEN USING AUTOSHIFT” on page page 2-100 . When the machine is traveling at high speed, if the gear shift lever is shifted down to a lower speed, such as 4th <-> 3rd or 4th <-> 2nd, with the accelerator still depressed, the transmission is not shifted down. This is to prevent the engine from overrunning. In this case, the central warning lamp lights up and the alarm buzzer sounds. At the same time, “E00” is displayed on the top line of the character display and “OVERRUN PROTECT” is displayed on the bottom line. If the alarm buzzer sounds, release the accelerator pedal immediately and depress the brake pedal to reduce speed, then carry out the gearshift operation.
CHANGING DIRECTION
When changing directio n between FORW FORWARD and REVE REVERS RSE, E, check that t he new dir ection of t ravel is safe. There is a blind spot behind the machine, so be particularly careful when changing direction to travel in reverse. Do not switch between FORWARD and REVERSE when traveling at high speed. When switching between FORWARD and REVERSE, depress the brake to reduce the travel speed suffi ciently, then change the direction of t ravel. (Max. (Max.speed speed for changing directio n: 12 km/h (7.5 (7.5 mph))
There is no need to stop the machine even when switching between FORWARD and REVERSE. Place the directional lever (1) in the desired position.
Remark
The directional selector switch makes it possible to change the direction of travel by operating a switch.
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OPERATION If an attempt is made to switch the direction between forward and reverse while traveling at high speed (when using 3rd or 4th), if the travel speed and engine speed are in ranges I or II in the chart on the right, the central warning lamp will light up and the buzzer will sound. At the same time, “E00 OVERRUN PROTECT” is displayed on the character display. If the alarm buzzer sounds, depress the brake immediately to reduce the travel speed, then operate the directional lever to switch between forward and reverse.
WHEN USING AUTO-SHIFT If the directional lever is operated slowly or is stopped midway between the forward and reverse directions, “E01 MAINTENANCE” may be displayed on the character display. In this case, there is no failure, but try to operate the directional lever so that the change in direction is completed within 2 seconds. If an attempt is made to switch the direction between FORWARD and REVERSE while traveling at high speed (when using 3rd or 4th), if the travel speed and engine speed are in ranges (A) or (B) in the chart, the central warning lamp will light up and the alarm buzzer will sound. At the same time, “E00” is displayed on the top line of the character display and “OVERRUN PROTECT” is displayed on the bottom line. If the alarm buzzer sounds, depress the brake pedal immediately to reduce speed, then operate the directional lever to switch between FORWARD FORWARD and REVERSE. (X): Travel speed (km/h) (Y): Engine speed (rpm)
WHEN USING AUTO-SHIFT If an attempt is made to switch the direction between forward and reverse when the auto-shift is ON, normally, the gearshift range will switch F3 -> R2, F4 -> R2, or R3 -> F2, R4 -> F2 to make it possible to move the machine off quickly. However, if an attempt is made to shift between forward and reverse when the machine is traveling at high speed, such as shown in ranges (A) or (B) in the chart, the central warning lamp will light up and the buzzer will sound. At the same time, “E00” is displayed on the top line of the character display and “OVERRUN PROTECT” is displayed on the bottom line. If the alarm buzzer sounds, depress the brake pedal immediately to reduce speed, then operate the directional lever to switch between FORWARD FORWARD and REVERSE. In particular, if an attempt is made to switch between forward and reverse in range (B), the speed range will not shifted to 2nd, but will switch F3 -> R3, F4 -> R4, or R3 -> F3, R4 -> F4. As a result, the reduction in speed will be less than in range (A), so care is necessary.
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OPERATION
STOPPING STOPPING AND A ND PARK PARKING ING THE MACHINE
Avoi Av oi d s to pp in g s ud den ly. Gi ve y ou rs elf amp le ro om wh en s to pp in g. Even if the parking parking brake switch i s turned “ ON” ON” , there is danger until th e parking parking brake pilot lamp lig hts up, so k eep eep th e brake pedal pedal d epressed. Remark
Never use the parking brake switch to brake the machine when traveling except in an emergency. Apply the parking brake only after the machine has stopped.
1. Release the accele accelerator rator pedal pedal (1), then then depress depress brake pedal (2) to stop the machine.
•
Brak Brakee and and acce accele lera rato torr ped pedal alss
2. Place Place dire directio ctional nal lever lever (3) (3) in N (neut (neutral) ral)..
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OPERATION 3. Turn the parking parking brake switch to the “ON” position to apply apply the the parking brake. Remark
When the parking brake is applied, the transmission is automatically returned to neutral.
4. Lower Lower the the lift arm and bucket bucket to the the groun ground. d. 5. Set Set safe safety ty lock lock leve leverr to to the the LOCK position.
6. Do not not park the the machi machine ne on slope slopes. s. If the mach machine ine has has to be parked on a slope, set it facing directly down the s lope, then dig the bucket into the ground and put blocks under the tires to prevent the machine from moving.
7. Allow Allow the engin enginee to run at at a low idle idle for abou aboutt 5 minutes minutes to cool cool down gradually. Never shut down an engine that is over heating or has just finished work operations always allow it a time to cool down before turning the ignition key to the “OFF” position.
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OPERATION Always lock the following parts. 1. 2. 3. 4. 5.
Fuel Fuel tank tank fill filler er cap cap Engi Engine ne side side pan panel el (2 poin points) ts) Cab door Hydraulic tank Rear grille
TRANSMISSION CUT-OFF SWITCH When the transmission cut-off switch is pressed, the pilot lamp lights up, and the following transmission cut-off function is actuated. Position (a): OFF Position (b): ON When the brake pedals are both depressed, the brake is actuated, and in addition, the transmission is shifted to neutral at the pre-selected brake pedal depression position.
Remark
The cut-off function is actuated only with the left and right brake pedals are depressed. For details of adjusting the brake pedal depression position, see “ADJUSTING THE TRANSMISSION CUT-OFF” on page 2-104. 2-104. Raise or lower the pre-selected brake pedal depression position to adjust the cut-off to match the type of work. When carrying out scooping-up work, lower the brake pedal depression position for the cut-off (transmission shifted to neutral). In this setting, the transmission driving force is cut at a point where there is ample braking force, so this prevents the machine from slipping down. When approaching dump trucks during loading operations, raise the brake pedal depression position for the cut-off (transmission shifted to neutral). In this setting, the fine control of the braking immediately before dumping the load can be carried out with the brake only, so this makes it easy to control and allows the machine to be brought to a soft stop.
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OPERATION ADJ USTING THE TRANSMISSION CUT-OFF CUT-OFF
Ap pl y th e par ki ng br ake bef or e adj us ti ng th e tr ans mi ss io n cut-off position.
In the transmission cut-off function, it is possible to adjust the depression position of the left brake pedal used to shift the transmission to neutral. 1. Start the engine with the the ignition ignition switch (1), then set the the parking parking brake switch (2) to the “ON” position. posit ion. 2. Set the the transmis transmission sion cut-o cut-off ff switch switch (3) (3) to the “ON” “ON” positi position. on. 3. Depress Depress left brake pedal (4) and and set it to the desired desired position to shift the transmission to neutral. 4. Press the transmission transmission cut-off cut-off set switch (5), then then release it. When When the switch is released, the buzzer will sound with a repeated short sound, and the cut-off position is set. Method of canceling cut-off position 5. After the the buzzer buzzer sounds in Step Step 4 of the adjustment adjustment procedure procedure,, the transmission cut-off switch flashes for 2 seconds. While it is flashing, press transmission cut-off set switch (5) again and release it. 6. The buzzer buzzer will sound sound with with a long sound and the the adjusted adjusted cut-off cut-off position is canceled.
STOPPING WHEN TRANSMISSION CUT-OFF IS ON When the transmission cut-off switch is at the “ON” position and the left brake pedal is depressed, the transmission is shifted to neutral at the pre-selected brake pedal depression position. The transmission is also shifted to neutral when the right brake pedal is operated. Remark
When the transmission cut-off switch is “OFF”, both brake pedals act in the same way, and the transmission is not shifted to neutral.
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OPERATION TURNING
Operating the steering wheel suddenly at high speed or operating the steering wheel on steep slopes is dangerous. Do not operate the steering wheel in such si tuations. If the engine stops when the machine is traveling, the emergency steering steering i s actuated. This This sys tem is only for st eering eering i n emergencies, so never stop the engine. It is partic partic ularly dangerous if the engine stops when the machine is traveling on slopes, so never let the engine stop when traveling on slopes. If the engine stops, sto p the machi ne immediately at a safe place.
When traveling, use the steering wheel to turn the machine. The center pin joins the front frame to the rear frame. The front and rear frames pivot at the center point, and the rear wheels follow in the same track as the front wheels when turning. Turn the steering wheel lightly to follow the machine as it turns. Remark
When the steering wheel is turned fully, if it reaches the end of its stroke, do not try to turn it further. 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.
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OPERATION
EMERGENCY STEERING • • •
Never actuate actuate the emergency emergency steering steering except except during during emergencie emergenciess or when when checki checking ng the function. function. The emergen emergency cy steering steering can can be used used continuously continuously for a maximum maximum of 60 seconds. seconds. Operating Operating it continuously continuously for more than 60 seconds may damage the system. When When using using the the emerge emergency ncy stee steering ring,, travel travel at less less than than 5 km/h km/h (3.1 (3.1 mph). mph).
USING THE EMERGENCY STEERING During emergencies or when stopping the engine to check the function, press emergency steering switch (1). Emergency steering pilot lamp (green) (2) when the engine is running or when the machine is operated, indicating the condition is normal. The emergency steering system is provided to enable the machine to be steered under the following conditions. The ignition switch is at the “ON” position. The steering oil pressure is low or there is no pressure. (When the engine has stopped or there is a failure in the steering oil pressure pump, etc.) When Key SW is turned on, during the emergency steering motor is running for automatic self-checking, it indicates that the emergency steering system is functional. For details, see “EMERGENCY STEERING STEERING SELF-CHECK FUNCTION” FUNCTION” on page 2-107. 2-107.
When the emergency steering controller detects lack of oil pressure in the steering system, steering oil pressure caution lamp (red) (3) and central warning lamp (4) light up, and the alarm buzzer sounds intermittently. When this happens, if the machine is traveling at a speed of more than 2 km/h (1.2 mph), the electric pump motor is automatically actuated and emergency steering pilot lamp (green) (2) lights up. Steering oil pressure caution lamp (red) (3) lights up to inform the operator that there is a failure in the steering system. If steering oil pressure caution lamp (red) (3) lights up, move the machine immediately to a safe place and stop it. Locate the cause and do not operate the machine until it has been repaired. Remark
If any function of the oil pressure system is used when the engine is running at low speed, steering oil pressure caution lamp (red) (4) may light up for a moment, but if the lamp goes out again soon, there is no problem.
When the emergency steering controller detects that the oil pressure in the steering circuit has been restored, the actuation of the emergency steering system is stopped.
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OPERATION EMERGENCY STEERING STEERING SELF-CHECK FUNCTION When the ignition switch is turned “ON”, the emergency steering is automatically actuated for approximately 3 seconds to check that the emergency steering is functioning properly properl y. When this happens, steering oil pressure caution lamp (red) (1) and emergency steering pilot lamp (green) (2) light up.
If machine is steered during the steering self-check, it may move. Do not steer the machine during th e steering steering s elf-check.
The emergency steering function check is not performed in the following cases. • • •
If the the igniti ignition on switc switchh is turne turnedd “ON”, “ON”, turne turnedd “OFF” “OFF” again again witho without ut starting the engine, and is then turned “ON” again. If the the igniti ignition on switc switchh is turned turned “ON” again again immed immediate iately ly after after stopping the engine when the steering oil pressure has not gone down completely. When When aut autom omati aticc preh prehea eatin tingg is bei being ng car carrie riedd out. out.
Remark
During automatic preheating, the emergency steering self-check function is not actuated. To check the emergency steering function, press the emergency steering switch after completing the warm-up operation.
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OPERATION
STARTING YOUR WORK OPERATIONS • • • • •
Do not not start the engine engine if warning warning tags tags have have been been attached attached to the steering steering wheel wheel or control control levers. levers. Sound your horn to warn others in the area before starting the engine engine or moving moving the machine machine.. Operate Operate the machine machine in a seated seated position position only, only, with the the seat seat belt fastened fastened snugly around your waist. waist. Do not not allow allow anyo anyone ne in the cab cab or or on the the mach machine ine during during oper operati ations. ons. Check Check the the area area to be sure sure all perso personne nnell are clear clear of of the machi machine ne and and your your work area area..
WORK EQUIPMENT EQUIPMENT 1. Lift arm arm control control leve leverr (1) and and bucket bucket contro controll lever lever (2) can be be used used to operate the lift arm and bucket as follows.
LIFT ARM LEVE L EVER R Position (a): RAISE Position (b): HOLD The lift arm is kept in the same position. Position (c): LOWER Position (d): FLOAT FLOAT The lift arm moves freely under external force.
When the lift arm control lever is pulled further from the raise position, the lever is stopped in this position until the lift arm reaches the preset kick-out position, and the lever is return to the hold position. Remark
Do not use the FLOAT position when lowering the lift arm. Use the FLOAT position when leveling in reverse direction only.
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OPERATION BUCKET LEVE L EVER R Position (a): TIL TILT T Position (b): HOLD The bucket is kept in the same position. Position (c): DUMP
When the bucket control lever is pulled further from the TILT position, the lever is stopped in this position until the bucket reaches the preset position of the positioner, positi oner, and the lever is returned to the HOLD position.
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OPERATION
SCOOPING A LOAD OR CUTTING A GRADE
Never perform digging or scooping operations with the machine articulated because the machine may tip over. The work equipm ent will mov e when the travel damper switch is tu rned “ ON” (ECCS), (ECCS), regardless if the machine is traveling or the work equipm ent is raised. Remark
If the tires slip, tire life will be reduced. Do not allow the tires to slip during operation.
LOADING PILED SOIL OR BL ASTED ROCK When loading piled soil or blasted rock, drive the machine forward (as follows) to load. To prevent the tires from getting cut caused by the tires slipping, be careful of the following points during the operation. •
Always Always keep keep the operati operating ng job job site site flat, flat, and remove remove any any fall fallen en rocks. • When When workin workingg with with stock stockpil piles, es, oper operate ate the machin machinee in 1st or or 2nd; when loading blasted rock operate the machine in 1st. 1. When When driving driving the machin machinee forward forward and lower lowering ing the buck bucket, et, stop stop the bucket about 30 cm (12 in.) from the ground, then lower it slowly. Remark
If the bucket hits the ground, the front tires will come off the ground and the tires will slip.
2. Downshift Downshift immediately immediately in front front of the material material to be loaded. loaded. After After downshifting, depress the accelerator pedal at the same time and thrust the bucket into the load. Remark
To reduce fuel consumption, depress the accelerator pedal the minimum possible amount. If it is fully depressed, the fuel consumption will increase, but there will be no increase in the amount loaded.
3. When the material material is in a stockpile, stockpile, keep the cutting edge of the the bucket horizontal; when loading blasted rock, have the bucket tilting slightly down. Be careful not to get blasted rock under the bucket. This will make the front tires come off the ground and slip. 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.
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OPERATION 4. At the same same time you you are thru thrustin stingg the bucke buckett into the the material material,, raise the lift arm slightly to help keep the tires from slipping. While continuing to enter the pile of material, roll the bucket back to fully fill it.
5. Once the bucket bucket is full check check the amount amount of material material loaded loaded into the bucket, then t hen operate the bucket control lever to t o tilt t ilt the bucket and load back fully. Remark
If the bucket edge is moved up and down while pushing in the bucket and digging, the front tires will come off the ground and this will cause the tires to slip.
6. If there is too much material material loaded loaded in the bucket, bucket, dump and and tilt the bucket quickly to remove the excessive load. This prevents spillage of the load during hauling.
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OPERATION CUTTING A GRADE ON LEVEL GROUND When digging and loading on level ground, set the bucket edge facing down slightly as follows fol lows and drive the machine forward. Always be careful not to load the bucket on one side and cause an unbalanced load. Perform this operation in 1st gear.
Do not set th e bucket facing dow n mor e than 20 degrees.
1. Set the edge edge of the the bucke buckett facing facing sligh slightly tly down down..
2. Drive the machin machinee forward forward and and operate operate the lift lift arm control control lever lever forward to cut a thin layer of the surface each time when excavating the soil.
3. Operate the lift arm control control lever lever slightly slightly up and and down to reduce reduce the the resistance when driving the machine forward. When digging with the bucket, avoid imposing the digging force onto only one side of the bucket.
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OPERATION
LEVELING LEVEL ING OPERATIONS OPERATIONS • •
•
Always Always oper operate ate the the mach machine ine in rever reverse se when when carry carrying ing out leve levelin lingg operations. If it is is necessa necessary ry to perform perform levelin levelingg opera operation tionss when when trave traveling ling forward, do not set the bucket dumping angle to more than 20 degrees. Turn Turn the the E.C.S.S E.C.S.S.. OFF OFF carry carrying ing out levelin levelingg oper operatio ations. ns.
1. Scoop Scoop soil soil into the buck bucket. et. Move Move the machin machinee backwa backward rd while while spreading soil from the bucket little by little. 2. Go over over the spread soil with with the bucket bucket teeth teeth touching touching the ground ground and level the ground by back-dragging. 3. Scoop some more soil soil into into the bucket, bucket, put put the lift arm arm in float, level the bucket at ground level, and smooth the ground by moving backward.
PUSHING OPERATION
Never Never set the buck et to the DUMP DUMP positi on when push ing.
When pushing, set the bottom of the bucket parallel to the ground surface.
LOA D AND CA RRY OPERA OPERATIONS TIONS
• • •
When When carrying carrying a load, load, lower lower the bucke bucket to lower the ce center nter of gravity when when traveli traveling. ng. Always stop the machine and lower the work equipment equipment to the ground before operating operating the E.C. E.C.S. S.S. S. switch. When When performing performing inspection inspection and and mainten maintena ance, nce, first lower lower the work equipme equipment nt to the ground, ground, then then turn the E.C.S E.C.S.S. .S. switc h “ OFF” OFF” before starting t he inspection and maintenance operation. operation.
The load and carry method for wheel loaders consists of a cycle of scooping → hauling →loading (into a hopper, truck, etc.) Always keep the travel path properly maintained. When using the load and carry method, see “LOAD AND CARRY OPERATIONS” OPERATIONS” on page 2-113. 2-113. Remark
When approaching dump trucks during loading operations, raise the brake pedal depression position for the cut-off (transmission shifted to neutral). In this setting, the fine control of the braking immediately before dumping the load can be carried out with the brake only, so this makes it easy to control and allows the machine to be brought to a soft stop.
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OPERATION
LOA DING OPERATIONS OPERATIONS Select the method of operation which will give the minimum amount of turning and travel in order to provide the most efficient method for the job site.
Al way s k eep t he j ob si te f lat , and do no t o per ate t he s teer in g w heel su dd enl y o r ap pl y t he b rak es s ud den ly when the lift arm is raised wit h a loaded loaded bucket. This action is dangerous. Never Never thru st the bucket in w hen traveling at high speed (when loading loading so il or cr ushed rock). This action is dangerous. The work equipm ent will mov e when the travel damper switch is tu rned “ ON” (ECCS) (ECCS),, regardless regardless if th e machine is traveling or the work equipm ent is raised.
CROSS DRIVE LOADING Always set the wheel loader facing at a right angle to the stockpile. After digging in and scooping up the load, drive the machine straight back in reverse, then bring the dump truck in between the stock pil e and the wheel loader. This method requires the least time for loading, and is extremely effective in reducing the cycle time. Remark
If the tires slip, the life of the tires will be reduced. Do do not allow the tires to slip during operation. Avoid excessive bucket shaking also.
V-SHAPE LOADING Position the dump truck so that the direction of approach of the wheel loader is approximately 60 degrees from the direction of approach to the stockpile. After loading the bucket, drive the wheel loader in reverse, then turn it to face the dump truck and travel forward to load the dump truck. The smaller the turning angle of the wheel loader is, the more efficient the operation becomes. When loading a full bucket and raising it to the maximum height, first shake the bucket to stabilize the load before raising the bucket. This will prevent the load from spilling spilli ng to the rear.
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. Remark
When scooping-up, avoid using the transmission cut-off function as much as possible. It will prevent the machine from moving back. When using the transmission cut-off function, adjust the cut-off position to match the amount that the brake pedal is depressed in order to ensure ample braking force.
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OPERATION LOADING TRUCKS OR HOPPERS •
Approach the truck or hopper slowly and cautiously from the side with the load low, arms 300mm (12 in) above the ground
•
When within 0.2~1.0 m (5~6 ft) of the truck or hopper, STOP the machine and raise the load to the proper height keeping it as level as possible.
•
When you have reached the proper height, slowly slowl y move toward the truck or hopper in a straight line until the bucket is totally over the truck body or hopper opening and stop the machine.
•
Carefully and slowly roll the bucket forward dumping the load. After the load is completely out of the bucket, roll the bucket back completely, back the machine away from the truck or hopper 0.2~1.0 m (5~6 ft) and lower the arms to the 300mm (12 in) above the ground.
• •
Neve Neverr turn or mane maneuve uverr machine machine with the the load load raise raised. d. Never ver raise raise the the loa load d while approa pproaching ching the truck truck or hopper. Never ver bang bang the bucke buckett aga against the the hopp hoppe er or truck truck body to loosen loads in the bucket. Be sure sure the the drive driver or ope operator rator of of the truck truck or hoppe hopperr are are aware of when yo u are loading.
• •
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OPERATION
PRECAUTIONS DURING OPERATION PERMISSIBLE WATER WATER DEPTH When working in water or on swampy ground, do not let the water come above the bottom of the axle housing. After finishing the operation, wash and check the lubricating points.
IF WHEEL BRAKE DOES NOT WORK If the machine is not stopped by depressing the brake pedal, use the parking brake to stop the machine. Remark
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 BRAK ING ON DOWNHILL DOWNHILL SLOPE If the footbrake is used frequently when traveling downhill, the brake will overheat and may be damaged. Place the gearshift lever at a low speed range and use the braking force of the engine when traveling downhill. Use the right brake pedal for braking. If the brakes are used excessively, the axle oil temperature caution lamp may light up and the alarm buzzer may sound intermittently. For details of the necessary action to take, see “AXLE OIL TEMPERATURE TEMPERATURE CAUTION LAMP” on page 2-17. 2-17 . If the speed range selected by the gearshift lever is not correct, the torque converter oil may overheat. If this situation happens, downshift one gear range to reduce the oil temperature. If the oil temperature does not return to the white range even when the gearshift lever is at 1st, stop the machine, return the directional lever to the N position, and run the engine at a mid-range speed until the gauge returns to the white range.
