Komatsu PW180-7E0 Manual

Operation &
Maintenance Manual
VEAM400102
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must
read this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel
who will come into contact with the machine.
PW180-7E0
WHEELED EXCAVATOR
SERIAL NUMBER
PW180-7E0 – H55051 and up

1-2 PW180-7E0 – VEAM400101

Foreword
PW180-7