IF THE ENGINE STOPS If the engine stops on a slope, apply the parking brake immediately, lower the work equipment, then stop the work machine. Put the directional lever in neutral, and start the engine again.
PRECAUTIONS FOR USING LOAD AND CARRY METHOD When traveling continuously with load and carry operations, choose the correct tires to match the operating conditions, or choose the operating conditions to match the tires. If this is not done, the tires will be damaged, so contact your Komatsu distributor or tire dealer when selecting tires.
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OPERATION
PRECAUTIONS WHEN DRIVING THE MACHINE When the machine travels at high speed for a long distance, the tires become extremely hot. This action causes early wear of the tires, so it should be avoided as much as possible. If the machine must be driven for a long distance, take the following precautions. • • • • •
• • • •
Follow Follow the the regula regulation tionss relate relatedd to this this machi machine, ne, and and drive drive care carefull fullyy. Before Before drivi driving ng the the machi machine, ne, perform perform the checks checks befo before re starti starting. ng. The most most suitable suitable tire pressure, pressure, travel travel speed, speed, or or tire type type differ differ according according to to the conditio conditionn of the travel surface. surface. Contact Contact your Komatsu distributor or tire dealer for information. The following following is a guide guide to suitable tire pressures pressures and and speeds speeds when traveling traveling on a paved surface surface with standar standardd tires. (23.5-25A) Check Check the the tire tire pressur pressuree before before starting starting when when each each tire tire is cool cool • Front ront whee wheel: l: 310k 310kPa Pa (45 (45 psi psi)) • Rear Rear whee wheel: l: 310k 310kP Pa (45 (45 psi) psi) Spe Speed: ed: 14 km/h km/h (8.7 (8.7 mph) mph) After traveling traveling for 1 hour, hour, stop stop for 30 minutes. Check the tires tires and other other parts parts for damage; damage; also also check check the oil oil and coolan coolantt levels. Alway Alwayss tra trave vell with with the buck bucket et empty empty.. Never Never put put “calci “calcium um chlori chloride” de” or or “dry ballast ballast”” in the the tires tires when when travel traveling ing..
PRECAUTIONS REGARDING REGARDING BRAK B RAKE E FUNCTION FUNCTION When traveling long distances continuously downhill, the frequency of using the brake may increase. As a result, depending on the weight of the machine and the grade of the slope, the machine's braking capacity may be exceeded and the brakes may overheat. The table below shows a guideline of the values for this machine. Braking capacity limit Machine weight (t)
Slope grade (%)
17.3 - 19.5 (unloaded) 22.5 - 24.5 (loaded)
Average Average travel speed limit (km/h (mph))
Downhill distance limit (continuous) (km)
10
40 (24.9)
1.9
20
38 (23.6)
0.6
10
38 (23.6)
1.5
20
32 (19.9)
0.5
If the braking capacity limit is exceeded, a forced cooling system for the brakes is needed. Please consult your Komatsu distributor.
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OPERATION
WORK EQUIPMENT EQUIPMENT AND MACHINE POSTURE • • • • •
Stop Stop the machi machine ne on flat flat ground ground and and put put blocks blocks in front front and and behind behind the the wheels. wheels. Appl Applyy the the park parkin ingg bra brake ke.. Secure Secure the front front and and rear rear fram frames es with with the safety safety bar bar.. Be sure sure to put put a warning warning tag on work work equipm equipment ent control control levers levers.. Do not not go go under under the work work equip equipmen mentt when when the the arm arm is is raised raised..
ADJ A DJUSTING USTING BUCKET BUC KET The kickout makes it possible to set the bucket so that it automatically stops at the desired lifting height (lift arm higher than horizontal) and the bucket positioner makes it possible to set the bucket so that it automatically stops at the desired digging angle. The setting can be adjusted to match the working conditions. •
Set Set the the par parki king ng brak brakee i pos posit itio ionn (A) (A)
•
Lock Lock the the fram framee of the the mach machin inee
BOOM KICKOUT A DJUSTMENT DJUSTMENT 1. Raise the bucket bucket to the desired height, height, set the the lift arm control control lever lever at HOLD and lock the lever in position with the safety lock lever. Then stop the engine. 2. Loosen two bolts bolts (1), and adjust adjust plate plate (2) (2) so that the the bottom bottom edge edge is in line with the center of the sensing surface of proximity switch (3). Then tighten the bolts to hold the plate in position. 3. Loosen Loosen two two nuts nuts (4) to make make a clea clearan rance ce of 3 to to 5 mm (0.1 (0.118 18 to 0.197 in.) between plate (2) and the sensing surface of proximity switch (3). Then tighten the nuts to hold in position. Tightening torque: 17.2 ± 2.5 N·m (12.7 ± 1.8 lbft) 4. After adjusting adjusting,, start the engine engine and raise raise the lift arm. arm. Check Check that that the bucket control lever is automatically returned to HOLD when the lift arm reaches the desired height.
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OPERATION BUCKET POSITIONER ADJUSTMENT 1. Lower the bucket bucket to the ground and adjust the the bucket bucket to the desired desired digging angle. Set the bucket control lever at HOLD, stop the engine and adjust as follows. 2. Loosen the bolts bolts (1), (1), adjust adjust the position position of mounting mounting bracket bracket (4) of the proximity switch so that the rear tip of bar (2) is in line with the center of the sensing surface of proximity switch (3), then tighten the bolts to hold the bracket in position. 3. Loosen the bolts bolts (5), adjust so that that the clearance clearance between between the bar bar (2) and support (6) is 0.5 to 2 mm (0.020 to 0.079 in.), then tighten the bolts (5) to hold in position. posit ion. 4. Loosen Loosen the nuts (7), (7), adjust adjust so that that the clearance clearance between between bar (2) (2) and the sensing surface of proximity switch (3) is 3 to 5 mm (0.118 to 0.197 in.), then tighten the nuts to hold in position. Tightening torque: 17.2 ± 2.5 N·m (12.7 ± 1.8 lbft) 5. After adjusting, adjusting, start the engine engine and and raise the lift arm. arm. Operate the the bucket control control lever lever to the DUMP position, position, then operate operate it to the TILT BACK position and check that the lever is automatically returned to the HOLD position when the bucket reaches the desired digging angle.
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
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OPERATION
TRANSPORTING THE MACHINE Before transporting the machine be sure what you are using to transport the machine is capable of supporting the weight and size of the machine. Be sure it is wide enough and rated for the load.
LOA DING AND SECURING THE THE MACHINE Load the machine onto a trailer as follows: 1. Be sure sure the area area you you will be be loadin loadingg the machi machine ne in is flat flat and and dry. 2. Be sure sure the machi machine ne is free free of mud mud or debris debris that that may hinde hinderr loading.
3. Check Check the ramps ramps and and support support surfac surfaces es for damag damage, e, week week spots, spots, missing boards or excess ware. If these surfaces look unsafe, too week or unstable do not load the machine. Be sure the loading equipment and transportation equipment are in good condition and rated for your load. 4. Lowe Lowerr the work work equ equipm ipmen entt slowly slowly.. 5. Check Check that that the work work equi equipme pment nt contro controll lever lever is at the HOLD HOLD position, then set the work equipment lock l ock lever to the LOCK position (L). 6. Set the the parking parking brake switch to ON position (A) to apply the parkparking brake securely. s ecurely. 7. Turn the starting starting switch to the OFF position position and stop stop the the engine. engine. 8. Remove Remove the key from the ignition ignition switch. switch. 9. Center the machines machines frame and lock lock the frame frame with the safety safety bar bar.. 10. Block the the wheels on the the trailer (D) before before attempting attempting to load load the machine. 11. Locate the tie down down and transporta transportation tion brackets brackets (A & C)on C)on the machine. Be sure they are in good condition. 12. Position the machine machine squarely squarely on the deck. deck. Raise the loader loader bucket bucket high enough to clear all surfaces. 13. Once the machine machine has has been loaded, loaded, rest rest the front bucket bucket on the the floor, set the machine in neutral and set the parking brake and lock the controls.
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OPERATION 14. Secure the the machine with tie-downs/c tie-downs/chains hains (C) at the anchor anchor points shown shown in illustrations illustrations (A).
• •
To help keep the machine in position, place blocks (B) in front and behind the front and rear wheels for extra support. Protect the exhaust stack from moisture if needed.
UNLOADING MACHIN MA CHINE E • • •
Load Load and and unload unload on firm firm level level ground ground only only.. Mainta Maintain in a safe safe distance from the edge of a road. Apply Apply the the brake brakess on the the trail trailer er secur securely ely and insert insert locks locks (1) (1) under under the tires to hold the trailer in position. Set the distanc distancee (3) (3) betwee betweenn ramps ramps (2) (2) to match match the the distan distance ce between the left and right tires, and make angle (4) of the ramps a maximum of 15°.
• • • • •
Remove Remove the chains chains and wire ropes ropes faste fastenin ningg the the mach machine ine.. Set Set the the fram framee lock lock bar bar to FREE FREE pos positi ition on (F). (F). Start the engine. Warm arm the the engi engine ne up full fullyy. Check Check that that the work work equip equipmen mentt contro controll lever lever is at the HOLD HOLD position, then set the work equipment lock l ock lever to the FREE posiposi tion (F).
•
Set the parking parking brake brake switc switchh to OFF posit position ion (B) to to cance cancell the the parkparking brake. Determi Determine ne the the direc direction tion of the the ramps, ramps, then then drive drive the the mach machine ine slowly down the ramps to unload the machine.
•
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OPERATION
LIFTING THE MACHINE Lifting hooks (A) are located in 4 places on the machine as shown in the diagram below. Use only these 4 places when lifting; do not use any other places. There is a serious danger that the machine may lose its balance. Always stay clear of the machine and maintain a safe distance when lifting it.
L IFTING LOCATIONS LOCATIONS AND A ND PROCEDURES PROCEDURES
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OPERATION
USING WIRE ROPE
•
• • • • •
When When lifting the machine, machine, if the wire rope is not installed installed correctly correctly on the machine, machine, the machine may fall and cause serous i njury or even death. Raise the machine 100 to 200 mm (3.9 to 7.9 in) from t he ground, check to be sure the machine is hori zontal, level and and that there is no slack in t he wire rope, then continu e to lift the machine. Before lifting the machine, machine, always always stop the engine and lock the brakes. brakes. Lock front frame and rear rear frame with s afety bar. bar. Lifting Lifting opera operations tions using using a crane crane must must be carr carried ied out out by a quali qualified fied ope opera rator tor.. Never ver raise raise the machin machine e with with any any perso personne nnell on it. Always Always make make sure sure tha that the wire rope use used d for lifting the machine machine is of ample ample stre strength ngth for the weight of the machine. When When carrying carrying out the lifting ope opera ration, tion, pleas please e conta contact ct your Komatsu Komatsu distributor distributor..
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, contact your Komatsu distributor for information. For details of the weight see “MACHINE DIMENSIONS AND WEIGHTS” WEIGHTS” on page 4-2. 4-2. Never use a wire rope which has cut strands st rands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break during the lifting process.
PRE LIFTING PROCEDURES 7. Start Start the engi engine ne and and raise raise the work work equip equipmen mentt to the trave travell height and roll the bucket back. Be sure the bucket is empty.
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OPERATION 8. Once at the travel height, height, lock the controls controls and cut the the engine engine off.
9. Place the directio directional nal lever lever in the N (neutral) (neutral) position position and and set the parking brake.
10. Lock the the frames frames with the the safety bar. bar.
11. Using the lifting lifting points, points, carefully carefully lift the machine. machine. Stay Stay clear of the machine at a safe distance until at this point the machine is fully resting in place and the cables are slack.
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OPERATION LIFTING MACHINE
The person person usi ng the crane to carry out li fting op erations must b e a qualified crane operator. Never Never carry out li fting operation s if any person is on the machine being lifted. Al way s u se a w ir e ro pe t hat has amp le s tr eng th fo r t he w eig ht of th e mac hi ne b ein g l if ted . Keep the machine machine hori zontal when lifting it . When carryi carryi ng out li fting operation s, do as as follo ws to prevent the machine from moving u nexpectedly. Set the parking brake switch t o the ON posit ion. Set the work equipment loc k lever to the LOCK LOCK position . Set the frame lock bar to th e LOCK LOCK posit ion. Never Never enter the area under or aroun d a raised machine. There is danger of t he machine losing its balance. Use the procedure below to set the machine in the proper posture and use the lifting equipment when lifting the machine.
The lifting procedure applies to machines with standard specifications. The method of lifting differs according to attachments and options actually installed on the machine. For the proper lifting procedures, contact your Komatsu distributor. For details of the weight, see “MACHINE DIMENSIONS DIMENSIONS AND WEIGHTS” WEIGHTS” on page 4-2. 4-2. Lifting position
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OPERATION
TOWING THE MACHINE If this machine must not be towed except in emergencies. When towing the machine, take the following precautions. 1. Align Align the towing towing pin pin (1) with groo groove ve (2) in the the counterw counterweig eight, ht, 0 then insert the pin and turn it 180 . 2.
To prevent prevent the towing towing pin pin from from turning, turning, fold fold the handle of the towing pin and set it in position. Reverse this operation to remove the pin.
3. Never Never use use a wire rope rope whic whichh has cut cut strands strands (A), (A), reduced reduced diameter (B), or kinks (C). There is danger that the rope may break during the towing process. 4. Before releasing releasing the the brakes, put put blocks blocks under the wheels to prevent prevent the the machine machine from moving. moving. If the wheels wheels are not not blocked, the machine may suddenly move. 5. When towing towing a machine, machine, tow tow it at a low speed speed of less less than 2 km km h (1.2 MPH), MPH), and for for a distance distance of a few few meters to a place where repairs can be carried out. If the machine must be moved long distances, use a transporter. 6.
To protect protect the the operator operator if if the towing rope or bar should break, install a protector plate to the machine being towed.
7. If it is impossi impossible ble to oper operate ate the the steerin steeringg and brak brakes es of the the machine being towed, do not let anyone ride on the machine. 8. Check that the the tow rope or or bar is of ample strength strength for the weight weight of the machine being towed. If the machine being towed must travel through mud or up hills, use us e a tow rope or bar of a strength of at least 1.5 times the weight of the machine being towed. 9. Keep the the angle angle of of the tow tow rope as small small as possible. possible. Keep the angle angle between the center lines of the two machines to to within 30 degrees. 10. If the machine is moved suddenly, the tow rope or bar will be subjected to an excessive load, and it may break. Start the machine gradually and travel at a constant speed. 11. The towing machine should normally be of the same class as the machine being towed. Check that the towing machine has ample braking power, weight, and rim pull to allow it to control both machines on slopes or on the tow road. 12. When towing a machine downhill, use a larger machine for towing to provide ample rim pull and braking braking power, or connect another machine to the rear of the machine being towed. This way it is possible to prevent the machine from losing control and turning over. 13. Towing may be carried out under various differing conditions, so it is impossible to determine beforehand there requirements for towing. Towing on flat horizontal roads will require the minimum rim pull, while towing on slopes or on uneven road surfaces will require the maximum rim pull.
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OPERATION
COLD WEATHER OPERATION If the temperature becomes low, it becomes difficult to start the engine, and the coolant may freeze, so do as follows.
FUEL AND LUBRICANTS L UBRICANTS Change to fuel and oil with low viscosity for all components. For details of the specified viscosity. see “FUEL, COOLANT AND LUBRICANTS” on page 3-11. 3-11.
COOLANT Antifreeze is toxic. Be careful not to get it into your eyes or on your skin. If it should get into your eyes or on your skin, wash it off with large amount of fresh water and see a doctor at once. When changing the coolant contact your Komatsu distributor. Antifreeze is toxic, so do not dispose of antifreeze in drainage ditches, sewers, on the ground or other areas always trap and recycle this fluid. Never use methanol, ethanol or propanol based antifreeze. Never use flammable liquids in the cooling system. Avoid using any leak-preventing agent, regardless if it is sold separately or in antifreeze. do not mix one antifreeze with a different brand. For details on the antifreeze mixture when changing the coolant. see “CLEANING “CLEANING THE COOLING SYSTEM” on page page 3-22. 3-22. Standard requirements for permanent antifreeze: • SAE J1034 • FEDE FEDERA RAL L STAN STANDA DARD RD O-AO-A-54 548D 8D
PRECAUTIONS AFTER COMPLETION OF WORK To prevent mud, water, or the undercarriage from freezing and making it impossible for the machine to move on the following morning, always observe the following precautions. Remove all the mud and water from the machine body. In particular, wipe the hydraulic cylinder rod clean to prevent damage to the seal caused by mud or dirt on the rod surface getting inside the seal together with drops of water. Park the machine on hard, dry ground. If this is impossible, park the machine on wooden boards. The boards help protect the wheels from being frozen in soil and the machine can start next morning. Open the drain valve and drain any water collected in the fuel system to prevent it from freezing.
AFTER A FTER COLD COL D WEATHER When season changes and the weather becomes warmer, do as follows. Replace the fuel and oil for all parts with oil of the viscosity specified. For details, see “FUEL, COOLANT AND LUBRICANTS” on page 3-11. 3-11.
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2-127
OPERATION
BASIC TROUBLESHOOTING WHEN MACHINE RUNS OUT OF FUEL When starting the engine again, check carefully that the area around the engine is safe before cranking the engine. When starting the engine after running out of fuel, fill with fuel and bleed the air from the fuel system before starting. For details of bleeding the air, see “REPLACING PRIMARY FUEL FILTER” FILTER” on page 3-45. 3-45 .
TOWING MACHINE
Serious Serious injury or death could result if there is any any mistake in the selection selection of wire rope or method of t owing a disabled machine. Al way s b e su re t o c hec k c aref ul ly th at t he c apaci ty of th e wi re r op e us ed f or to wi ng is amp le f or th e wei gh t of the towed machine. Never use a wire rope which has cut strands (A), reduced diameter (B), or kinks (C). There is danger that the rope may break break during t he towing operation. Al way s w ear l eath er g lo ves wh en h and li ng wi re r op e. Never Never tow a machine on a slop e. During th e towing op eration, never never stand between the towin g machine and the machine being towed. Move the machine machine slow ly and be sure not to apply any sudd en load on the wire rope. If there is a failure in th e brake line, the brakes brakes cannot be used, so be extremely careful when towi ng.
• • • •
Only Only tow tow the machin machinee for for a short short distanc distances, es, such such as to to a plac placee for for inspection or maintenance. The The mach machine ine must must not not be be towe towedd for for long long dist distan ance ces. s. For details details of the the permissi permissible ble towing towing load load for for this this mach machine ine,, see “SPECIFICATIONS” “SPECIFICATIONS” on page page 4-2. 4-2 . For details details of the the proce procedur duree for towing towing a machin machinee when when it has brobroken down, please contact your Komatsu distributor.
This machine must not be towed except in emergencies. When towing the machine, take the following precautions. • •
• • •
Before Before rele releasin asingg the brakes, brakes, put bloc blocks ks under under the the whee wheels ls to prev prevent ent the machine from moving. If the wheels are not blocked, the machine may suddenly move. When towing towing a machine, machine, tow it at a low speed speed of less less than than 2 km/h km/h (1.2 MPH), and and for a distance distance of of a few meters to to a place place where repairs can be carried out. The machine should be towed only in emergencies. If the machine must be moved long distances, use a transporter. If it is impossible impossible to operate operate the the steering steering and brakes of the machine machine being being towed, towed, do not not let anyone anyone ride on on the machine machine.. Keep the the angle angle of the towrope towrope as small as as possible. possible. Keep the angle angle between between the the center center lines of the two machin machines es to within within 30 degrees. The towing towing machine machine should should normally normally be of the the same class as the machine machine being being towed. towed. Check Check that that the towing towing machine machine and towed machine both have ample braking power and that the towing machine has ample rimpull to control both machines on the slopes or on the tow road.
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WA380-6
OPERATION •
•
•
When When towin towingg a mach machine ine downhill downhill,, it may be nece necessa ssary ry to connec connectt another machine to the rear of the machine being towed in order to provide ample rimpull and braking power. This makes it possible to prevent the machine from losing control. Towing owing may may be carri carried ed out out under under variou variouss differ differing ing cond conditio itions, ns, so it is impossible to determine beforehand the requirements for towing. Towing on flat horizontal roads will require the minimum rimpull, while towing on slopes or on uneven road surfaces will require the maximum rim pull. Connec Connectt a wire wire rope rope to to the part part indica indicated ted with with the the arrow arrow in the the diadiagram at right.
WHEN ENGINE CAN BE USED • •
If the transmissi transmission on and steering wheel can be operated, operated, and and the engine engine is running, running, it is possible possible to tow tow the machine machine out of mud or to move it for a short distance to the edge of the road. The operator operator should sit on the the machine machine being being towed towed and and operate operate the steering in the directio directionn that the machine machine is towed. towed.
WHEN ENGINE CANNOT BE USED When towing a machine with the engine stopped, use the following procedure. 1. The transmission transmission oil does does not lubricate lubricate the system, system, so remove the the front and rear rear drive shafts. shafts. If necessary necessary,, block the tires tires to prevent the machine from moving. 2. The steering steering cannot cannot be operated, operated, so remove remove the steering steering cylinder. cylinder. Even Even if the brakes are in good good condition, condition, the brakes brakes can only be used a limited number of times. There is no change in the operating force for the brake pedal, but t he braking force is reduced each time the pedal is depressed. 3. Connect Connect the towing equipment equipment securely securely.. When carrying carrying out towing operation operations, s, use two machines machines of at least the same class class as the machine being towed. Connect one machine each to the front and rear of the machine being towed, then remove the blocks from the tires and tow the machine. Parking brake The parking brake cannot be turned tur ned OFF. To To release the parking brake, do as follows. follows .
RELEASING PARKING PARKING B RAKE
When releasing releasing t he parkin parkin g brake, stop the machine on level groun d and check that the surr oundi ng area is safe. If it is necessary necessary t o release the brake on a slop e in an emergency, emergency, block t he tires before startin g the operation. If the parking br ake is released, released, the brake cannot cannot b e used, so check the safety carefully wh en moving the machine.
If the engine will not run for some reason, use the following methods to release the parking brake and tow the machine.
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2-129
OPERATION METHOD OF RELEASING RELEASING BRA KE B Y USING EMERGENC EMERGENCY Y PARKING PARKING B RAK E CANCEL SWITCH
When the parking brake switch is at the OFF position and the emergency parking brake release valve is opened, the parking b rake is released immediately. In this cond ition , even even if you feel danger and and try t o stop t he machine, the parking brake will not be applied immediately even if y ou cl ose the emergency parking br ake release release valve. valve.
If the pressure in the brake accumulator is high, do as follows. 1. Turn Turn the the startin startingg switch switch to the the OFF positio positionn (A). (A).
2. Loosen Loosen relief relief valve valve lock lock nut (1) by turning it countercl counterclockwise ockwise,, and turn grip (2) likewise to relieve the valve. Remark
The relief valve is located on the left front portion inside the rear frame and secured to the accumulator mounting bracket.
3. Turn Turn igni ignition tion switch switch to to the the ON positio positionn (B). (B).
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WA380-6
OPERATION 4. Move the parking parking brake switch to the ON (A) position (actuated), (actuated), then move it to the OFF (B) position (released). The parking brake is released.
5.
To restore restore the function function of the parking parking brake, brake, turn grip (2) (2) of the the release valve clockwise to close the release valve, then turn locknut (1) clockwise to lock it.
•
Tightening to torque • Grip Grip (2): (2): 20 ± 5 Nm (14. (14.55 ± 3.6 3.6 lbf lbft) t) • Lock Locknu nutt (1): (1): 20 ± 5 Nm (14. (14.55 ± 3.6 3.6 lbf lbft) t)
6. Move the parking parking brake switch to the ON (a) (a) position. position. The parking brake is applied. To release the parking brake again, repeat the procedure in Steps 1 to 4. Remark
If the brake accumulator pressure is low, the parking brake warning lamp may not go out and the alarm buzzer may sound (a long continuous sound). If this happens, release the brake. For details, see “METHOD OF RELEASING RELEASING WITH ADJUSTMENT SCREW” SCREW” on page 2-132 .
WA380-6
2-131
OPERATION METHOD OF RELEASING WITH ADJUSTMENT SCREW If the brake accumulator pressure is low, do as follows. 1. Loosen Loosen bolt bolt (2) (2) and adju adjustme stment nt screw screw (1) at at 3 places places (A, (A, B, C) at at the front of the transmission case.
2. Rotate lock plate (3) to release the lock, lock, then tighten adjustment adjustment screw (1) until it stops. 3. If this this operat operation ion is carr carried ied out out at the the same same time at at A, B, and and C, the parking brake can be released.
EMERGENCY TRAVEL OPERATION OPERATION The normal gear shifting operation is carried out by electric signals. If there should be a failure in the electrical system and the machine does not move, please contact your Komatsu distributor to have the machine moved. Always request your Komatsu distributor to carry out the emergency travel operation.
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OPERATION
IF BATTERY IS DISCHARGED
It is dangerous to charge a battery when mounted on a machine. Make sure that it is dismounted before charging. When checking or handling the battery, stop the engine and turn the starting switch key to the OFF position. The battery generates generates hydro gen gas, so there is a hazard of explosi on. Do not brin g ligh ted cigarettes near near the battery, or do anythi ng that wil l cause sparks. sparks. Battery electrolyte is dilute sulfuric acid, and it will attack your clothes and skin. If it gets on your clothes or on yo ur ski n, immediately wash it off w ith a large amount of water. If it gets in your eyes, wash it out wi th fresh water and and consu lt a doctor. When handling batteries, always wear wear safety glasses and rubber gl oves. When removing the battery, first disco nnect the cable from the grou nd (normally the negative (-) (-) termin termin al). When installing, install the posit ive (+) (+) terminal first . If a tool touches the positive terminal and the chassis, there is danger that it will cause a spark, so be extremely careful. If the terminals are loos e, there is danger th at the defective contact may generate sparks sparks th at will cause an explosion. When removing or installing the terminals, check which is the positive (+) terminal and which is the negative (-) terminal.
REMOVAL REMOVAL AND INSTAL INSTAL LATION 1. Before removing removing battery battery,, remove remove the the ground ground cable (normally (normally connected to the negative (-) terminal). If any tool touches between the positive terminal and the chassis, there is danger of sparks being generated. Loosen the nuts of the terminal and remove the wires from the battery. 2. After installing installing the the battery battery,, fix it with the battery hold down. •
Tigh Tighte tenin ningg torq torque ue:: 2 to 2.9 Nm (1. (1.44 to 2.2 lbft) lbft)
3. When installing installing the battery battery,, connect connect the the ground ground cable cable last. last. Insert Insert the hole of the terminal on the battery and tighten the nut. •
Tigh Tighte tenin ningg torq torque ue:: 5.9 5.9 to 9.8 9.8 Nm Nm (4.3 (4.3 to to 7.2 7.2 lbft) lbft)
Remark
The batteries are on both sides at the rear of the machine. The battery used for the ground is on the left side of the machine.
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2-133
OPERATION BATTERY
The battery generates generates flammable gas. Do not b ring fire or sparks near the battery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with a large amount of water and consult a docto r. Battery electrolyte dissol ves paint. paint. If it gets on the bodywo rk, wash it off imm ediately with water. water. If the battery electrolyte is frozen, do not charge the battery or start the engine with a different power sourc e. There There is danger that t he battery may explode. Battery electrolyte is toxic . Do Do not let it flo w into dr ainage ditch es or spray it on to the ground su rface.
When the ambient temperature drops, the capacity of the battery will also drop. If the battery charge ratio is low, the battery electrolyte may freeze. Maintain the battery charge as close as possible to 100%. Insulate it against cold temperature to ensure the machine can be started easily the next morning. Remark
Measure the specific gravity and calculate the charging rate from the following conversion table.
Electrolyte Temperature oC (oF)
20 (68)
0 (32)
-10 (14)
-20 (-4)
100
1.28
1.29
1.30
1.31
90
1.26
1.27
1.28
1.29
80
1.24
1.25
1.26
1.27
75
1.23
1.24
1.25
1.26
Charging Rare %
As the battery capacity drastically drops in low temperatures, cover or remove the battery from the machine, store the battery in a warm place, and install it again the next morning. If the electrolyte level is low, add distilled water in the morning before beginning work. Do not add water after the day's work to prevent diluted electrolyte in the battery from freezing during the night.
PRECAUTIONS FOR CHARGING CHA RGING BATTERY When charging the battery, if the battery is not handled correctly, there is danger that the battery may explode. Always follow the instructions in “BATTERY “BATTERY (PAGE (PAGE 3-155)” and the instruction inst ruction manual accompanying the charger, and do as follows. • • • • • • •
Do not use use or charge charge the battery battery if the the battery battery electrolyte electrolyte level level is below below the LOWER LEVEL LEVEL line. line. This may cause cause an explosion. Check the battery battery electrolyte electrolyte level periodic periodically ally and and add distilled distilled water water to bring bring the electroly electrolyte te level level to the UPPER UPPER LEVEL LEVEL line. Set the voltage voltage of the charger charger to match match the voltage voltage of the battery to be charge charged. d. If the correc correctt voltage voltage is not selected selected,, the charger may overheat and cause an explosion. explosi on. Connect Connect the positive positive (+) charge chargerr clip of the charger charger to the positive positive (+) terminal terminal of the the battery battery, then connect connect the the negative negative () charger clip of the charger to the negative (-) terminal of the battery. Be sure to attach the clips securely. Set the chargi charging ng current current to 1/10 of the value value of the rated battery battery capacity capacity;; when carrying carrying out rapid charging, charging, set set it to less than the rated batter y capacity. If the charg charger er current current is too high, the the electroly electrolyte te will leak leak or dry dry up, and and this this may cause cause the battery to catch catch fire and and explode. If the battery battery electroly electrolyte te is frozen, frozen, do do not charg chargee the battery battery or start the the engine engine with a different different power power source. source. There There is a danger that this will ignite the battery electrolyte and cause the battery to explode.
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OPERATION
STARTING STARTING ENGINE WITH BOOSTER CABL E When starting the engine with a booster cable, do as follows: Never try to start the m achine by tampering or shorting the starter terminals. Accidental movements of the machine could cause injury or even death. Always start the machine seated in the operators cab using the ignition switch. See “ELECTRICAL “ELECTRICAL CIRCUITS” CIRCUITS” on page 2-137
Never Never use a welder or a machine with a hig her voltage system to j ump s tart the machine. Using Using a higher vo ltage to jump-start a machine may damage the machines machines electrical sys tem or cause an unexpected explosion or fire. Always jump-start a machine with equal voltages and never allow the machines to touch each other when jump starting a machine.
PRECAUTIONS WHEN CONNECTING CONNECTING AND DISCONNECTING DISCONNECTING BOOSTER CAB LE
When connecting the cables, never never con tact the posi tive (+) and and negative (-) terminals. terminals. When starting t he engine with a booster cable, wear safety glasses and rubber gloves. Be careful not to let the normal machine and problem machine contact each other. This prevents sparks from g enerating enerating n ear ear the battery which could i gnit e the hydrogen gas given off by the battery. Make Make sure that there is no mistake in the booster cable connection s. The final connection is to the engine block of the problem machin e, but sparks wi ll be generated generated when this is do ne, so connect to a place as far as possible fro m the battery. When disconnecting the booster cable, take care not to bring the clips in contact with each other or with the machine body.
Keep in mind! • • • • • •
The size size of of the boos booster ter cabl cablee and clip should should be be suitab suitable le for for the battery battery size size.. The battery battery of the normal machine machine must must be the same same capacity capacity as that that of the the engine engine to be started. Chec Checkk the cab cable less and clip clipss for dam damag agee or corr corrosi osion on.. Make Make sure sure that that the the cabl cables es and and clips clips are firmly firmly conn connect ected. ed. Check that the work equipme equipment nt lock levers and parking parking brake levers of of both machine machiness are in the LOCK LOCK position. position. Chec Checkk that that eac eachh leve leverr is in the NEUTR NEUTRAL AL posi positio tion. n.
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2-135
OPERATION CONNECTING THE BOOSTER CABLE Keep the starting switch of the normal machine and problem machine in the OFF position. 1. Connect Connect the booster cable as follows, follows, in the the order order of the numbers numbers marked in the diagram. 2. Connec Connectt the clip clip of booste boosterr cable cable (A) to the posit positive ive (+) termin terminal al of battery (C) on the problem machine. 3. Connect Connect the clip at at the other end of of booster booster cable cable (A) to the positive positive (+) terminal of battery (D) on the normal machine. 4. Connect Connect the clip of of booster booster cable cable (B) to the negative negative (-) terminal terminal of battery (D) on the normal machine. 5. Connec Connectt the clip clip at the the other other end of boost booster er cable cable (B) (B) to engine engine block (E) on the problem machine.
STARTING ENGINE Always check that the work equipment lock lever is set to the LOCK position, regardless of whether the machine is working normally or has failed. Check also that all the control levers are in the HOLD or NEUTRAL position. 1. 2. 3. 4.
Make sure the the clips clips are are firmly firmly connec connected ted to the battery terminals. terminals. Start engine engine of the normal normal machine machine and run it at high high idle speed. Turn the starting starting switch switch of the problem problem machine machine to the the STAR START T position position and start start the engine. engine. If the engine engine doesn't doesn't start at first, wait wait for at at least 2 minutes minutes before trying again.
DISCONNECTING THE BOOSTER CABLE After the engine has started, disconnect booster cables in the reverse order in which they were connected. 1. Remove Remove the the clip of of booster booster cabl cablee (B) from from engine engine block block (E) on on the problem machine. 2. Remove the clip clip of booster booster cable cable (B) from the the negative negative (-) terminal terminal of battery (D) on the normal machine. 3. Remove the clip clip of of booster booster cable cable (A) from from the the positive positive (+) terminal terminal of battery (D) on the normal machine. 4. Remove the clip clip of of booster booster cable cable (A) from from the the positive positive (+) terminal terminal of battery (C) on the problem machine.
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OPERATION
ELECTRICAL CIRCUITS Trouble
Possible Cause
Remedy
Lights do not work satisfactory even with the engine running at high RPMs:
•
Faulty wiring.
•
Lights come on intermittently with the engine running:
•
Poor fan belt tension.
•
Alternator charge indicator does not go out with the engine running and engine speed is increased:
•
•
•
Faulty alternator. Faulty wiring. Serpentine belt worn or damaged.
•
Replace alternator. Check and repair wiring. Replace belt.
Alternator is very noisy:
•
Defective alternator.
•
Replace alternator
Starter does not operate when the ignition key is turned to the “START” position:
•
Faulty wiring. Low battery charge.
•
Check condition of wiring. Check battery charge state.
Low battery charge. Faulty wiring. Battery charge insufficient.
•
Faulty wiring. Battery charge insufficient.
•
Faulty wiring. Battery charge insufficient.
•
•
• •
Starter drive chatters:
• •
Starter cranks slowly: Starter cuts out while cranking the engine:
• • • • •
Preheat pilot lamp does not light up:
• •
Even when engine is stopped, battery charge circuit caution lamp does not light up (ignition switch ON):
WA380-6
• •
Bad bulb. Defective heater relay, heater, controller, temperature sensor. Faulty wiring Defective monitor. Faulty wiring.
•
•
• •
•
• • •
• •
Check and repair terminal connections. Adjust fan belt tension.
Check battery charge state. Check condition of wiring. Charge the battery. Check condition of wiring. Charge the battery. Check condition of wiring. Charge the battery. Replace bulb. Check condition of wiring and components. Replace or repair. Check condition of wiring.
2-137
OPERATION
CHASSIS • •
(): Alway Alwayss contac contactt your your Komatsu Komatsu distr distribu ibutor tor when when deal dealing ing with with these these items items.. In cases cases of problems problems or causes causes which are not not listed below, below, contact contact your Komatsu distributor distributor for repairs. Trouble
Possible Cause
Remedy
Transmission
Engine is running but machine does not move:
• • • •
Park Parkin ingg brak brakee is appli pplied ed Dire Direct ctio iona nall lev lever er is not not shi shift fted ed properly Lack Lack of oil oil in in tra trans nsmi miss ssio ionn cas casee
• •
Lack Lack of oil oil in in tra trans nsmi miss ssio ionn cas casee Screen is clogged
•
•
Too much much oil oil or or too too litt little le oil oil in in transmission case Mach Machin inee is not not tra trave veli ling ng in in corr correc ectt speed range Torqu orquee con conve verte rterr is is sta stalle lledd for for long long periods Engine is is ov overhe rheatin ting
•
Lack of oil in transmission transmis sion case
Even when engine is run at full throttle, machine only move
• • •
Rele Releaase parking ing bra brakke Shif Shiftt lev lever properly Add Add oil oil to spec specif ifie iedd lev level el.. See See WHEN REQUIRED
• •
Add Add oil oil to spec specif ifie iedd lev level el.. See See WHEN WHEN REQU REQUIR IRED ED (Dis (Disaassem ssem- ble, clean)
•
Add Add or or dra drain in oil oil to to spe speci cifi fieed level. See WHEN REQUIRED Plac Placee in in cor corre recct spee speedd ran range ge Reduce stall time (Check engine)
slowly and lacks power
• Oil overheats •
Noise generated
• • • • •
Add Add oil oil to spec specif ifie iedd lev level el.. See See WHEN REQUIRED
• • •
Add Add oil oil to spec specif ifie iedd lev leveel. See WHEN REQUIRED Chan Change ge to spec specif ifie iedd oil oil
• • •
Replace disc) Add Add oil oil to spec specif ifie iedd lev level el.. See See EVERY 100 HOURS Bleed air
Axle
Noise generated
• •
Lack of oil Impr Improp oper er oil oil use usedd (fo (forr mac machi hine ness with limited-slip differential) Brake
• • •
Disc Disc has has rea reacched hed wea wearr lim limit it Lack Lack of oil oil in in hydr hydrau auli licc tank tank Air in brake line
Brake drags or remains applied
•
Vent hole of brake valve is clogged
•
Clean
Brakes squeal
• • •
Disc is worn Larg Largee amo amoun untt of of wat water er in axle axle oil oil Dete Deteri rior orat ated ed axle axle oil oil due due to over over-use of brake
• • •
Replace disc Change axle oil Change axle oil
Brake is not applied when pedal is depressed
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WA380-6
OPERATION
Trouble
Possible Cause
Remedy
Steering
Steering wheel is heavy
Steering wheel is loose
•
• •
Lack of oil in hydraulic tank
Play Play in stee steeri ring ng cyli cylind nder er pin pin Lack Lack of oil oil in in hydr hydrau auli licc tank tank
•
Add Add oil oil to spec specif ifie iedd lev level el.. See See EVERY 100 HOURS SERVICE SERVICE
•
Grea Grease se bear bearin ingg or or rep repla lace ce pin pin and bushing where there is play Add Add oil oil to spec specif ifie iedd lev level el.. See See EVERY 100 HOURS SERVICE SERVICE
•
Parking brake
Braking effect is poor
•
Disc is worn
Brake drags or remains applied
• •
Lack Lack of oil oil in in tra trans nsmi miss ssio ionn cas casee Screen is clogged
•
(Replace disc)
•
Add Add oil oil to spec specif ifie iedd lev level el.. See See WHEN REQUIRED (Dis (Disaassem ssembl blee and and clea clean) n)
•
Hydraulic system
Lack of lifting power for bucket Bucket takes time to rise
Excessive bubbles in oil
• • •
Lack Lack of oil oil in in hydr hydrau auli licc tank tank Clog Clogge gedd hyd hydra raul ulic ic tank tank filt filter er
• • •
Low Low qua quali lity ty oil oil be being ing use usedd Lack Lack of oil oil in in hydr hydrau auli licc tank tank Air in oil line
• • • • •
Hydraulic pressure is low
Movemen ment of of cy cylin linder is is ir irreg regular lar
WA380-6
•
Lack Lack of oil oil in hydr hydraaulic ulic tank tank causes pump to suck in air •
•
Lack of of oil oil in hydrau raulic lic ta tank
•
Add Add oil oil to spec specif ifie iedd lev level el.. See See EVERY 100 HOURS SERVICE SERVICE Repl Replac acee fil filte terr. See See EVER EVERY Y 200 20000 HOURS SERVICE Repl Replac acee with with good good qual qualit ityy oil oil Add Add oil oil to spec specif ifie iedd lev level el.. See See EVERY 100 HOURS SERVICE SERVICE Blee Bleedd air air.. See See EVER EVERY Y 200 20000 HOURS SERVICE Add Add oil oil to spec specif ifie iedd lev level el.. See See EVERY 100 HOURS SERVICE SERVICE Then Then blee bleedd air air.. See See EVER EVERY Y 2000 HOURS SERVICE Add Add oil oil to spec specif ifie iedd lev level el.. See See EVERY 100 HOURS SERVICE SERVICE
2-139
OPERATION
ENGINE • •
(): Alway Alwayss contac contactt your your Komatsu Komatsu distri distribut butor or when when deali dealing ng with with these these items. items. In cases cases of problems problems or causes causes which are not not listed below, below, contact contact your Komatsu distributor distributor for repairs. Trouble
Oil pressure light remains on even with the engine at high idle:
Possible Cause
Oil level too low. Oil filter plugged. Incorrect oil for the season.
•
•
•
Coolant low due to leaks. Fan belt slipping. Cooling system blocked. Radiator fins damaged. Faulty thermostat. Radiator cap defective.
•
Top off and repair. Check belt tension. Flush cooling system. Repair or clean. Replace. Replace.
•
Faulty temperature indicator.
•
Replace.
•
No fuel. Air in fuel system. Low compression.
•
Refuel. Bleed system. Adjust valve clearance.
Too much oil in oil pan. Unstable fuel.
•
•
•
Air cleaner clogged. Faulty injectors or injection pump. Low compression.
•
Clean or replace. Replace. Adjust valve clearance.
•
Faulty injectors.
•
Replace injectors.
•
Improper fuel Cetane rating. Overheating. Damaged exhaust muffler. Excessive valve clearance.
•
Change fuels. See “temperature indication”. Replace. Adjust valves.
• • • • •
Cooling system overheating:
• • •
Temperature Temperature gauge stuck at “white range”
Engine cranks but will not start:
• •
White or light blue exhaust gasses:
• • •
Exhaust gasses are black:
Popping noise heard at exhaust stack:
Abnormal engine noise:
•
• • •
2-140
Remedy
• •
• • • •
• •
•
•
• • •
Top off. Change oil and filter. filt er. Change oil.
Correct the oil level. Change to suitable fuel.
WA380-6
OPERATION
LONG-TERM STORAGE BEFORE STORAGE When keeping in long-term storage (more than one month), store as follows. • • • • • • •
Clean and wash wash all parts, parts, then then store the the machine machine indoors. indoors. If the machine machine has to be stored stored outdoors, outdoors, select select level level ground ground and cover the machine with a sheet. Comple Completely tely fill the the fuel fuel tank. tank. This This prev prevent entss moisture moisture from coll collect ecting ing.. Lubr Lubrica icate te and and cha chang ngee the the oil oil befo before re stor storag age. e. Coat Coat the expo exposed sed porti portion on of the the hydra hydraulic ulic cylind cylinder er piston piston rod rod with with greas grease. e. Disconnect Disconnect the the negative negative terminals terminals of of the battery battery and and cover cover it or or remove remove it from the machine machine and store store it separate separately ly.. Set the the lock lock lever lever to to the LOCK LOCK posi position tion to to preven preventt the machin machinee from from moving moving.. To prevent prevent corrosion, corrosion, be sure to fill the the cooling cooling system system with Superc Supercoolant oolant (AF-NAC) (AF-NAC) or permanen permanentt type antifreeze antifreeze (den(density between 30% and 68%).
DURING STORAGE
If it is necessary to perform the rust-prevention operation while the machine is indoors, open the doors and windows to improve ventilation ventilation and prevent gas poisoning.
• • •
During storage storage,, operate operate and move move the machine machine for a short short distance distance once once a month month so that that a new film film of oil will will coat moving moving parts. At the same time, also charge the battery. When operating operating the the work work equipment, equipment, wipe off all all the grease from the the hydraulic hydraulic cylinder cylinder rods. rods. If the machine machine is equipped equipped with an an air conditione conditioner, r, operate operate the the air condition conditioner er for 3 to to 5 minutes minutes once a month to to lubricate lubricate all parts of the air conditioner compressor. Always run the engine at low idle when doing this. In addition, check the refrigerant level twice a year.
AFTER A FTER STORAGE Remark
If the machine has been stored without carrying out the monthly rust-prevention operation, consult your Komatsu distributor before using it.
• • • •
When When using using the machi machine ne after after long-te long-term rm storag storage, e, do as as follows follows before before using using it. it. Wipe Wipe off the grease grease from the hydrau hydraulic lic cylinde cylinderr rods. rods. Add Add oil oil and and grea grease se at at all all lubr lubric icat ation ion poin points. ts. When the the machine machine is stored for a long long period, period, moisture moisture in the air air will mix with the oil. Check Check the the oil before before and and after after starting the engine. If there is water in the oil, change all the oil.
WA380-6
2-141
OPERATION
2-142
WA380-6
MAINTENANCE
WA380-6
3
3-1
MAINTENANCE
GUIDES TO MAINTENANCE Do not perform any inspection and maintenance operation that is not found in this manual.
Due to the high voltage/amps and high pressure fuel avoid any contact wit h the engine electrical system (1) and and the fuel injection system (2) when the engine is running. Severe injury may result.
CHECK SERVICE METER Check the service meter reading every day to see if the time has come for any necessary maintenance to be performed.
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. Choose oils and grease with proper viscosities specified for ambient temperature.
ALWA A LWAYS YS USE CLEA N WASHER FLUID FL UID Use automobile window washer fluid, and be careful not to let any dirt get into it.
ALWA A LWAYS YS USE CLEA N OIL AND AN D GREASE Use clean oil and grease. Also, keep containers of the oil and grease clean. Keep foreign materials away from oil and grease.
CHECKING FOR FOREIGN MATERIAL MATERIALS S IN DRAINED OIL AND ON FILTERS FILTERS After oil is changed or filters are replaced, check the old oil and filters for metal particles and foreign materials. If large quantities of metal particles or foreign materials are found, always report to the person in charge, and perform suitable action.
FUEL STRAINER If your machine is equipped with a fuel strainer, do not remove it while fueling.
WELDING INSTRUCTIONS • • • • •
3- 2
Turn Turn off off the engi engine ne starti starting ng switch switch.. Do not not app apply ly mor moree than than 200 200V V conti continu nuou ously sly.. Connect Connect grounding grounding cable cable within within 1 m (3.3 ft.) from the area to be welded. welded. If groundin groundingg cable is connected connected near instrumen instruments, ts, connectors, etc., the instruments may have troubles. Avoid seals seals or bearing bearingss from being being between between the area area to be be welded welded and and the position position of grounding grounding point. Do not use the area around the work work equipment equipment pins pins or the the hydraulic hydraulic cylinder cylinderss as the grounding grounding point. point.
WA380-6
MAINTENANCE
DO NOT DROP THINGS INSIDE THE MACHINE •
•
When opening opening inspection inspection windows windows or the oil filler filler port of the the tank to perform perform an inspection inspection,, be careful careful not to drop nuts, nuts, bolts, or tools inside the machine. If such things are dropped inside ins ide the machine, it will cause damage and malfunction of the machine, and will lead to failure. If you drop anything inside the machine, always remove it immediately. Do not not put unnecessary unnecessary things in your your pockets. pockets. Carry only things things which which are are necessary necessary for inspection inspection..
DUSTY WORKSITES When working at dusty worksites, do as follows: • • • • • •
Inspect Inspect the air cleaner cleaner clogging clogging monitor monitor frequently frequently to see see if the air cleane cleanerr is clogged. clogged. Clean Clean the the air air cleane cleanerr elemen elementt at a shorter shorter interva intervall than than speci specified fied.. Clean Clean the radiat radiator or core core frequen frequently tly to avoi avoidd clog cloggin ging. g. Clean Clean and and rep replac lacee the the fuel fuel filt filter er freq freque uent ntly ly.. Clean electrica electricall components components,, especially especially the starting starting motor motor and alternator, alternator, to avoid avoid accumulation accumulation of dust. dust. When inspecti inspecting ng or changin changingg the oil, oil, move the machine machine to a place place that that is free of dust to prevent prevent dirt dirt from getting getting into into the oil.
AVOID MIXING OIL Never mix different kinds of oil. If a different type of oil has to be added, drain the old ol d oil and replace all t he oil with the new type of oil.
LOCK ING INSPECTION INSPECTION COVERS Lock inspection cover in position securely with a lock bar. If inspection or maintenance is performed with the inspection cover open and not locked in position, there is a hazard that it may be suddenly blown shut by the wind and cause injury to the worker.
BLEEDING AIR FROM HYDRAULIC CIRCUIT If the hydraulic oil equipment has 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 HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT” on page page 3-52 3-52.
PRECAUTIONS WHEN INST INSTAL LING HYDRAUL IC HOSES • •
When removing removing parts at at locations locations where where there there are O-rings or gasket gasket seals, seals, clean clean the mounting mounting surface, surface, and and replace replace with with new parts. When doing this, be careful not to forget to assemble the O-rings and gaskets. When installing installing the hoses, hoses, do not twist them or bend them them into into loops loops with a small radius. radius. This This action action will cause cause damage damage to the hose and markedly reduce its service life.
CHECKS AFTER A FTER INSPECTIO INSPECTION N AND MAINTENANCE MA INTENANCE If you forget to perform the checks after inspection and maintenance, unexpected problems may occur, and this may lead to serious injury or property damage. Always do as follows. •
Chec Checks ks afte afterr oper operat ation ion (with (with eng engine ine stopp stopped ed)) • Have Have any any inspe inspectio ctionn and and mainte maintenan nance ce poin points ts been been forgo forgotten tten?? • Have Have all insp inspect ection ion and and mainte maintenan nance ce items items been been carried carried out corre correctly ctly?? • Have any any tools tools or parts parts been dropped dropped inside inside the machine machine?? It is particu particularly larly dangerou dangerouss if parts are dropped dropped inside machine and get caught in the lever linkage mechanism. • Is there there any any leakag leakagee of water water or or oil? oil? Have Have all the the bolts bolts been been tight tightene ened? d?
WA380-6
3-3
MAINTENANCE
HANDLING HANDL ING THE TIRES TIRES 1. Side wall 2. Shoulder 3. Tread 4. Break Breaker er or belt belt (co (cord rd laye layer) r) 5. Bead 6. Inner liner 7. Carcass If a tire has reached any of the following service limits, there is danger that the tire may burst or cause an accident, so to ensure safety, s afety, replace it with a new tire.
SERVICE LIMITS FOR WEAR •
When When the the remai remainin ningg depth depth of the the groo grooves ves on cons construc truction tion equipequipment tires (at a point approx. 1/4 of the tread width) is 15% of the groove depth on a new tire. • When the the tire shows shows marked marked uneven uneven wear, wear, stepped stepped wear or other other abnormal abnormal wear, wear, or when the cord cord layer layer is exposed. exposed. • Serv Servic icee lim limit itss for for dama damage ge • When When there there is extern external al damag damagee extend extending ing to the the cord cord or when when the the cord cord is broke brokenn • When When the the cor cordd is is cut cut or there there is dra dragg ggin ingg • When When the the tire tire is pee peelin lingg (the (there re is is sepa separa ratio tion) n) • When When the the bead bead is dama damage gedd • For tubele tubeless ss tires tires,, when when ther theree is air leak leakage age or impro improper per repair repair 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. If the tire inflation pressure is too low, there will be overload; if it is too high, it will cause tire cuts and shock burst. To prevent these problems, adjust the tire inflation pressure according to the table on the next page. Deflection ratio = H - h / H x 100 As a guideline that can be checked visibly, the deflection ratio of the front tire (deflection/free height) is as follows. When carrying normal load (lift arm horizontal): Approx. 15 to 25 % When digging (rear wheels off ground): Approx. 25 to 35 %
3- 4
WA380-6
MAINTENANCE When checking the tire inflation pressure, check also for small scratches or peeling of the tire, for nails or pieces of metal which may cause punctures, and for any abnormal wear. Clearing fallen stones and rocks from the operating area and maintaining the surface will extend the tire life and give improved economy.
Tire size (Pattern)
H Free height mm (in)
Inflation pressure kgf/cm2 (psi) Soft ground (sandy soil)
Normal road
Stockpile
Stockpile
Digging
0.24 - 0.35
0.26 - 0.35
0.26 - 0.35
(2.4 - 3.6,
(2.6 - 3.6,
(2.6 - 3.6,
34.1 - 51.1)
36.9 - 51.1)
36.9 - 51.1)
When shipped from factory
23.5-25 (L3: Rock) (Standard) 23.5-25-20PR
424 [BS] (17)
(L2: Traction) (if equipped) 23.5-25-16PR (L2: Traction) (if equipped) 23.5-25-20PR
Front and Rear tire: 0.30 (3.1, 44.0)
434 [BS] (17)
(L3: Rock) (if equipped) •
For oper operatio ations ns on normal normal road road surfa surfaces ces,, rock rock diggin diggingg operati operations ons:: High end of range in air pressure chart • Stockp Stockpile ile oper operati ations ons on on soft soft ground ground:: Aver Average age pressur pressuree in air air pressure chart • Operati Operations ons on on sand sand (opera (operatio tions ns not not using using much much diggin diggingg force) force):: Low end of range in air pressure chart If the deflection of the tire is excessive, raise the inflation pressure within the limits given in the table to give a suitable deflection (see deflection ratio). Stockpile operations mean the loading of sand and other loose materials.
WA380-6
3-5
MAINTENANCE
OUTLINES OF SERVICE • •
Always Always use use Komatsu Komatsu genuine genuine parts parts for repl replace acemen mentt parts, parts, greas greasee or oil. oil. When changin changingg the oil oil or adding adding oil, do not mix mix different different types types of oil. oil. When changin changingg the type type of oil, oil, drain all the old old oil and fill completely with the new oil. Always replace the filter at the same time. (There is no problem if the small amount of oil remaining in the piping mixes with the new oil.) Unless otherwise otherwise specified, specified, when the machine machine is shipped shipped from from the factory factory,, it is filled with the oil oil and coolant coolant listed listed in the the table below.
•
Item
Type
Engine oil
EO15W40-DH (Komatsu genuine parts) API CI-4, JASO DH-1
Transmission oil
Power train oil TO10 (Komatsu genuine parts)
Hydraulic system oil
Power train oil TO10 (Komatsu genuine parts)
Axle oil
AX080 (Komatsu genuine parts)
Engine coolant
Supercoolant AF AF-NAC (density: 30 30% or or ab above) (K (Komatsu genuine pa parts)
HANDLING HANDL ING OIL, FUEL, COOLA NT, NT, AND PERFORMING OIL OIL CL INIC OIL •
•
• • • • •
Oil is used in the engine engine and and work equipment equipment under under extremely extremely severe severe conditio conditions ns (high temperature, temperature, high high pressure), pressure), and and it deteriorates with use. Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual. Even if the oil is not dirty, always change the oil after the specified interval. Oil corresponds corresponds to blood in the human human body, body, so always always be careful careful when when handling handling it to prevent prevent any any impurities impurities (water (water,, metal particles, dirt, etc.) from getting in. The majority of problems with machine are caused by the entry entr y of such impurities. i mpurities. Take particular care not to let any impurities get in when storing or adding oil. Neve Neverr mix mix oils oils of dif differ feren entt grad grades es or or bran brands ds.. Always add the specified specified amount amount of oil. oil. Having Having too much oil or too too little oil are both causes causes of problems. problems. If the oil oil in the work equipmen equipmentt is not clear clear,, there is is probably probably water water or air air getting into the circuit. circuit. In such cases, please contact your Komatsu distributor. When When changin changingg the oil, oil, alway alwayss replac replacee the rela related ted filte filters rs at the the same same time. time. We recommend recommend you have have an analysis analysis made made of the the oil periodica periodically lly to check check the the condition condition of the machine. machine. For For those who wish to use this service, please contact your Komatsu distributor.
FUEL • • • • • • • •
3- 6
The fuel fuel pump pump is a precisio precisionn instrument, instrument, and and if fuel containing containing water water or dirt dirt is used, used, it cannot cannot work properly properly.. Be extrem extremely ely care careful ful not not to let let impur impuritie itiess get in in when when storin storingg or addin addingg fuel. fuel. Always Always use use the fuel fuel specifie specifiedd in the the Operati Operation on and and Mainten Maintenanc ancee Manual Manual.. Fuel may may congeal congeal dependin dependingg on the the temperature temperature when itit is used (particularly (particularly in low temperature temperature below -15º -15º C (5º (5º F). It is is necessary to change for the fuel that is suitable for the temperature. To prevent prevent the moisture moisture in the air air from condensi condensing ng and forming water water inside inside the fuel fuel tank, tank, always fill the fuel fuel tank after completing the day's work. Before starting the engine, engine, or when 10 minutes have have passed passed after after adding adding fuel, drain the the sediment sediment and water from from the fuel fuel tank. If the engine engine runs out of fuel, or if the the filters have been been replaced replaced,, it is necessa necessary ry to bleed bleed the air from the circuit. circuit. The engine engine mounted mounted on this machine machine employs employs electronic electronic control control and a high-pressure high-pressure fuel injection injection system to obtain good fuel consumption and good exhaust gas characteristics. For this reason, it requires high precision for the parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a big drop in the durability, so do not use such fuel.
WA380-6
MAINTENANCE COOLANT • • • • • • •
• • • • • • •
The coolant coolant has the the important important function function of preventing preventing corrosio corrosionn as well well as preventing preventing freezing. freezing. Even in the areas where freezing freezing is not not an issue, the use use of antifreeze antifreeze coolant coolant is essential. essential. Komatsu machines machines are supplied supplied with Komatsu Supercoolant Supercoolant (AF-NAC). (AF-NAC). Komatsu Komatsu Supercool Supercoolant ant (AF-NAC) (AF-NAC) has has excellent excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu Komatsu Super Supercoo coolan lantt (AF-NAC) (AF-NAC) is strong strongly ly recomme recommende ndedd whereve whereverr availab available. le. When using Komatsu Supercoolant Supercoolant (AF-NAC), (AF-NAC), there there is no no need need to use a corrosion corrosion resistor resistor.. For details, details, see “CLEANING THE COOLING COOLING SYSTEM” on page page 3-22. 3-22. When When diluting diluting the the antifr antifreez eezee coolan coolant, t, use disti distilled lled wate waterr or tap wate waterr (soft wate water). r). Natural Natural water, water, such as as a river water water or well well water (hard (hard water), water), contains contains large large amounts amounts of minerals minerals (calcium (calcium,, magnesium, magnesium, etc.), and this makes it easier for scale to form inside the engine or radiator. Once scale is deposited inside the engine or radiator, it is extremely difficult to remove. It also causes overheating due to poor heat exchange, so when you dilute the coolant, we recommend that you use water with an overall hardness of less than 100 PPM. When using antifreeze, antifreeze, always always observe the precauti precautions ons given given in the Operation Operation and and Maintenanc Maintenancee Manual. Manual. Antifre Antifreeze eze coolan coolantt is flamm flammabl able, e, so be sure sure to to keep keep itit away away from from flame. flame. The ratio of Superco Supercoolant olant (AF-NAC) to water water differs differs according according to the the ambient ambient temperature. temperature. For For det detail ailss of of the the ratio ratio when when mixin mixing, g, see “CLEANING “CLEANING THE COOLING SYSTEM” SYSTEM” on page 3-22. 3-22. Supercoolant Supercoolant (AF-NAC) (AF-NAC) may be supplied supplied already already mixed. mixed. In such cases, never dilute with water water.. If the engi engine ne overhe overheats, ats, wait wait for for the engin enginee to cool cool before before addi adding ng coola coolant. nt. If the coolant coolant level level is low, low, it will cause cause overheat overheating, ing, and and will also cause problems problems with corrosion corrosion due due to air air entering entering the coolant.
GREASE • • • • •
Grease Grease is is used used to prev prevent ent twisting twisting and noise noise at at the the joints joints.. The grease grease fittings fittings not not included included in the MAINTENANC MAINTENANCE E section section are grease fittings fittings for for overhaul, overhaul, so they do do not need need grease. If any part part becom becomes es stiff stiff or makes makes noise noise after after being being used used for long long time, time, apply apply grea grease. se. Always Always wipe wipe off off all all of the old old grea grease se that that is pushed pushed out when when greasin greasing. g. Be particularl particularlyy careful careful to wipe wipe off the the old grease grease in places places where sand or dirt sticking sticking in the grease grease would would cause wear of the rotating parts.
WA380-6
3-7
MAINTENANCE
PERFORMING KOWA (KOMATSU OIL WEAR ANALYSIS) KOWA (Komatsu Oil Wear Analysis) is a maintenance service that makes it possible to prevent machine failures and downtime. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other abnormalities. Periodic use of KOWA makes the following possible: • •
It enables enables the accura accurate te understandi understanding ng of the the machine machine condition condition by by utilizing utilizing our long long experienc experiencee and accumu accumulated lated data data base. The report report on the result result of analysis analysis and recomme recommendatio ndationn will be be delivered delivered to the customer customer soon at low cost cost (only (only the actual expenses will be charged). Use of this service is strongly recommended.
KOWA A NALYSIS ITEMS ITEMS •
Anal Analys ysis is of of meta metall wear wear par parti ticl cles es.. This uses the latest ICP (Inductively Coupled Plasma) analyzer to measure the density of metal wear particles in the oil.
•
Meas Measur urem emen entt of of part partic icle le qua quant ntit ityy This uses a PQI (Particle Quantifier Index) measurer to measure the quantity of large iron particles (larger than 5 microns) in the oil, which enables the early detection of defect.
•
Others. Measurements are made of items such as the ratio of water in oil or fuel in the oil, and the dynamic viscosity.
OIL SAMPLING •
Sampling in interval • 250 hours: Engine • 500 500 hour hours: s: Othe Otherr comp compon onen ents ts • Prec Precau auti tioons when when samp sampli ling ng • Make Make sur suree that that the the oil oil is wel welll mixe mixedd befo before re sam sampli pling ng.. • Perfo Perform rm sampl sampling ing regu regula larly rly at fixe fixedd inte interv rval als. s. • Do not not perform perform sampli sampling ng on rainy rainy or wind windyy days when when water water or or dust can can get get into the the oil. For further details of KOWA, please contact your Komatsu distributor.
3- 8
WA380-6
MAINTENANCE STORING OIL AND FUEL • •
•
Keep Keep indoors indoors to prev prevent ent any any water water,, dirt, dirt, or other other impurit impurities ies from from getting getting in. in. When keeping keeping drum cans cans for a long period, put the drum on its side so so that the the filler filler port of the drum drum can is at the side. This action prevents moisture from being sucked in. If the drum cans have to be stored outside, cover them with a water proof sheet or take other measures to protect prot ect them. To prevent prevent any change change in quality quality during during long-term long-term storage, storage, be be sure to use in the the order of first in - first out (use (use the oldest oldest oil or fuel first).
FILTERS •
• • • • •
Filters are extremely extremely important important safety parts. Filters Filters prevent prevent impurities impurities in the fuel fuel and air circuits circuits from from entering entering important important equipment and causing problems. Replace all filters periodically. For details, see the Operation and Maintenance Manual. However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel (sulfur content) being used. Never try to clean the filters filters (cartridge (cartridge type) and use them them again. again. Always Always replace replace with new new filters. filters. When replacin replacingg oil filters, filters, check check if any metal particle particless are affixed affixed to the old filter. filter. If any metal metal particles particles are are found, found, please contact your Komatsu distributor. When replacing replacing the the engine engine oil oil filter, filter, fill the the new new filter filter with the specified specified clean oil, then then install install it. Do not not open open pack packss of spar sparee filters filters until until just just before before they they are to be be used. used. Alwa Always ys use use Kom Komat atsu su gen genui uine ne fil filte ters rs..
OUTLINE OF ELECTRIC SYSTEM •
• • • • •
It is extremely extremely dangero dangerous us if the electrical electrical equipment equipment become becomess wet or the the covering covering of of the wiring wiring is damaged damaged.. This situation situation will cause an electrical short circuit and may cause the machine to malfunction. Do not wash the inside of the operator's cab with water. When washing the machine, be careful not to let water get into the electrical components. Service Service relating relating to the electric electric system system is check check of fan fan belt tension, tension, check check of of damage or wear in the fan belt belt and check check of of battery fluid level. Never Never install install any any elect electric ric compo componen nents ts other other than than there there specifi specified ed by Koma Komatsu. tsu. External External electrical electrical interfere interference nce may may cause cause malfunction malfunction of the control control system controller, controller, so before before installing installing a radio receiver or other wireless equipment, please contact your Komatsu distributor. When When working working at the the seashor seashore, e, carefu carefully lly clean clean the elec electric tric system system to prev prevent ent corros corrosion ion.. The optiona optionall power power source source must must never never be connected connected to to the fuse, starting switch, or battery battery relay relay..
WA380-6
3-9
MAINTENANCE
WEAR PARTS PARTS LIST L IST Wear parts such as the filter element, air cleaner element, bucket tooth, etc. are to be replaced at the time of periodic maintenance or before their abrasion limits. The wear parts should be changed correctly in order to use the machine economically. For part change, Komatsu genuine parts of excellent quality should be used. When ordering parts, please check the part number in the parts book. The parts in parentheses are to be replaced at the same time. Item
Part Name
Q'ty
Replacement frequency
Engine oil filter
Cartridge
1
EVERY 500 HOURS
Fuel filter
Cartridge
1
EVERY 500 HOURS
Fuel strainer
O-ring
1
-
Transmission oil filter
Cartridge
1
EVERY 1000 HOURS
Transmission strainer
O-ring
1
-
Hydraulic filter
Element (O-ring)
1 (1)
EVERY 2000 HOURS
Hydraulic tank breather
Element
1
EVERY 2000 HOURS
Hydraulic oil strainer
Strainer
1
-
Air cleaner
Element assembly
1
WHEN REQUIRED
PPC accumulator
Accumulator and O-ring
1
EVERY 4000 HOURS
Fresh
Element
1
EVERY 2000 HOURS
Recirc
Element
1
EVERY 2000 HOURS
Standard type
Center edge Side edge (Bolt) (Nut) (Washer)
1 2 (14) (14) (14)
WHEN REQUIRED
Long life type
Center edge Side edge (Bolt) (Nut) (Washer)
1 2 (14) (14) (14)
WHEN REQUIRED
Segmented type
Edge (Bolt) (Nut) (Washer)
7 (14) (14) (14)
WHEN REQUIRED
Air conditioner air filter
Bolt on cutting edge
3-10
WA380-6
MAINTENANCE
FUEL, FUEL, COOLANT COOLA NT AND LUBRICANTS L UBRICANTS
3
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS Kind of Fluid
Reservoir
Engine oil pan
Ambient Temperature -22
-4
14
32
50
68
86
104
122 F°
-30
-20
-10
0
10
20
30
40
50 C°
Refill
25.5 (6.7)
23 (6.0)
47 (12.4)
38 (10.0)
210 (47.6)
139 (36.4)
40 (10.6)
*40 (10.6)
300 (79.26)
⎯
⎯
⎯
30 (8)
⎯
EO10W40-DH EO30-DH
PT oil
TO10
PT oil
TO10
Hyd. oil
Hydraulic system
Specified
EO10W 3030-DH DH
Engine oil API CI-4 JASO DH-1
Transmission case (✸ 1)
Capacity L/US Gal
HO46-HM EO10W30-DH
Engine oil
EO10W30-DH
Axle oil
AX 080 (See
Axle
✸
3
ASTM D S15/500 S15/500 No. 2
Diesel fuel
No.1
Hyper grease (✸ 5) Lithium EP grease
Pins (See ✸ 4)
2)
[EO50-CD] See
Engine oil
Fuel Tank
✸
G2-T,G2-TE G2-L1 S u p e r c o o l a n t A F -N -N A C ( ✸ 6)
Cooling system
Capacity Engi Engine ne oil oil pan pan
Trans ransmi miss ssio ionn cas casee
Hydraulic system
Axles (each)
Pins
Fuel tank
Cooling system
Liters
25.5
47
210
40
-
300
30.5
USgal
6.7
12.4
47.6
10.6
-
79.3
8.0
Liters
23
38
139
40
-
-
-
USgal
6.0
10.0
36.4
10.0
-
-
-
Reservoirs Specified
Refill
WA380-6
3-11
MAINTENANCE Remark
Use only diesel f uel only. This engine uses an electronically controlled high-pressure fuel injection system to obtain good fuel economy and low emissions. For this reason, it requires high precision parts and good lubrication. If kerosene or other fuel with low lubricating ability is used, there will be a big drop in durability. ✸
1: Power train of oil has different properties from engine oil. Be sure to use the recommended oil.
✸
2: Axle oil AXO80 has the function of preventing squealing from the brakes and LSD (Limited Slip Differential).If only AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.
✸
3: When the ambient temperature is higher than 45 °C (113°F) and the machine operation hour is longer than 12 hours/day, then the use of EO50-CD instead of AXO80 is recommended. Squealing of the brakes may occur with EO50-CD, but there is no problem with the brake performance or durability.
✸
4: Hyper grease (G2-T, G2-TE) has a high performance. When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings, the use of G2-T or G2-TE is recommended.
✸
5: Supercoolant (AF-NAC)
The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF NAC). Komatsu Komats u Supercoolant (AF-NAC) ( AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available. For details of the ratio when diluting super coolant with water, see “CLEANING “CLEANING THE COOLING SYSTEM” on page 3-22. 3-22. When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant (AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F). (never dilute with water) To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant between 30% and 68%. ✸
6: Supercoolant (AF-NAC)
Coolant has the important function of anticorrosion as well as antifreeze. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant AF-NAC. Komatsu Supercoolant AF-NAC has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu Supercoolant AF-NAC is strongly recommended wherever available. For details of the ratio when diluting super coolant with water, see “CLEANING “CLEANING THE COOLING SYSTEM” on page 3-22. 3-22. Supercoolant AF-NAC may be supplied in premix. In this case, always top off with premix solution. (never dilute with water) To maintain the anticorrosion properties of Supercoolant AF-NAC, always keep the density of Supercoolant between 30% and 68%.
RECOMMENDED RECOMMENDED BRA NDS, OTHER THAN KOMATSU GENUINE OIL When using commercially available oils other than Komatsu genuine oil, or when checking the latest specifications, refer to the Komatsu web page or consult your Komatsu distributor.
3-12
WA380-6
MAINTENANCE
STANDARD TIGHTENING TORQUES FOR FASTENERS AND HOSES TORQUE LIST If nuts, bolts, or other parts are not tightened to the specified torque, looseness or damage to the tightened parts, which will cause machine failure or problems with operation. Always pay careful attention when tightening parts. Unless otherwise specified, tighten the metric nuts and bolts to the torque shown in the table below. bel ow. The tightening torque is determined by the width across the flats of the nut and bolt. 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 Thread diameter a(mm)
★
Width across flat b(mm)
Target value
Service limit
N•m
lbft
N•m
lbft
6
10
13.2
9.8
11.8 - 14.7
8.7 - 10.8
8
13
31
23.1
27 - 34
20.3 - 25.3
10
17
66
48.5
59 - 74
43.4 - 54.2
12
19
11
83.2
98 - 123
72.3 - 90.4
14
22
177
130.2
157 - 196
115.7 - 144.7
16
24
279
206.1
245 - 309
180.8 - 227.8
18
27
382
282.1
343 - 425
253.2 - 314.6
20
30
549
405.0
490 - 608
361.7 - 448.4
22
32
745
549.7
662 - 829
488.2 - 611.2
24
36
927
683.5
824 - 1030
607.6 - 759.5
27
41
1320
976.5
1180 - 1470
868.0 - 1085.0
30
46
1720
1265.8
1520 - 1910
1121.1 - 1410.4
33
50
2210
1627.4
1960 - 2450
1446.6 - 1808.3
36
55
2750
2025.2
2450 - 3040
1808.3 - 2242.2
39
60
3280
2423.1
2890 - 3630
2133.7 - 2676.2
Use the following table for Hydraulic Hose.
Thread diameter a(mm)
Width across flat b(mm)
Tightening torque Target value N•m
lbft
Service limit N•m
lbft
14
19
29.4
21.7
27.5 - 39.2
20.3 - 28.9
18
24
78.5
57.3
58.8 - 98.1
43.4 - 72.3
22
27
117.7
86.8
88.3 - 137.3
65.1 - 101.3
24
32
147.1
108.5
117.7 - 176.5
86.8 - 130.2
30
36
215.7
159.1
176.5 - 245.2
130.2 - 180.8
WA380-6
3-13
MAINTENANCE 33
3-14
41
255.0
188.1
215.7 - 284.4
159.1 - 209.8
WA380-6
MAINTENANCE
PERIODIC PERIODIC REPLACEMENT REPLA CEMENT OF SAFETY CRITICAL PARTS To ensure safety at all times when operating or driving the machine, the user of the machine must always perform periodic maintenance. In addition, to further improve safety, the parts in the safety-critical parts list on the next page must also be replaced at the specified interval. These parts are particularly closely connected to safety and fire prevention, so please contact your Komatsu distributor to have them replaced. With these parts, the material changes as time passes, or they easily wear out or deteriorate. However, it is difficult to judge the condition of the parts simply by periodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition. This is necessary to ensure that they always maintain their function completely. However, if these parts show any abnormality before the replacement interval has passed, they should be repaired or replaced immediately. If the hose clamps show any deterioration, such as deformation or cracking, replace the clamps at the same time as the hoses. In addition, perform the checks for the hydraulic hoses other than periodic replacement parts. If any abnormality is found, tighten the clamps or replace the parts. When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time.
WA380-6
3-15
MAINTENANCE No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
3-16
Safety critical parts for periodic replacement
Q'ty
Fuel hose (fuel tank - fuel strainer) 1 Fuel hose (fuel strainer - supply pump) 1 Fuel return hose (supply pump - fuel tank) 2 Fuel hose (supply pump - fuel filter) 1 Fue Fuel ret retur urnn tub tubee (in (inje ject ctoor, sup suppl plyy pump pump,, fu fuel retu return rn merg mergee tube tube from from commo ommonn rail rail)) 1 Steering hose (pump - merge block) 1 Steering hose (merge block - steering valve) 1 Steering hose (steering valve - steering cylinder) 6 Steering hose (steering valve - drain merge block) 1 Steering hose (drain merge block - hydraulic tank) 1 Steering hose (hydraulic tank - steering pump) 1 Steering hose (hydraulic tank - emergency steering pump) 1 Steering hose (accumulator charge valve - orbital valve) 2 Steering hose (orbital valve - stop valve) 2 Steering hose (stop valve - steering valve) 2 Steering hose (stop valve drain - drain merge block) 2 Steering hose (orbital valve drain - drain merge block) 1 Steering hose (accumulator charge valve - drain merge block) 1 Steering hose (orbital valve drain - drain merge block) 1 Steering hose (steering valve - drain merge block) 1 Steering hose (drain merge block - hydraulic tank) 1 Steering hose (accumulator charge valve - fan pump) 1 Steering hose (fan pump - steering pump) 1 Steering hose (fan pump - work equipment pump) 1 Steering pump LS hose 1 Steering oil pressure check line hose (for emergency steering) 2 Brake hose (pump - accumulator charge valve) 1 Brake hose (accumulator charge valve - brake accumulator) 2 Brake hose (brake accumulator - brake valve) 2 Brake hose (valve drain - hydraulic tank) 1 Brake hose (brake valve - front brake) 3 Brake hose (brake valve - rear brake) 2 Brake Brake hose hose (bra (brake ke acc accum umula ulator tor - redu reduct ctio ionn valv valvee for for emer emerge genc ncyy park parking ing brak brakee canc cancel el)) 1 Brake Brake hos hosee (red (reduc uctio tionn valve valve for emer emerge genc ncyy park parkin ingg brak brakee canc cancel el - transm transmiss issio ionn valv valve) e) 1 Turbocharger lubrication hose 1 Ac Accumulator (for PPC) 1 Engine high pressure pip clamp 1 set Fuel splash prevention cap 1 s et Seat belt 1
Replacement interval
Every 2 years or every 4000 hours, whichever comes first
every 8000 hours Every 3 years
WA380-6
MAINTENANCE
MAINTENANCE SCHEDULE CHART This is a schedule outlining the maintenance to be performed on the machine according to the hours accumulated on the machine. Following these scheduled items will prolong the life of the machine. Maintenance Interval And Item
Section - Page
GENERAL GENERAL MAINTENANCE AND A ND INSPECTION INSPECTION INITIAL INITIAL 250 HOURS SERVICE SERVICE CHANGE TRANSMISSION OIL FILTER CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACE HYDRAULIC TANK FILTER ELEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-49 3-52
WHEN REQUIRED CLEANING THE MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING CLEANING THE COOLING COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AXLE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK AXLE VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONING CONDITIONING CONDENSER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDOW WASHER WASHER FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING RADIATOR RADIATOR FINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING ELECTRICAL INTAKE AIR HEATER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACE BOLT ON CUTTING EDGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACE BUCKET TEETH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING REPLACING SLOW BLOW FUSE FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION OF TIRES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-19 3-19 3-22 3-26 3-27 3-28 3-29 3-29 3-30 3-32 3-33 3-33 3-34 3-35
EVERY 50 HOURS SERVICE DRAIN SEDIMENT SEDIMENT FROM FUEL FUEL TANK TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-35
EVERY 100 HOURS SERVICE LUBRICATE REAR AXLE PIVOT PIN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HYDRAULIC TANK TANK OIL LEVEL AND ADDING OIL . . . . . . . . . . . . . . . . . . . . . . CLEANING THE AIR CONDITIONER FRESH ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-37 3-37 3-38
EVERY 250 HOURS SERVICE CHECK BATTERY ELECTROLYTE LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALTERNATOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER COMPRESSOR BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB NUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER RECIRCULATION FILTER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WA380-6
3-39 3-41 3-41 3-41 3-42 3-42 3-51
3-17
MAINTENANCE
EVERY 500 HOURS SERVICE CHANGE ENGINE OIL, REPLACING ENGINE OIL FILTER CARTRIDGE CARTRIDGE . . . . . . . . . . . . . . . . . . . REPLACING FUEL FILTER CARTRIDGE CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE FUEL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-44 3-45 3-45
EVERY 1000 HOURS SERVICE CHANGE TRANSMISSION OIL AND FILTER FILTER CARTRIDGE, CLEANING STRAINER . . . . . . . . . CLEAN THE TRANSMISSION CASE VENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING PARTS PARTS OF TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-49 3-50 3-51 3-51
EVERY 2000 HOURS SERVICE CHANGE HYDRAULIC OIL REPLACE HYDRAULIC OIL FILTER ELEMENT. . . . . . . . . . . . . . . . HYDRAULIC TANK VENT ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHANGE AXLE OIL (*). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CONDITIONER RECIRCULATION FILTER FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK ALTERNATOR, STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK ENGINE VAL VALVE VE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK INJECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK ACCUMULATOR GAS PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING CHECKING BRAKE DISC WEAR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . * The interval of 2000 hours for changing the axle oil is for standard operations. If the brake is used frequently or the brakes make a sound, change the oil after a shorter interval.
3-52 3-54 3-55 3-55 3-57 3-57 3-36 3-57 3-57 3-56
EVERY 4000 HOURS SERVICE LUBRICATING POINTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECK AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACE REPLACE INJECTOR INJECTOR NOZZLE TIP TIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER . . . . . CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER . . . . .
3-58 3-60 3-60 3-60 3-60 3-61
EVERY 8000 HOURS SERVICE REPLACE HIGH-PRESSURE PIPING CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACE FUEL SPRAY SPRAY PREVENTION CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-18
3-62 3-62
WA380-6
MAINTENANCE
GENERAL GENERAL MAINTENANCE AND A ND INSPECTION INSPECTION INITIAL 250 HOURS SERVICE SERVICE •
Perform Perform the followi following ng mainte maintenan nance ce only only after after the first first 250 250 hours. hours. • Chan Change ge transm transmiss issio ionn oil oil filt filter er cartr cartridg idgee • Repla Replace ce hydr hydrau aulic lic tank tank filte filterr ele eleme ment nt For details of the method of replacing or maintaining, see the section EVERY 1000 HOURS and 2000 HOURS SERVICE.
INITIAL 1000 HOURS SERVICE SERVICE •
Perform Perform the followi following ng main maintena tenance nce only only after after the the first first 1000 1000 hour hours. s. • Chec Checkk engi engine ne valv valvee clea cleara ranc ncee For details of the method of replacing or maintaining, see the section EVERY 2000 HOURS SERVICE
WHEN REQUIRED CLEANING THE MACHINE CLEAN TIPS
Never use flammable liquids to clean your machine. Use only approved non-flammable cleaning solvents to clean parts or the machine itself. Avoid using high pressure steam cleaners or caustic soaps to wash the machine if possible. Steam cleaning or using caustic soaps may damage paint, wiring or sensitive electrical components. Never use high pressure water or flood f lood the inside of the operator ’s cab. Doing so may damage sensitive electrical components. When pressure washing, use high pressure hot water and mild grease cutting soaps.
If inspection, cleaning, or maintenance is carried out with the engine running, dirt will get into the engine and the engine engine wil l suff er damage. damage. Always stop the engine before performin g these operation operation s. When using compr essed air, air, there is danger that dirt m ay be blown around and cause serious serious i njury. Al way s u se s afet y g las ses , du st mas k, and ot her pr ot ect iv e equ ip men t.
ENGINE AIR FILTER If air cleaner clogging caution lamp (1) on the machine monitor lights up, clean the air cleaner element. Remark
Do not clean the element until the air cleaner clogging caution lamp lights up. If the element is cleaned frequently before the air cleaner clogging caution lamp lights up, the air cleaner will not be able to display its performance fully and the cleaning efficiency will drop. In addition, the frequency of dirt stuck to the element falling inside the inner element will increase.
WA380-6
3-19
MAINTENANCE CLEANING OR REPLA CING OUTER ELEMENT ELEMENT
1. Open the top top cover cover at the front front of the the engine engine side cover cover on on the right side of the machine. 2. Remove Remove three three clips clips (1), (1), then then remo remove ve dust dust cup cup (2). (2).
3. Remo Remove ve the the oute outerr elem elemen entt (4). (4). •
Never Never remo remove ve the the inner inner eleme element nt (5). (5). If If it is is remov removed, ed, dust dust will will enter and cause engine trouble.
4. Clean Clean the insid insidee of the the air clea cleaner ner body body and and dust dust cup. cup. •
The inner inner elem element ent must not be cleane cleanedd and and used used agai again. n. When When replacing the outer element, replace the inner element at the same time.
5. Direct Direct dry comp compress ressed ed air air (less than than 0.69 0.69 MPa (99.4 (99.4 psi)) psi)) to the the outer element (4) from inside along its folds, then direct it from outside along its folds and again from inside.
3-20
WA380-6
MAINTENANCE 6. If small holes holes or thinner thinner parts parts are found found on the the element element when when it is checked checked by by shining shining a light through it after cleaning, replace the element. 7. Seat the the cleaned cleaned outer outer element element and and install install dust cup cup (3), then secure secure them them with clips (2). (2). Remark
When cleaning the element, do not hit or beat it against anything. Do not use an element whose folds, gasket or seal are damaged.
Remark
When installing the cover (2), check O-ring (7) and replace it if there are any scratches or damage.
8. Set the the cleaned cleaned outer element element in position, position, then then secure secure cover cover (3) (3) with mounting clips (1). 9. Press Press the dust dust indicat indicator or button button to return return the the yellow yellow pisto pistonn to its original position. 10. Close the engine engine side cover cover on the the right side of the the machine. machine. After cleaning, if the air cleaner clogging caution lamp lights up immediately or the yellow piston reaches the red line (7.5 kPa), replace the inner and outer elements.
WA380-6
3-21
MAINTENANCE CLEANING THE COOLING SYSTEM
Immediately after stopping the engine, the engine coolant is HOT and the pressure inside the radiator is high. Removing the cap and draining the water under this condition could cause burns. Allow the engine to coo l down, then tur n the cap slowly t o release release the pressure. Start Start t he engine and flush t he system. When standing standing up or leaving the operator's s eat, eat, set the shift l ever to the N positio n and set the parking parking brake switch to t he PARKING PARKING posit ion. For details of s tarting t he engine, see “ STARTSTART-UP UP PROCED PROCEDURE URES” S” on page 2-85. 2-85. When the undercover is removed, there is danger of tou ching t he fan. Never Never go t o the rear of the machine when th e engine engine is r unnin g.
Stop the machine on level ground when cleaning or changing the coolant. Clean the inside of the cooling system, change the coolant, and replace the corrosion resistor according to the table below. Type of coolant
Cleaning inside of cooling system and changing coolant
Replacing corrosion resistor
Komatsu supercoolant (AF-NAC)
Every two years or every 4000 hours, whichever comes first
unnecessary
Permanent type antifreeze (all season type,* )
Every 6 months (spring, autumn) (Drain antifreeze in spring, add antifreeze in autumn).
Every 1, 000 hours and when cleaning the inside of the cooling system and when changing coolant.
*: Permanent type antifreeze shall meet the requirements of ASTM D3306-03. Stop the machine on level ground when cleaning or changing the coolant. The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Supercoolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. Komatsu Supercoolant (AF-NAC) is strongly recommended wherever available. To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant between 30% and 68%. When using Komatsu Supercoolant (AF-NAC), there is no need to use a corrosion resistor. When no corrosion resistor is used, use the special cover (600-411-9000). Consult your Komatsu distributor about the method of installing. When deciding the ratio of antifreeze to water, check the lowest temperature in the past, and decide from the mixing table given below. It is actually better to estimate and temperature about 10°C (18°F) lower when deciding the mixing ratio. The mixing ratio depends on the ambient temperature, but it should always be a minimum of 30% by volume (antifreeze/total amount of coolant x 100). The freezing temperature of undiluted antifreeze is -15 °C (5°F). Do not store undiluted antifreeze at a temperature of below 15°C (5°F)
3-22
WA380-6
MAINTENANCE .
Min. atmospheric temperature Amount of antifreeze
Amount of water Ratio • • •
°C
-10
-15
-20
-25
-30
°F
14
5
-4
-13
-22
Liters
10.8
12.6
14.4
16.2
18.0
US gal
2.85
3.33
3.80
4.28
4.76
Liters
25.2
23.4
21.6
19.8
18.0
US gal
6.66
6.18
5.71
5.23
4.75
%
30
36
41
46
50
Use disti distille lledd water water for for the the cooli cooling ng sys syste tem m wate waterr. We recomme recommend nd use use of an antifreez antifreezee density density gauge to control control the mixing proportions. proportions. Prepare Prepare the following: following: Container Container should should hold hold a minimum minimum of of 50 liters liters (13.21 (13.21 US gal) gal) capacity capacity to mix the coolant. coolant.
1. Stop the engine engine and tighten 2 valves valves (1) (1) of the the corrosion corrosion resistor. resistor.
2. Turn the radiato radiatorr cap cap (2) (2) slowly slowly to release release the pressure, pressure, then then remove it. Remark
When mixing coolant with water, do not use tap water, river water, well water or water from any local source. Use only distilled or deionized water.
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3-23
MAINTENANCE 3. Set a container container in in position position to catch the drained drained antifreeze antifreeze mixture, mixture, then open drain valve (3) under the left side of the fuel tank and drain the coolant. 4. After draining draining the coolant coolant,, close drain valve (3) and and fill with city city water. 5. When When the radia radiator tor is full full of water water,, start start the engin enginee and run run the engine at low idling for about 10 minutes with the water temperature at 90° or higher. 6. Stop the engine, engine, allow it to cool down then open open drain valve (3) and and then tighten them again. 7. After draining draining the water, water, clean clean the the cooling cooling system with cleanin cleaningg agent. For the cleaning method, see the instructions for the cleaning agent (FLEETRITE Restore CC261 or restore plus CC2638). 8. Replace Replace the corrosion corrosion resistor, resistor, (if equipped equipped)) the open valves 1 and and Pour the coolant and water mixture into the filler port. See “Mixing rate of coolant and water table” for the mixing rate of coolant and water. 9. To remove the the air in the cooling cooling system, system, run the the engine engine for 5 minutes minutes at low idling, idling, and for another another 5 minutes minutes at high idle. idle. When doing this step, leave the radiator cap off. 10. Drain the coolant coolant from sub-tank sub-tank (4), (4), clean the inside inside of the subsubtank, then add water until the coolant level is between the FULL and LOW marks.
11. Stop the engine, engine, wait for approximat approximately ely 3 minutes, then then add tap water until the water level is near the water filler port, and tighten the cap. Check the coolant level and add water, if necessary. necessar y.
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WA380-6
MAINTENANCE WATER WATER SEPARATOR SEPARATOR
• • •
Each Each part part of the engine engine is still very hot immediate immediately ly after after the engine engine is stopped. stopped. Do Do not attempt attempt to drain cooli ng water or remove the fill er element element cup. High pressure pressure is genera generated ted inside the engine fuel piping while the engine is running. Wait Wait for more than than 30 seconds after the engine stops for it to cool s uffi ciently, then then start with drainin g coolant or removing the filter element cup. Do not bring a flame close to coolant, coolant, since antifreez antifreeze e is flammable flammable..
1. Open the the engine engine side side cover cover on the the right side of of the chassis. chassis. 2. Check the water water separator separator (1) (1) to see that the red ring inside has has risen to the marked line. 3. If red ring ring (2) has come come up to to the marked line, perform perform the the operation 4. Prepare Prepare a container container to catch the the drained drained fuel and place place it under under the water separator.
5. Loosen drain valve valve (2) at the bottom bottom of the water water separator separator and and drain the water and fuel into the container.
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MAINTENANCE TRANSMISSION OIL LEVEL
The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work.
Perform this procedure if there is any sign of oil on the transmission case, or if there is oil mixed with the cooling water. 1. Start Start the the engin enginee and and run it for for at least least 5 minute minutes. s. 2. Open Open the cap cap of oil filler filler port port (F), (F), remove remove dipst dipstick ick (G), (G), and and wipe the oil off with a cloth. 3. Insert the the dipstick dipstick (G) (G) again again from the top of the oil filler filler port port diagodiagonally as shown in the diagram, then pull it out again. When doing this, insert the dipstick so that the tip contacts the bottom of the dipstick guide.
4. The oil oil level level should should be be between between the the H and and L marks marks on dipstic dipstickk (G). If the oil level is below the L mark, add engine oil through oil filler (F).
5. If the oil is above above the H mark, drain the excess excess engine engine oil from drain drain plug (P), and check the oil level again. 6. If the oil level level is correct, correct, insert insert dipstick dipstick (G) (G) into the oil oil filler filler pipe, pipe, then tighten the cap.
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WA380-6
MAINTENANCE AXLE AXL E OIL LEVEL
When checking the oil level, apply apply parkin g brake and lock th e front and r ear ear frames wit h the safety bar. Af ter st op pi ng th e eng in e, the t he p art s and oi l are at a hi gh tem per atu re. Wait fo r th e tem per atu re to go do wn before starting the operation.
Perform this procedure if there is any sign of oil on the axle case. Perform the inspection with the machine on a horizontal road surface. If the road surface is at an angle, the oil level cannot be checked correctly. 1. Stop Stop the engin enginee and remove remove the the oil oil level level plug plug (1). (1). Remark
Remove the mud and dirt from around plug (1), then remove the plug.
2. Wipe off any any oil adhering adhering to the oil oil level level gauge gauge attached attached to plug plug (1) with waste cloth.
3. Set the the oil oil level level gauge gauge (G) (G) as shown shown in in the righ rightt diagra diagram. m.
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MAINTENANCE 4. The oil oil level level is correct correct when it is between between the two lines provide providedd on the oil level gauge. If the oil level does not reach the lower line, add axle oil through the filler port (F). Remark
For axles with ASD (Antislip Differential), the brand of lubricating oil is different, so always use the specified lubricating oil.
5. If the oil oil level level is above above the the upper upper line, line, drain drain off off the exce excess ss oil through drain plug (P) and check the oil level again. 6. If the oil level level is correct, correct, install install plug plug (1). Tightening Tightening torque: torque: 127 to 177 Nm (94 to 177 lb. ft.).
CHECK AXLE VENT VENT
When When cleaning the axle breather, breather, apply apply t he parking parking brake and and loc k the fro nt and rear frames with the safety bar.
Remove all mud and dirt from around the breather with a brush. After removing the mud or dirt from around the breather, remove the breather, immerse it in cleaning fluid and clean it. When cleaning the breather, clean the breathers at two places (front and rear).
After removing the breather, take steps to prevent dirt or dust from entering the mount.
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WA380-6
MAINTENANCE AIR CONDITIONER CONDENSER
Do not wash th e condenser using a steam cleaner because because the condenser could overheat. If high-pressure water hits your body directly or high-pressure water sends dirt flying, there is danger of personal inju ry. Always wear protectiv e glasses, dust mask, and other prot ective equipment.
If there is mud or dust on the air conditioner condenser (1), clean it with water. If the water pressure is too high, the fins may get deformed. When washing with a high-pressure washing machine, apply the water from a reasonable distance.
WINDOW WASHING FLUID LEVEL Check the washing fluid levels in washer tank (1). When the fluid has run short, add automotive window washing fluid. To prevent the nozzles from clogging, be careful not to let dust get into the fluid.
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3-29
MAINTENANCE CLEAN RADIATOR FINS
Never Never open th e engine engine sid e cover when the engine is run ning. Stop the engine comp letely before starting the cleaning operation. If compressed air, pressurized water, or steam hits your body directly, or causes dirt to fly, it may lead to personal inju ry. Always wear safety glasses, dust mask, or ot her protectiv e equipm equipm ent.
Clean the radiator or cleaner if mud or dirt is stuck to it. CLEAN FINS BY ROTATING COOLING FAN IN REVERSE Remark
When rotating the fan in reverse, be careful of flying dust, and be careful not to let any cloth get caught in the fan. Dust may rise, so check that there is no one in the surrounding area when rotating the fan in reverse.
On jobsites where it is easy for dirt to stick to the radiator or cooler, turn cooling fan reverse rotation switch (1) ON to rotate the fan in reverse. This will blow off the dirt and dust stuck to the radiator or cooler, and can extend the cleaning interval. MANUAL FAN REVERSING REVERSING FUNCTION Remark
Never rotate the fan in reverse by hand when carrying out the operation. Before operating the fan reverse rotation switch, run the engine at low idling.
1. Set the the direc direction tional al lever lever to to the Neutral Neutral posit position ion.. 2. Set the the parking parking brake switch to the ON position position to apply apply the the parkparking brake. 3. Run Run the the engin enginee at at low low idl idlin ing. g. 4. Press Press position position (a) (a) (manua (manuall reverse reverse rotatio rotationn ON) of coolin coolingg fan reverse rotation switch (1). 5. After After the coolin coolingg fan reverse reverse rota rotation tion pilot pilot lamp lamp on the the machine machine monitor flashes, check that it lights up. At the same time, “COOLING FAN REVERSE ROTATION” is displayed on the character display and the fan is set to rotate in reverse. 6. Run Run the the eng engin inee at at high high idlin idling. g. • Select Select the time for running running the engine engine at high high idle as follo follows ws according to the condition of clogging. • Norm Normal al clog cloggi ging ng:: 1 to 2 min minut utes es • Exce Excess ssiv ivee clo clogg ggin ing: g: 2 to 3 minu minute tess
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WA380-6
MAINTENANCE 7. When When the clea cleanin ningg is comple completed ted,, run the the engine engine at at low idling idling.. 8. Press Press position position (a) (a) (manua (manuall reverse reverse rotatio rotationn ON) of coolin coolingg fan reverse rotation switch (1).
9. After After the coolin coolingg fan reverse reverse rota rotation tion pilot pilot lamp lamp on the the machine machine monitor flashes, check that it goes out. The fan is set to rotate in the normal direction. 10. Run the engine at low idling idling for approx. approx. 10 seconds. seconds.
AUTO REVERSE FUNCTION (IF EQUIPPED)
1. Run Run the the engin enginee at at low low idl idlin ing. g. 2. Press position position (a) (auto (auto reverse reverse rotation rotation ON) of cooling cooling fan reverse rotation switch (1). 3. Check Check that that pilot pilot lamp insid insidee of the switc switchh and the the coolin coolingg fan reverse rotation pilot lamp on the machine monitor light up. The fan automatically rotates in reverse for 2 minutes every 2 hours.
Remark
When the fan direction is switched, the reverse rotation pilot lamp flashes. When the machine is operating under high load or in low temperatures, the direction of rotation of the fan may not change. This is to protect the machine. Run the engine at low idling and wait for the oil temperature or water temperature to go down before operating the switch.
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MAINTENANCE CLEAN FINS WITH COMPRESSED AIR Insert the air nozzle through the gap between the radiator oil cooler after cooler (1) and the air conditioner condenser (2) to clean the fins.
When cleaning the face behind the radiator, or oil cooler, and after cooler (1), remove bolt (2) and plate (3), then insert the jet nozzle through the opening to clean the fins. Remark
If the steam jet nozzle is brought too close to the radiator fins, it may damage the fins, so keep the nozzle a suitable distance away from the fins when cleaning.
• • • •
Work unde underr the the follo followin wingg roug roughh cond conditi ition ons. s. Injecti Injection on pressur pressure: e: Max. Max. 9.8 MPa (100 (100 kgf/c kgf/cm2, m2, 1420 1420 PSI) PSI) Nozz Nozzle le diam diamet eter er:: Max. Max. 2 mm mm (0. (0.11 in) in) Distanc Distancee betwe between en nozz nozzle le and and radi radiato atorr fins: fins: Min. Min. 100 100 mm mm (3.9 (3.9 in) Examine the rubber hoses, and if any hose is cracked or deteriorated, replace it. Check also that there are no loose hose clamps.
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
AIR CONDITIONING SYSTEM. Inspection location
Maintenance interval Item to check for
Check before operating
6 months
Replacement interval
Filter
Clogging or dirt
Condenser
Clogging or dirt
Inspect
Inspect
2 years
Looseness damage or wear
Inspect
Inspect
2 years
Refrigerant gas
⎯
⎯
⎯
⎯
Piping
⎯
⎯
⎯
⎯
Receiver dryer
⎯
⎯
⎯
⎯
Belt
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WA380-6
MAINTENANCE REPLACE REPLA CE BOLT-ON CUTTING EDGE
It is extremely extremely dangerous if the work equipment mov es when performi ng the turnin g or replacement replacement operation. Set Set the work equipment in a stable positi on, stop th e engine, engine, then set the safety safety loc k lever securely to the LOCK position.
Turn or replace the cutting edge before the wear reaches the edge of the bucket. 1. Raise Raise the buck bucket et to a suitab suitable le heigh height, t, then then put block blockss under under the bucket to prevent the bucket from coming down. • Raise Raise the the buck bucket et so so that that the the bottom bottom surface surface of the the buck bucket et is is horizontal. 2. Remo Remove ve the the nut nutss and and bol bolts ts (1). (1). 3. Remo Remove ve the the cut cuttin tingg edg edgee (2). (2). 4. Clean Clean the the mountin mountingg surface surface of of the cutti cutting ng edge edge (2). (2). 5. Turn cutting edge (2) and and install install it to the bucket. bucket. When turning turning the edge, install it to the opposite side (left edge to right side, right edge to left side). • If both both side sidess of the the cutti cutting ng edge edge are worn, worn, replac replacee with with a new part. • If the the wear wear extend extendss to the mountin mountingg surfac surface, e, repair repair the mounting surface before installing the cutting edge. 6. Tighten Tighten nuts and and bolts (1) uniformly uniformly so that that there is no gap gap between between the bucket bucket and cutting cutting edge. edge. Tightening Tightening the the torque for for the mounting bolt: 745 ± 108 N·m (549.7 ± 79.6 lb. ft.) 7. Tighten Tighten the the mounting mounting bolts again again after operating operating for for several several hours. hours.
REPLACE BUCKET BUCK ET TEETH
If the pin is hit w ith a strong f orce, there is danger that the pin may fly out. Check that there is no one in the surrounding area. There is danger of pieces flying during the replacement operation, so always wear protective clothing, such as safety glasses and glov es.
Replace the bucket teeth before they wear down as far as the bucket edge. 1. Raise the the bucket bucket to a suitable height, then put put blocks blocks under under the bucket bucket to prevent the bucket from coming down. Raise the bucket so that the t he bottom surface of the bucket is horizontal. 2. Remove the bolt bolt and nuts (1) (1) and (2), then then remove remove bucket bucket tooth (3). 3. Clean Clean the insta installat llation ion surf surface ace of of bucket bucket toot toothh (3). (3). 4. Install new teeth teeth to the the bucket. bucket. When installing installing new teeth, insert shims so that there is no clearance between the teeth and the top surface of the bucket. Continue to add shims until unt il it becomes impossible impossibl e to add a 0.5 mm (0.02 in.) shim. If the mounting surface is worn, correct the mounting surface before installing the teeth.
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MAINTENANCE 5.
To prevent prevent any gap from from forming between between the teeth teeth and and tip of the bucket, bucket, tighten tighten bolts and nuts nuts (1) and (2) temporarily temporarily,, then hit the tip of the teeth with a hammer. Tightening torque of mounting bolt (1): 902 ± 39 Nm (665.4 ± 28.9 lb/ ft.) Tightening torque of mounting bolt (2): 902 ± 39 Nm (665.4 ± 28.9 lb/ ft.)
After operating the machine for a few hours, tighten the mounting bolts again
REPLACING SLOW-BLOW FUSE Remark
Always turn the power OFF when replacing the slow blow fuse (turn the starting switch to the OFF position). Always replace the slow blow fuse with one of the same capacity.
1. Turn Turn the the startin startingg switch switch to to the OFF positio position. n.
2. Remove Remove the slow blow blow fuse fuse box box from from the chassis. chassis. 3. Open Open covers covers (1), (1), (2), (2), and (3) (3) of the slow slow blow blow fuse fuse box. box. Covers Covers (2) and (3) can be removed easily by using protrusion (A) on the body as a fulcrum and levering the catch of the cover with a flat-headed screwdriver to release it. 4. Loosen Loosen scre screws ws (4) and and (5), (5), and remo remove. ve. When When scre screws ws (4) and and (5) (5) are removed, slow blow fuse (6) will also come off together with electric wiring (7) and (8). 5. Using Using screws screws (4) and and (5), (5), install install a new new slow blow blow fuse fuse togethe togetherr with electric wiring (7) and (8) to the slow blow fuse box, then close covers (1), (2), and (3). 6. Install Install the slow blow blow fuse fuse box box to to the the chas chassis. sis.
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WA380-6
MAINTENANCE INSPECTION OF TIRES
If a tire or a rim is h andled wrongly, the tire may burst or may be damaged and and th e rim may be br oken and scattered, and that can cause serious in jury and death. • Beca Because use main mainte tena nance nce,, disasse disassembly mbly,, repa repair ir and asse assemmbly of the tires and rims r equire special special equipment and skill , ask ask a tire repair repair shop to perfor m the work. • Do not he heat or weld weld the rim to whic which h the tire is insta installe lled. d. Do not m ake a fire near near th e tire.
Select Select the tires according t o the condit ions of use and attachments attachments on the machine. Use Use only specified tires and infl ate them to the specified pressure.
Because the indicated speed varies with the tire size, consult your Komatsu distributor when using optional tires.
Standard
Maximum load [kg (lb.)]
Tire size
Front wheel
9,095 (20,054)
23.5-25
Rear wheel
7,720 (17,023
23.5-25
Remarks
CHECKING TIRE PRESSURE
When inflating a tire, check that no one will enter the working area and use an air chuck which has a clip and which can be fixed to th e air air valve. While inflating the tire, che check ck the inflation pr essure occasionally occasionally so that it will not rise too high. If the rim is not fitted normally, it may be broken and scattered while the tire is inflated. To ensure safety, place a guard around the tire and do not work in fro nt of the rim bu t work on th e tread tread side of the tire. Ab no rm al dr op of in fl ati on pr ess ur e an d abn or mal fi tt in g of th e r im in di cat e a tr ou bl e i n th e t ir e o r ri m. In this case, be sure to ask a tire repair shop t o perform repairs. Be sure to observe the specified infl ation pressure. Do not adjust the inflation pr essure of the tires just after high-speed high-speed travel or heavy-duty heavy-duty wor k.
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MAINTENANCE CHECK
Measure the inflation pressure with a tire pressure gauge while the tires are cool before starting work.
INFLATION OF TIRES
Adjust the inflation pressure properly. When inflating a tire, use an air chuck which can be fixed to the air valve of the tire as shown in the figure. Do not work in front of the rim but work on the tread side of the tire. ti re. The proper inflation pressure is shown below. Tire size
Inflation pressure
23.5-25 (standard)
Front Tire: 0.30 MPa (44.0 psi) Rear Tire: 0.30 MPa (44.0 psi)
CHECKING FUNCTION OF ACCUMULATOR For details of handling the accumulator, see “ACCUMULATOR” “ACCUMULATOR” on page 1-34. 1-34 .
ACCUMULATOR ACCUMUL ATOR FOR TRAVEL DAMPER When the travel damper switch is ON, the hydraulic spring effect of the accumulator absorbs the up-and-down motion of the machine during travel and reduces the swaying. Drive the machine and compare the up-and-down movement of the machine during travel when the travel damper switch is ON and when it is OFF. If there is no change in the up-and-down movement of the machine, the gas pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected. Remark
Carry out the inspection with the speed range set to 2 - 4, with the machine traveling at a speed of at least 5 km/h. If the speed range is 1st or the machine is traveling at a speed of less than 5 km/h, the E.C.S.S. will not be actuated even if the E.C.S.S. switch is turned ON.
ACCUMULATOR ACCUMUL ATOR FOR FOR BRAKE BRA KE DAMPER DA MPER When the brake pedal is depressed, the hydraulic spring effect of the accumulator actuates the brake smoothly. If any change is felt in the smoothness of the brake operation during daily operations, the gas pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected. Remark
Even if there is any change in the smoothness, there is no drop in the braking force or brake performance.
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WA380-6
MAINTENANCE
EVERY SPECIFIC HOURS OF SERVICE EVERY 50 HOURS OF SERVICE DRAIN SEDIMENT FROM FUEL TANK Open the drain plug (1) on the right side of the fuel tank so that the sediment and water will be drained together.
EVERY 100 HOURS SERVICE Maintenance for every 50 hours service should be performed at the same time.
LUBRICATE THE REAR AXLE PIVOT PIN (3 points) 1. Using Using a grease grease pump, pump, pump pump in greas greasee through through the the grease grease fittin fittings gs marked by the arrow. 2. After After greasing greasing,, wipe off off any any old greas greasee that that was pushe pushedd out. out.
CHECKING THE HYDRAULIC HYDRAULIC TANK OIL LEVEL AND A ND ADDING OIL
The parts and oil are HOT after stopping the engine, and may cause burns. Wait for the temperature to decrease before starting t he work. When removing the oil f iller cap, turn it s lowly to release the internal pressure, then remove it.
1. Lower the bucket bucket horizontally horizontally to the ground. ground. It is correct correct if the the oil amount is between H and L marks on the gauge (G) when measured approximately 5 minutes after the engine stopped. Remark
Do not add oil if the level is above the H line. If the oil has been added to above “H” level, stop the engine and wait for the hydraulic oil to cool down, then drain the excess oil from the drain plug. If the oil is above H level, it will damage the hydraulic circuit or cause the oil to spurt out.
2. If the oil is below the L mark, open open the inspecti inspection on cover cover on on the step and add the oil through the filler (F).
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MAINTENANCE CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT
If compressed air is used, there is danger that dirt may fly and cause personal injur y. Al way s w ear s afet y g las ses , du st mas k, an d o th er p ro tec ti ve eq ui pm ent .
If the air conditioner has been used, the air filter should be cleaned. Stop the air conditioner before cleaning the element. When replacing the air filter element, set the machine facing directly to the front or articulate it to the right. 1. Insert the starting starting key into key key slot slot (1), release the lock, lock, loosen loosen knob (2), and open cover (3).
2. Take ake out out elem elemen entt (4) (4) and and clea cleann it. 3. Direct Direct dry comp compress ressed ed air air less than than 0.69 0.69 MPa MPa (99.4 (99.4 PSI) PSI) to the element from inside along its folds, then direct it from outside along its folds and again from inside. 4. If the dirt clogging clogging the filter filter cannot cannot be be removed removed by blowing blowing itit with air, replace the filter with a new part. 5. After cleaning, cleaning, return return filter (4) to its original original position and close the cover. Use the starting switch key to lock the cover. Do not forget to remove the starting switch key. Remark
If the filter becomes clogged, the air flow will be reduced, and there will be an abnormal noise from the air conditioner unit.
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WA380-6
MAINTENANCE
EVERY 250 HOURS OF SERVICE Maintenance for every 50 and 100 hours service should be performed at the same time.
CHECK B ATTERY ATTERY ELECTROLYTE LEVEL Perform this check before operating the machine.
Do not use the battery if the battery electrolyte level is below the LOWER LEVEL line. This situation will accelerate accelerate deterior deterior ation of the inside of t he battery and reduce the service life of the battery. In In addition , it may also cause an explosi explosi on. The battery battery generates flammable gas gas and there is danger of explosio n, so do not b ring f ire or sparks near the b attery. attery. Battery electrolyte is dangerous. If it gets in your eyes or on your skin, wash it off with large amount of water and consult a docto r. When adding distilled water to the battery, do not allow the battery electrolyte to go above the UPPER LEVEL LEVEL line. If the electrolyte level is to o high , it may leak and cause damage damage to the paint surf ace or corrod e other parts.
Remark
When adding distilled water in cold weather, add it before starting operations in the morning to prevent the electrolyte from freezing.
Inspect the battery electrolyte level at least once a month and follow the basic safety procedures given below.
WHEN CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY
If it is possible to check the electrolyte level from the side of the battery, check as follows. 1. Open the cover cover of of the battery box.There box.There are two two battery battery boxes: boxes: One on each side at the rear of the machine. 2. Use a wet cloth cloth to clean clean the area area around around the electrolyte electrolyte level lines lines and check that the electrolyte level is between the UPPER LEVEL (U.L) and LOWER LEVEL (L.L) lines. If the battery is wiped with a dry cloth, static electricity may cause a fire or explosion.
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MAINTENANCE 3. If the electrolyte electrolyte level is below below the midway point between between the U.L and L.L lines, remove cap (1) and add distilled water to the U.L line. 4. If distilled distilled water water has has been added to any cell of of cap (1), add add distilled distilled water also to the other cells. 5. Clean the vents vents of the battery battery caps, caps, then then close close the caps securely securely.. Keep the top of the battery clean and wipe it with a wet cloth. Remark
If distilled water is added to above the U.L line, use a pipette to lower the level to the U.L 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.
If it is impossible to check the electrolyte level from the side of the battery, or there is no display of the UPPER LEVEL line on the side of the battery, check as follows. 1. Open the cover cover of the battery battery box.There box.There are are two battery battery boxes: One One on each side side at the rear rear of the machine. machine. 2. Remove cap (1) (1) at the top of the battery battery,, look through through the water water filler port, and check the electrolyte surface. If the electrolyte does not reach the sleeve, add distilled water so that the level reaches the bottom of the sleeve (UPPER LEVEL line). 3. If distilled distilled water water has been been added added to any cell cell of cap cap (1), add add distilled distilled water water also to the other cells. Use the diagram below for reference, and check if the electrolyte reaches the bottom of the sleeve.
4. After adding adding distilled distilled water, water, tighten tighten the cap cap (1) (1) securely securely..
Remark
If distilled water is added to above the bottom of the sleeve, use a pipette to lower the level to the bottom of the sleeve. 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.
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WA380-6
MAINTENANCE CHECK PARKING PARKING BRAKE BRA KE 1. Set the the machin machinee on a dry down downhil hilll slope. slope. Press Press the park parking ing brake brake switch to the ON position. Check if the parking brake holds the machine in position. 2. If any abno abnorma rmality lity is foun found, d, please please cont contact act your your Komat Komatsu su distributor.
CHECK A IR CONDITIONER COMPRESSOR COMPRESSOR BELT TENSION CHECKING
The standard deflection between the air conditioner compressor pulley and crank pulley when pressed with a thumb (approx. 98 N (10 kgf)) should be approx. 11 to 15 mm (0.4 to 0.6 in). When a belt tension gauge is used, the standard tension is within a range of 353 to 530 N (36 to 54 kgf). CHECK WHEN CHANGING THE V-BELT
The standard deflection between the air conditioner compressor pulley and fan pulley when pressed with a thumb approx. 98 N (10 kgf should be approx. 8 to 11.5 mm (0.315 to 0.5 in). When a belt tension gauge is used, the standard tension is within a range of 530 to 745 N (54 to 76 kgf). Remark
When the belt has been replaced with a new part, a high tension is necessary, so the initial tension is in the value given above. ADJ USTING
1. Loosen bolt (1), (1), then then loosen loosen the the locknut locknut of bolt bolt (2), tighten tighten bolt (2), and move compressor (3) to adjust. 2. Tighten Tighten bolt bolt (1) (1) and the locknut locknut of bolt bolt (2) to hold hold the compressor compressor (3) in position. Remark
Check each pulley for damage, wear of the V-groove, and wear of the V-belt. In particular, be sure to check 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. * A cut or crack is found on the belt. * Slipping or creaking sound is heard coming from the belt. When the new V-belt is set, readjust it after one hour of operation.
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MAINTENANCE WHEEL HUB NUTS If wheel hub nuts (1) are loose, tire wear will be increased and accidents may be caused. 1. Check for loose loose nuts, nuts, and tighten if necessary necessary.. When checking checking for for loose nuts, always turn the nuts in the direction of tightening to check. Tightening torque: 825 to 1030 N·m (608.5 to 759.7 lbft). 2. If any stud stud bolt bolt is broke broken, n, replac replacee all the the stud bolts bolts for for that wheel wheel..
AIR CONDITIONER RECIRCULATION FILTER FILTER 1. Loosen Loosen the the knob knob (1), remo remove ve the filte filterr inspect inspection ion cove coverr (2).
2. Pull Pull the filter filter (3) (3) out out in the the direct direction ion of of the arrow arrow.. 3. Clean Clean with compr compresse essedd air in the the same way way as for for the fresh fresh air filter filter.. If the filter is extremely dirty, rinse it in water. After rinsing the filter, dry it completely before installing it again.
CHECKING FUNCTION OF ACCUMULATOR For details of handling the accumulator, see “ACCUMULATOR” on page 1-34. 1-34. BRAKE ACCUMULATOR
If the engine stops when the machine is traveling, the oil pressure in the accumulator can be used to apply the brake as an emergency measure. 1. Stop the the machine machine on level level ground ground and lower the the work equipmen equipmentt completely completely to the the ground. ground. 2. Appl Applyy the the park parkin ingg brak brake. e. 3. Start the the engine, engine, run run it at a mid-range mid-range speed speed for 1 minute, minute, then then stop the engine. engine. 4. Turn the starting starting switch switch key to the the ON position position and depress depress the brake brake pedal pedal repeatedly repeatedly.. If the brake oil pressure caution lamp does not light up even when the brake is depressed 6 times, the gas pressure in the accumulator is normal.
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MAINTENANCE LUBRICATING POINTS 1. Using a grease grease pump, pump, pump pump in the grease grease through through the the grease grease fittings marked marked by by the arrows. arrows. 2. After After greasing greasing,, wipe off off any any old greas greasee that that was pushe pushedd out. out. Remark
On jobsites where there is a lot of heavy-duty work, or on jobsites where operations are performed continuously for more than eight hours, grease the machine more frequently than prescribed.
1. 2. 3. 4.
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Buck Bucket et pin pin (2 (2 poi point nts) s) Buck Bucket et link link pin pin (2 poin points) ts) Dump Dump cylin cylinde derr pin pin (2 point points) s) Lift Lift cyl cylind inder er pin (4 point points) s)
5. Lift Lift arm arm pivo pivott pin pin (2 point points) s) 6. Tilt ilt leve leverr pin pin (1 poin point) t) 7. Stee Steerin ringg cylin cylinde derr pin pin (4 poi point nts) s)
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MAINTENANCE
EVERY 500 HOURS OF SERVICE Maintenance for every 50, 100 and 250 hours service should be performed at the same time.
CHANGE THE ENGINE OIL, REPLACE THE ENGINE OIL FILTER CARTRIDGE
The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. When removing the oil f iller cap, turn it s lowly to release the internal pressure, then remove it.
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Refil Refilll cap capac acity ity:: 23 23 lite liters rs (6.0 (6.088 US US gal) gal) Filter wrench
1. 2. 3. 4.
Open Open the engi engine ne side side cover cover locate locatedd on the left left of mach machine ine.. Open Open the the eng engin inee oil oil fill filler er (F). (F). Loosen Loosen the drai drainn plug plug (P), (P), and and drain drain the the oil. oil. Check Check the drain drained ed oil. oil. If excessiv excessivee metal metal particle particless or foreign foreign material exist, please contact your Komatsu distributor. 5. Inst Instal alll dra drain in plug plug (P). (P).
6. Using a filter filter wrench, wrench, turn the the filter filter cartridge cartridge (1) counterc counterclockwis lockwisee to remove it. 7. If this opera operation tion is carri carried ed out immed immediate iately ly after after stopping stopping the the engine, a large amount of oil will come out. Therefore, wait for 10 minutes before starting the operation. 8. Clean the filter filter holder holder,, fill a new new filter filter cartridge cartridge with clean clean engine oil (or coat thinly with grease), then coat the seal and thread of the filter cartridge with engine oil. Install the filter. 9. When installing, installing, bring bring the the seal seal surface surface into contac contactt with the filter holder, and tighten another 3/4 to 1 turn.
10. Run the engine engine at idle idle for a while, then then stop the engine. engine. Check Check that the oil level is between the H and L marks on the dipstick. For details, see “PRE-OPERATIONAL “PRE-OPERATIONAL CHECKS” on page 2-76. 2-76 .
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MAINTENANCE REPLACING PRIMARY FUEL FILTER
Immediately after after the engine is stopp ed, all all parts are at high t emperature, so do not r eplace the filter imm ediately. Wait Wait for the engine to cool dow n before starting the operation. The inside of fuel piping system of the engine is under high-pressure when the engine is running. When replacing th e filter, wait wait for at least least 30 seconds seconds after after the engine stops to let the internal pressur e go down before replacing the filt er. er. Do not bring any fire or spark close. This engine consists of hi gher precision parts than on the conventional fuel injecti on pump and nozzle, so if dirt gets in, it will cause problems. If there is any dirt stuck to the fuel line, use fuel to wash it off completely. Al way s u se a K om atsu ats u g enu in e par t f or th e fu el f il ter car tr id ge. If fi lt ers ot her th an g enu in e fi lt ers are u sed , probl ems may occur in the injection sy stem, so never never use substitu te parts. parts. Be careful when opening the air bleed plug at the fuel filter head and the air bleeder of the supply pump. The system is sti ll under pressure and fuel may spurt out.
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Genuin Genuinee Komats Komatsuu fuel fuel filter filter cartri cartridge dgess use a specia speciall filter filter that that has has highly efficient filtering ability. When replacing the filter cartridge, always use a genuine Komatsu part. The common common rail fuel fuel inject injection ion system system used used on this this machin machinee conconsists of more precise parts than the conventional injection pump and nozzle. If any any part part other other than than a genui genuine ne Koma Komatsu tsu filte filterr cartri cartridge dge is used, used, dust or dirt may get in and cause problems with the injection system. Always avoid using substitute parts. When When carryi carrying ng out out inspe inspectio ctionn or mainte maintenan nance ce of of the fuel fuel system system,, pay more attention than normal to the entry of dirt. If dirt is stuck to any part, use fuel to wash it off completely.
Prepare a filter wrench 1. Open Open the engi engine ne side side cover cover on the the right right side side of the chas chassis. sis. 2. Prepare Prepare to remo remove ve prima primary ry (3) (3) fuel fuel filter filter.. 3. The fuel primary filter (1) forms forms one one unit unit with the water separator separator and is at the rear of the engine. 4. Set the the contain container er to catch catch the fuel fuel under under the filte filterr cartridg cartridge. e.
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MAINTENANCE 5. Open the drain drain (2) (2) on the filter filter to drain all fuel fuel from the pre pre filter. filter. 6. Once Once primary primary filter filter (3) (3) is empty empty use use a filter filter wrench wrench,, turn filte filterr cartridge counterclockwise on remove it.
7.
Take water water separato separatorr cup (2) installed installed on the bottom of the cartridge cartridge and turn it to the left to remove it. (This cup is used again. If it is damaged, replace it with a new part.) 8. Install Install cup cup (2) to the botto bottom m of the new fuel fuel pre-fil pre-filter ter cartri cartridge dge.. When doing this, always replace the seal ring with a new part. Tightening torque for cup: 10 Nm (88 in/lbs)
Remark
When filling the primary filter cartridge with fuel, carry out the filling operation with cap (A) fitted. Cap (A) acts to prevent the entry of dirt or dust into the filter cartridge.
9. Fill the the primary primary filter filter cartridg cartridgee with clean fuel through the 8 small small holes (B) in the new filter cartridge. 10. Coat the packing packing surface surface of the filter filter cartridge cartridge with oil. oil. 11. Remove filter filter cartridge cartridge cap (A) and and install install to the filter holder holder.. 12. When installing, installing, tighten tighten until the packing packing surface surface contacts contacts the seal surface of the filter holder, then tighten it 3/4 of a turn. • If the the filter filter cartr cartridg idgee is tigh tighten tened ed too too far, far, the packing packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount. • When tightening tightening with with a filter wrench, wrench, be extremel extremelyy careful careful not not to dent or damage damage the filter filter.. 13. When carrying out standard replacement of the fuel filter cartridge (every 1000 hours), replace the cartridge cartridge and bleed the air. For details, see “REPLACING PRIMARY AND SECONDARY SECONDARY FUEL FILTER” FILTER” on page 3-47. 3-47 . 14. Start the engine, check that there is no leakage of fuel from the filter seal surface or water separator mounting surface, then run for approx. 10 minutes at low idling.
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MAINTENANCE
EVERY 1000 HOURS OF SERVICE Maintenance for every 50, 100, 250 and 500 hours service should be performed at the same time.
REPLACING PRIMARY AND SECONDARY FUEL FILTER Prepare a filter wrench 1. Open Open the engi engine ne side side cover cover on the the right right side side of the chas chassis. sis. 2. Prepare Prepare to to remove remove primary primary (3) (3) and secon secondar daryy (4) fuel fuel filter filter.
3. The fuel fuel primary primary filte filterr (1) forms forms one unit unit with the the water water separa separator tor and is at the rear of the engine. 4. Set the the contain container er to catch catch the fuel fuel under under the filte filterr cartridg cartridge. e.
5. Open the drain drain (2) (2) on the filter filter to drain all fuel fuel from the pre pre filter. filter. 6. Once Once primary primary filter filter (3) (3) is empty empty use use a filter filter wrench wrench,, turn filte filterr cartridge counterclockwise on remove it.
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MAINTENANCE 7.
Take water water separato separatorr cup (2) installed installed on the bottom of the cartridge cartridge and turn it to the left to remove it. (This cup is used again. If it is damaged, replace it with a new part.) 8. Install Install cup cup (2) to the botto bottom m of the new fuel fuel pre-fil pre-filter ter cartri cartridge dge.. When doing this, always replace the seal ring with a new part. Tightening torque for cup: 10 Nm (88 in/lbs)
Remark
Fill only the primary fuel filter (3), do not pre-fill the secondary fuel filter (4) carry out the filling operation with cap (A) fitted. Cap (A) acts to prevent the entry of dirt or dust into the filter cartridge.
Fill the primary filter cartridge with clean fuel through the 8 small holes (B) in the new filter cartridge. When replacing the seal ring, coat the surface with clean fuel before installing it. 9. Check that drain drain plug plug (3) at the bottom of water water separator separator cup cup (2) is is tightened securely. • Tighte ighteni ning ng torq torque ue:: 0.2 0.2 - 0.45 0.45 Nm Nm (2 - 4.0 4.0 in/lb in/lbs) s) 10. Clean the filter filter holders holders and install install new primary primary fuel filter. filter. 11. Remove the the secondary secondary filter (4) in the same same manor. manor. Remove cap cap (A) from new cartridge and install filter dry.
Remark
It is not recommended to pre fill the secondary fuel filter. Due to the high pressure fuel system the smallest amount of debris may damage the fuel injection system.
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When When install installing ing,, tighten tighten until until the the packi packing ng surfac surfacee conta contacts cts the the seal surface of the filter holder, then tighten it 3/4 of a turn. If the filter cartridge is tightened too far, the packing will be damaged and this will lead to leakage of fuel. If the filter cartridge is too loose, fuel will also leak from the packing, so always tighten the correct amount.
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MAINTENANCE PROCEDURE PROCEDURE FOR BL EEDING AIR
1. Fill Fill the the fuel fuel tank tank with with fue fuel. l. 2. Loosen the feed feed pump pump knob knob by turning turning it counter counter clockwis clockwisee until until it pops out from its seated s eated position. • The plug plug on the fuel fuel filter filter head head does does not not need need to be be remov removed. ed.
3. Pump Pump the knob knob in and out out until until the pressu pressure re become becomess heavy heavy. 4. After After bleedin bleedingg air, air, push in in and tighte tightenn knob knob clockw clockwise. ise. After completing the air bleeding, start the engine and check that there is no leakage of fuel from the filter seal surface. If there is any leakage, check the tightening condition of the filter cartridge. If there is still fuel leakage, repeat Steps 1 - 3 to remove the filter cartridge, then check the packing surface for damage or embedded dirt. If any damage or embedded dirt is found, replace the cartridge with a new part and repeat Steps 4 - 8 to install it.
CHANGE TRANSMISSION OIL AND FILTER CARTRIDGE, CLEAN STRAINER
Immediately after stoppin g the engin e, the parts parts and o il are HOT and and m ay cause burns. Wait for the temperature to go down before starting the work. When removing the oil f iller cap, turn it s lowly to release the internal pressure. Remove Remove the cap.
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Refil Refilll cap capac acity ity:: 38 38 lite liters rs (10 (10.0 .044 US US gal gal)) Filter wrench
1. Set a container container to catch the oil oil under under drain drain plug plug (P), (P), then then remove remove drain plug (P) and drain the oil. To prevent the oil from pouring out suddenly, loosen drain plug (P) and remove r emove it gradually. 2. After After draini draining ng the the oil, oil, instal installl drain drain plug plug (P). (P). Tightening torque: 68.6 ± 9.8 N·m (50.6 ± 7.2 lb. ft.) 3. Set a containe containerr to catch the oil under under the transmission transmission filter filter..
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MAINTENANCE 4. Remove the drain drain plug plug (1) (1) of the transmissio transmissionn filter, filter, drain the oil, oil, then tighten the plug again. 5. Using a filter wrench, wrench, turn filter cartridge cartridge (2) to the left left to remove it. 6. Clean the filter filter holder holder,, coat the seal seal surface surface and and thread thread of the the new new filter cartridge with engine oil, then install it. 7. When the seal seal surface surface comes into contac contactt with the filter filter holder holder,, tighten another 2/5 turns with the filter wrench.
8. Remove Remove the the bolts bolts (3), (3), move move the tube tube (4), (4), and then then remo remove ve the the strainer (5). 9. Remove any dirt dirt stuck stuck to the strainer strainer (5), then then wash wash it in clean clean diediesel fuel or flushing oil. If the strainer (5) is damaged, replace it with a new one. 10. Install the strainer strainer (5) in the case. case. Replace Replace the O-ring O-ring of tube (4) with a new part, then install the tube (4).
11. Pour in the specified specified amount amount of engine engine oil into into the oil filler (F). (F). 12. After filling with with oil, check check that the oil is at the specified specified level. level. For details, see “TRANSMISSION “TRANSMISSION OIL LEVEL” LEVEL” on page 3-26. 3-26. 13. Check that that there is no oil oil leakage from from the transmission transmission case case or oil filter.
CLEAN THE TRANSMISSION CASE VENT Loosen bolt (1) and remove cover (2). Remove all dirt and mud from around the breather, then remove breather (3), soak it i n flushing fluid, and wash it. After removing the breather, take steps to prevent dirt or dust from entering the mount.
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MAINTENANCE LUBRICATING POINTS 1. Using a grease grease pump, pump, pump in the grease through through the grease fittings marked by the arrows. 2. After greasing, greasing, wipe wipe off off any old grease grease that was pushed pushed out. Center hinge pin (2 points).
3. Drive Drive shaf shaftt cente centerr suppo support rt (1 poi point nt). ).
CHECKING PARTS OF TURBOCHARGER Please contact your Komatsu distributor to have the tightening portions checked.
CHECK PL AY OF TURBOCHARGER ROTOR
Please contact your Komatsu distributor to have the rotor play checked.
CHECK AND REPLACEMENT OF SERPENTINE BELT Since inspection and replacement of the fan belt requires special tools, contact your Komatsu distributor. Remark
The machine is equipped with an auto tensioner, so there is no need to adjust the tension.
If the alternator drive belt is in the following condition, the belt must be replaced. Please ask your Komatsu distributor to replace the belt. When horizontal scratch (1) crosses vertical scratch (2) When there are tears (3) in part of the belt In case (4) where there are horizontal scratches only, there is no need to replace the belt.
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MAINTENANCE
EVERY 2000 HOURS OF SERVICE Maintenance for every 50, 100, 250, 500 and 1000 hours service should be performed at the same time.
CHANGE HYDRAULIC OIL, REPLACE HYDRAULIC OIL FILTER ELEMENT
The parts and oil are at high temperature after the engine is stopped, and may cause burns. Wait for the temperature to go down before starting the work. Before removing th e oil filt er cap for filter or oi l change, clean clean the place around fil ter cap to avoid any dust or dir t from entering t he hydraulic syst em which coul d cause damage to the system. When removing the oil f iller cap, turn it s lowly to release the internal pressure, then remove it.
Refill capacity: 139 liters (36.72 US gal) 1. Lower the bucket bucket horizontally horizontally to the ground and apply apply the the parking parking brake, then stop the engine. 2. Remo Remove ve oil oil fil fille lerr cap cap (F). (F).
3. 4. 5. 6.
Set a conta containe inerr to catch catch the the oil oil under under drain drain plug plug (2). (2). Remo Remove ve drai drainn plu plugg (2) (2).. Loosen drain valve (3), then then gradually gradually pull it out to drain the oil. oil. After drainin drainingg the oil, close close drain drain valve valve (3), install and tighten tighten drain plug (2). • Tightening to torque • Drain Drain plu plugg (2): (2): 68. 68.66 ± 9.8 9.8 Nm Nm (50. (50.66 ± 7.2 7.2 ft/ ft/lbs lbs)) • Drai Drainn valve valve (3): (3): 63. 63.77 ± 14.7 14.7 Nm Nm (47. (47.00 ± 10.8 10.8 ft/l ft/lbs) bs)
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MAINTENANCE 7. Remove mounting mounting bolt bolt (5) of filter filter cover cover (4) at the the top of the tank, then remove the cover. When doing this, the cover may fly fl y off under the force of spring (6), (6) , so keep the cover pressed down when removing the bolts. 8. Remove spring (6) and and bypass bypass valve valve (7), (7), then then take out element element (8). 9. Check that there there is no foreign foreign material material inside the tank, tank, then then clean clean it. it. 10. Install new new element element (8), then set set bypass valve valve (7), spring spring (6), and cover (4) on the tank. When doing this, check the cover O-ring. If it is damaged or deteriorated, replace it.
11. Remove 6 bolts (10), then then remove remove cover cover (9). (9). 12. Pull the top of rod rod (11) from from the top and remove remove strainer strainer (12). 13. Remove any any dirt stuck to strainer strainer (12), (12), then wash it in flushing flushing oil. If strainer (12) is damaged, replace it with a new part. 14. When installing installing the cover cover bolts, bolts, push down the cover cover and tighten tighten the bolts evenly. 15. Add engine engine oil through oil oil filler port (F) to the specified specified level, level, then install cap (F). 16. Check that that the hydraulic hydraulic oil oil is at the standard standard level. For For details,see details,see “CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL” OIL” on page page 3-37. 3-37. 17. Run the engine engine at low idle, idle, and extend extend and retract retract the steering, steering, bucket, and lift arm cylinders 4 to 5 times. Be careful not to operate the cylinder to the end of its stroke (stop approx. 100mm(3.9 in) before the end of stroke). Remark
If the engine is run immediately at high speed or the cylinder is operated to the end of its stroke, the air inside the cylinder will cause damage to the piston packing.
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MAINTENANCE 18. Next, operate operate the steering, steering, bucket, bucket, and and lift arm cylinders cylinders fully 3 - 4 times, then stop the engine and loosen air bleed plug (13). After bleeding the air from the hydraulic tank, tighten plug (13). Keep the engine running at low idling when bleeding the air. 19. Check that that the hydraulic hydraulic oil is at the standard standard level. level. For details, details, see “CHECKING THE HYDRAULIC TANK OIL LEVEL AND ADDING OIL” OIL” on page page 3-37. 3-37. 20. Next, raise the engine engine speed, speed, repeat the air bleeding bleeding procedur proceduree in Step 18, and continue the operation until no more air comes out from plug (13). 21. After bleeding bleeding the air, air, tighten tighten plug plug (13). (13). • Tighte ighteni ning ng torq torque ue:: 11. 11.33 ± 1.5 1.5 Nm (8. (8.33 ± 1.1 1.1 ft/lb ft/lbs) s) 22. Check that that the hydraulic hydraulic oil is at the standard standard level. level. For details, details, see “CHECKING THE HYDRAULIC TANK TANK OIL LEVEL AND ADDING OIL” on page 3-37. 3-37. 23. Check that that there is no leakage leakage of oil oil from the filter cover cover mount. mount.
REPLACE HYDRAULIC TANK BREATHER ELEMENT
The parts and oil are at high temperature immediately after the engine is stopped, and may cause burns. Wait Wait for the temperature to go down befor e starting starting the work. When removing the oil f iller cap, turn it s lowly to release the internal pressure, then remove it.
1. Before removing removing the breather, breather, wipe off off all all the dirt from from around around the breather. 2. Remo Remove ve the the cap cap of oil oil fill filler er (F). (F). 3. Remove Remove breath breather er (1) (1) built built into the cap. cap.
4. Replace Replace the filter element element (2) built built into the breathe breatherr with a new part, then install breather (1) to the cap. 5. Tigh Tighte tenn the the cap cap of oil fille fillerr (F). (F).
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MAINTENANCE CHANGE THE AXLE OIL
When changing the oil , apply the parking brake and secure the front and rear frames with th e safety safety bar. Immediately after stoppin g th e engine, the parts parts and o il are HOT and and may c ause burns. Wait Wait f or t he temperature to go down before starting the operation. When the plug is removed, oil may spurt out. Therefore, turn the plug slowly to release the internal pressure, then remove the plug carefull y.
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Refill Refill the the capac capacity ity (fron (frontt and and rear, rear, each): each): 40 40 liters liters (10. (10.57 57 US gal) gal)
1. Set a cont contain ainer er to catc catchh the oil oil under under drai drainn plug plug (P). (P). 2. Remove front and rear rear oil oil filler filler plugs plugs (1), then remove drain plug (P) to drain the oil. Remark
Remove the mud and dirt from around the plug (1), then remove it.
3. After After drainin drainingg the oil, oil, clean clean drain drain plug (P) (P) and install install it again again.. 4. Add axle axle oil oil through through plug plug hole hole (1) (1) at the the specifi specified ed level level.. Remark
For axles with ASD (Antislip Differential), the brand of lubricating oil is different, so always use the specified lubricating oil.
5. After adding adding oil, check check that the the oil is at the the specified specified level (1). For For details, see “CHANGE THE THE AXLE OIL” on page 3-55. 3-55.
Remark
For frequent brake use, change the axle oil at shorter intervals.
AIR CONDITIONER RECIRCULATION FILTER FILTER Remove both the recirculation air filter and fresh air filter in the same way as when cleaning, and replace them with new ones. For details of cleaning the recirculation air filter, see “AIR CONDITIONER RECIRCULATION RECIRCULATION FILTER” FILTER” on page 3-55. 3-55. To clean the element, see “CLEANING THE AIR CONDITIONER FRESH AIR FILTER FILTER ELEMENT” on page 3-38. 3-38 .
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MAINTENANCE CHECKING BRAKE DISC WEAR
When checking the brake disc f or wear, apply the parking b rake and and secure the fro nt and rear frames with the safety bar. Make sure that the brake oil temperature is less than 60° C (140° F) before checking the brake wear. If the disc is near the wear wear limi t, perform insp ection at short er intervals, regardless regardless of t he specified inspection interval. interval.
Check the brake disc for wear at four locations: front axle, rear axle, left, and right. 1. Remo Remove ve the the cap cap nut nut (1) (1)..
2. Depress Depress the brake pedal, keep it depressed, depressed, and push push in the rod rod (2) of the gauge until contacts the piston. 3. The wear wear is is the amoun amountt that the the end end face face of rod rod (2) is prot protrudi ruding ng from the end face of guide (3). Measure the amount of protrusion. The point where the rod groove is level with the end face of the guide is the permissible limit for the disc wear. If the wear has reached this point, please ask your Komatsu distributor for inspection and replacement parts. If the disc is near the wear limit, perform inspection at shorter intervals, regardless of the specified inspection interval. 4. Inst Instal alll the the cap cap nut nut (1). (1). Tightening torque: 29.4 to 39.2 N·m (21.7 to 28.9 lb. ft.) Remark
On new machines, the position of the guide is adjusted so that the end face of the rod (2) comes to the end face of the guide (3). For this reason, do not loosen the locknut (4), except when replacing the disc.Perform the operation with two workers: one worker depresses the brake pedal and the other worker pushes the rod (2) in.
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MAINTENANCE CHECKING FUNCTION OF ACCUMULATOR For details of handling the accumulator, see “ACCUMULATOR” “ACCUMULATOR” on page 1-34. 1-34 .
PPC A CCUMULATOR CCUMULATOR
If the engine stops with the work equipment raised, and it is impossible to start the engine again, it is possible as an emergency measure to actuate the valve with the oil pressure stored in the accumulator and lower the work equipment to the ground. 1. Appl Applyy the the park parkin ingg brak brake. e. 2. Raise the work work equipme equipment nt to the maximum maximum height, height, then operate operate the lift arm control lever to HOLD position (b). 3. Stop top the the engin ngine. e. 4. Leave Leave the the work equi equipme pment nt lock lock lever lever in the FREE FREE positi position. on. 5. Check that the the area around around the machine machine is safe, safe, then then operate operate the the lift arm control lever to FLOAT position (d) and lower the work equipment to a point 1m above the ground. 6. When When the lift lift arm come comess to the 1m posit position, ion, retu return rn the lift lift arm arm control lever to LOWER position (c), and lower the work equipment slowly to the ground.
Remark
Carry out the check within 2 minutes after stopping the engine. If the machine is left with the engine stopped, the accumulator pressure will drop and it will be impossible to check the cause of the problem.
If the work equipment stops while it is moving, the gas pressure in the accumulator has probably dropped. Please contact your Komatsu distributor to have the accumulator inspected. Replace the accumulator every 4000 hours or every 2 years.
CHECK ALTERNATOR, STARTER STARTER MOTOR The brush may be worn or may be no grease on the bearing, so contact your Komatsu distributor for inspection or repair. If the engine is started frequently, perform an inspection every 1000 hours.
CHECK ENGINE VALVE CLEARANCE As special tool is required for removing and adjusting the parts, contact your Komatsu distributor for service.
CHECK INJECTOR See EVERY 8000 HOURS OF SERVICE
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 distributor to have the parts replaced.
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MAINTENANCE
EVERY 4000 HOURS OF SERVICE Maintenance for every 50, 100, 250, 500, 1,000 and 2,000 hours service should be performed at the same time.
LUBRICATING POINTS Perform the greasing once every two years, regardless of whether the 4, 000 hour interval has passed. 1. 2. 3. 4.
Using a grease pump, pump pump in grease through through the grease grease fittings fittings marked marked by by the arrows. arrows. After After greasing greasing,, wipe off off any any old greas greasee that that was pushe pushedd out. out. When greasing greasing set the drive drive shaft so the the grease fitting fitting is positioned positioned as shown shown by the arrow arrow view in the drawings drawings below. below. All views views are are from from the the rear rear of the the machi machine. ne.
Center drive shaft spline (1 point)
View from rear of machine Front drive shaft (2 points)
View from rear of machine
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MAINTENANCE Rear drive shaft (2 points)
View from rear of machine Center drive shaft (2 points)
View from rear of machine
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MAINTENANCE 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.
CHECK A IR CONDITIONER COMPRESSOR COMPRESSOR Ask Komatsu distributor.
REPLACE INJECTOR NOZZLE TIP Ask your Komatsu distributor to perform this work.
CHECKING FOR L OOSENESS OF HIGH-PRESSURE HIGH-PRESSURE CLAMP, CLAMP, HARDENING OF RUBBER RUBB ER Visually check and touch areas by hand to check to be sure there is no hardening of rubber parts or loose bolts for the high pressure piping pipi ng between the supply pump and the common rail. (2 ( 2 places) If there are any problems found f ound the parts must m ust be replaced. Contact your Komatsu distributor for any repairs necessary.
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MAINTENANCE CHECKING FOR MISSING FUEL SPRAY SPRAY PREVENTION CAP, CAP, HARDENING OF RUB BER Check for any missing fuel spray prevention caps (12 places) on the fuel injection piping and both ends of the high-pressure piping act to t o prevent the fuel from coming into contact with high-temperature parts of the engine and possibly causing a fire. Visually check and touch by hand for missing or loose caps. If they are damaged, deteriorated, or missing replace them with new caps. Contact your Komatsu distributor for any repairs.
WA380-6
3-61
MAINTENANCE
EVERY 8000 HOURS OF SERVICE Maintenance for every 50, 250, 500, 1000, 2000 and 4000 hours service should be performed at the same time.
REPLACE HIGH-PRESSURE PIPING CLAMP Ask your Komatsu distributor to perform this work.
REPLACE FUEL SPRAY PREVENTION CAP Ask your Komatsu distributor to perform this work.
CHECK, REPLACE INJECTOR This machine uses an engine that conforms with all exhaust gas regulations. The exhaust gas regulations differ according to the applicable area. To ensure that the engine conforms with the regulations in the area of use and can fully display its performance, keep to the following periodic maintenance intervals when check and replace the injector. If the periodic maintenance intervals are not observed correctly, the engine may not be able to display its performance fully, and it may also not conform with the regulations. When transporting a machine from an A regulation area to a B regulation area, always replace all the injector assemblies before transporting the machine to the t he new area. Check with your Komatsu distributor to confirm if your area of operation is an A regulation area or a B regulation area. EVERY 8000 HOURS SERVICE Check injector Check the exhaust gas color visually. If there is any abnormality in the exhaust gas color, please ask your Komatsu distributor to carry out inspection or replacement.
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WA380-6
SPECIFICATIONS
WA380-6
4
4-1
SPECIFICATIONS
SPECIFICATIONS MACHINE DIMENSIONS AND WEIGHTS
TIRES Tire Specifications
mm
(in)
Tread
2160
7’1”
Width over tires
2780
9’1”
A
Wheel base
3300
10’10”
B
Hinge pin height at Max. height
4095
13’5”
C
Hinge pin height at carry position
520
1’8”
D
Ground clearance
455
1’6”
E
Hitch point height
1150
3’9”
F
Overall height, top of stack
2975
9’9”
G
Overall height ROPS cab
3390
11’2”
●
4- 2
Measured with 23.5-25-16PR (L3) tires, ROPS/FOPS cab
WA380-6
SPECIFICATIONS WORK EQUIPMENT General Purpose Bolt-on Cutting Edge
Bucket
Excavating Bolt-on Cutting Edge
Light Material Bolt-on Cutting Edge
Heaped
3.3m3
4.3yd3
2.9m3
3.8yd3
4.0m3
5.2yd3
Struck
2.9m3
8.3yd3
2.4m3
3.1yd3
3.4m3
4.4yd3
Bucket width
2905mm
9’6”
2905mm
9’6”
2905mm
9’6”
Bucket weight
1620kg
3,570lb
1720mm
3,790lb
1835kg
4,045lb
Dumping clearances maximum height and 45 o dump angle
2950mm
9’8”
3045mm
10’0”
2855mm
9’4”
Reach at (7’) 2130mm 45 o dump angle
1735mm
5’8”
1055mm
3’6”
1240mm
4’1”
Reach at maximum height 45 o dump angle
1150mm
3’9”
1070mm
3’6”
1275mm
4’1”
Reach with arm horizontal and bucket level
2590mm
8’6”
2450mm
8’0”
2715mm
8’11”
Operating height Fully raised
5600mm
18’5”
5470mm
17’11”
5720mm
18’9”
Overall length Bucket on ground
8140mm
26’8”
8000mm
26’3”
8265mm
27’1”
Loader clearance circle
14440mm
45’5”
14370mm
47’2”
14500mm
47’7”
0o
60mm
2.4”
60mm
2.4”
60mm
2.4”
10o
290mm
11’4”
265mm
10.4”
315mm
1.0”
158kN
35,490lb
176kN
39,680lb
144kN
32,405lb
17580kg
38’760lb
17960kg
39,000lb
17810kg
39,620lb
Bucket capacity
Digging depth Breakout force Operating weight
TRAVEL SPEEDS
Forward Travel speed Reverse
WA380-6
1st.
km/h (MPH)
6.6 (4.1)
2nd.
km/h (MPH)
11.5 (7.2)
3rd.
km/h (MPH)
20.2 (21.3)
4th.
km/h (MPH)
34.0 (21.3)
1st.
km/h (MPH)
7.1 (4.4)
2nd.
km/h (MPH)
12.3 (7.7)
3rd.
km/h (MPH)
21.5 (13.4)
4th.
km/h (MPH)
35.5 (22.2)
4-3
SPECIFICATIONS
MACHINE SYSTEMS SPECIFICATIONS
ENGINE Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Komatsu Komatsu SAA6D107E Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-cooled, 4-cycle Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged, and air-to-air after cooled Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bore x stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 mm x 124 mm4.21" x 4.88" Piston displacemen displacement. t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.69 ltr408 in3l Horsepower rating @ 2100 rpm (SAE J1995) • Gross horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 kW192 HP Net horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 kW191 HP Hydraulic fan at maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 kW179 HP Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Rail Injection • Lubrication system Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump, pump, force-lubricati force-lubrication on Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full-flow Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . Dry-type with double radial-sealed elements and dust evacuator, plus dust indicator
4- 4
WA380-6
OPTIONS, ATTACHMENTS
WA380-6
5
5-1
OPTIONS, ATTACHMENTS
TORQUE CONVERTER LOCK-UP
When traveling down slopes of a grade of more than 6°, never never depress the accelerator pedal full y, regardless of w hether the torque conv erter lock-up sw itch is ON or OFF. OFF. It is extremely dangerous to d rive fast.
The travel speed shown in this section is the value when the tire size is 23.5-20. The travel speed when the tire size is 20.5-20 is shown in {}. The travel speed is subject to the using condition and road condition. To prevent overrunning when traveling at high speed in the following cases, do not downshift. • •
When When travelin travelingg in F3 at a spee speedd of more more than than 18 km/h km/h (11.2 (11.2 mph), mph), do not not downsh downshift ift to F2. F2. When When travelin travelingg in F4 at a speed speed of of more than than 28 28 km/h (17. (17.44 mph), mph), do not not downshif downshiftt to F3.
When the actual speed range is 3rd or 4th in either FORWARD or REVERSE, the torque converter lock-up function is actuated according to the travel speed and sets to direct dir ect drive. To prevent overrun, the lock-up is automaticall y canceled to prevent the travel speed from going above 40 km/h (24.9 mph).
GENERAL LOCATIONS
1. Torqu orquee conve converte rterr lock-u lock-upp switc switchh 2. Torque orque conver converter ter lock-u lock-upp pilot pilot lamp lamp
5- 2
3. Shift Shift indic indicato atorr (displa (displays ys actua actuall speed speed range range)) 4. Cha Charact racter er dis displ play ay
WA380-6
OPTIONS, ATTACHMENTS TORQUE CONVERTER LOCK-UP SWITCH This switch (1) is the control switch for the torque converter lock-up function. Position (a): ON The pilot lamp inside the switch lights up and the lock-up is actuated according to the travel speed. While the lock-up is engaged, the lock-up pilot lamp on the machine monitor lights l ights up. Position (b): OFF The lock-up does not function.
TORQUE CONVERTER LOCK-UP PILOT LAMP This monitor (2) lights up when the torque converter lock-up is engaged and the transmission actually enters direct drive.
METHOD OF OPERATION 1. Press the the top (a) of the torque torque converter converter lock-up lock-up switch to turn turn it ON. The pilot lamp inside the switch lights up. 2. When the actual actual speed speed range range is 3rd or 4th in either either FORW FORWARD ARD or REVERSE, the torque converter lock-up function is actuated according to the travel speed and sets to direct drive. Remark
When 4th is selected in auto-shift mode, the lock-up is not actuated in 3rd. The lock-up is actuated only in the selected 4th gear.
When the lock-up is actually actuated, the lock-up pilot lamp on the machine monitor lights up. 3.
To cancel cancel the the lock-up, lock-up, press the the bottom bottom (b) of the torque converter converter lock-up switch to turn it OFF. The lock-up is canceled.
WA380-6
5-3
OPTIONS, ATTACHMENTS •
The trave travell speed speed for actuat actuation ion and and cancel cancellati lation on of the the lock-up lock-up is is as shown shown below below.. Lock-ups
FORW FORWARD t ravel speed (km/h (mph))
REVERSE REVERSE travel speed (km/h (mph))
Speed range
Actuated
Canceled
Actuated
Canceled
3rd
13 to 15 (8.1 to 9.3) {12 to 14} (7.5 to 8.7)
13 to 14 (8.1 to 8.7) {12 to 13} (7.5 to 8.1)
14 to16 (8.7 to 9.9) {13 to 15} (8.1 to 9.3}
14 to 15 (8.7 to 9.3) {13 to 14} (8.1 to 8.7)
4th
22 to 25 (13.7 to 15.5) {20 to 23} (12.4 to 14.3)
21 (13.0) {19} (11.8)
23 to 27 (14.3 to 16.8) {21 to 25} (13.0 to 15.5)
23 (14.3) {21} (13.0)
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED TRAVEL SPEED WARNING FUNCTION (This functions even when the torque converter lock-up switch is OFF.) When the travel speed goes above 40.0 km/h (24.9 MPH) {36.5 km/h (22.7 MPH)}, the central warning lamp lights up and the alarm buzzer sounds. At the same time, “E00 OVERRUN PROTECT” is displayed on the character display. If the alarm buzzer sounds, depress the brake immediately to slow the machine down. When the travel speed goes below 39.5 km/h (24.5 MPH) {36.0 km/h (22.4)}, the alarm buzzer stops.
TRAVEL SPEED LIMIT FUNCTION (This functions only when the torque converter lock-up switch is ON.) To prevent the travel speed from going above 40.0 km/h (24.9 MPH) {36.5 km/h (22.7 MPH)}, the lock-up is automatically canceled.The lock-up cancel continues until the travel speed goes below 38.0 km/h (23.6 MPH) {35.0 km/h (21.7 MPH)}.
5- 4
WA380-6
OPTIONS, ATTACHMENTS
SELECTING BUCKET AND A ND TIRES TIRES Select the most suitable bucket and tires for the type of work and the ground conditions on the job site. Type of work
Loading products Loading and carrying products
Loading crushed rock
Bucket
Stockpile bucket (with bolt-on cutting edge) 3.3 m³ (4.3 cu. yd.) Stockpile bucket (without teeth) 3.1 m³ (4.1 cu. yd.) Light material bucket (with bolt-on cutting edge) 3.8 m³ (5.0 cu. yd.)
Excavating bucket (with segment edge) 2.7 m³ (3.5 cu. yd.)
Ground Conditions
Tire
General ground conditions
23.5-25-16PR (L3 Rock)
Leveled ground
23.5-25-16PR (L2 Traction)
Soft ground
23.5-25-16PR (L2 Traction)
General ground conditions
23.5-25-20PR (L3 Rock)
Soft ground
20.5-25-16PR (L3 Rock)
Ground with many light 23.5-25-16PR (L3 Rock) rocks Soft ground with many 23.5-25-16PR (L3 Rock) light rocks
BOC indicates a bolt-on type cutting edge. The displayed travel speed changes according to the tire size, so when installing optional tires, please contact your Komatsu distributor.
WA380-6
5-5
OPTIONS, ATTACHMENTS
USING MACHINES EQUIPPED EQUIPPED WITH K OMTRAX KOMTRAX is a machine management system that uses wireless communications. • •
•
•
A contract contract with with your your Komatsu Komatsu distributor distributor is necessa necessary ry before before the KOMTRAX system can be be used. used. Any customers customers desiring to use the KOMTRAX system should consult their Komatsu distributor. The KOMTRAX KOMTRAX equipme equipment nt is a wireless device using radio radio waves, waves, so it is necessary necessary to obtain authorizatio authorizationn and conform conform to the laws of the country or territory where the machine equipped with KOMTRAX is being used. Always contact your Komatsu distributor before selling or exporting any machine equipped with KOMTRAX. When selling selling or exporting exporting the machine machine or or at other other times when when your your Komatsu Komatsu distributor distributor conside considers rs it necessary necessary,, it may be be necessary for your Komatsu distributor to remove the KOMTRAX equipment or to carry out action to stop communications. If you do do not obey obey the above precautions, precautions, neither neither Komatsu Komatsu nor nor your Komatsu Komatsu distributor distributor can take any any responsibility responsibility for for any problem that is caused or for any loss that results.
BASIC PRECAUTIONS
●
Never disassemble, repair, modify, or move the communications terminal, antenna, or cables. This may cause failure or fi re on the KOMTRAX KOMTRAX equipm equipm ent or th e machine itself. (Your (Your Ko matsu distr ibuto r will carry out r emoval and installation of KOMTRAX.) KOMTRAX.)
●
Do not allow cables or cords to b ecome caught; caught; d o not damage or pull cables or cords by f orce. Short Short circuits or discon nected nected wir es may cause failure failure or fire on t he KOMTR KOMTRAX AX equipment or the machine itself.
●
For anyone wearing a pacemaker, pacemaker, make sure that the comm unication s antenna is at l east east 22 cm (8.7 in) fr om t he pacemaker pacemaker..
●
The radio waves may have an adverse effect on the operation of t he pacemaker pacemaker..
Remark
Even when the key in the starting switch of the KOMTRAX system is at the OFF position, a small amount of electric power is consumed. When putting the machine into long-term storage, take the action given in “BEFORE STORAGE” STORAGE” on page page 2-141. 2-141.
Contact your Komatsu distributor before installing a top guard or other attachment that covers the cab roof. Be careful not to get water on the communications terminal or wiring. The KOMTRAX system uses wireless communications, so it cannot be used inside tunnels, underground, inside buildings, or in mountain areas where radio waves cannot be received. Even when the machine is outside, it cannot be used in areas where the radio signal is weak or in areas outside the wireless communication service area. There is absolutely no need to inspect or operate the KOMTRAX communications terminal, but if any abnormality is found, please consult your Komatsu distributor. distr ibutor.
5- 6
WA380-6
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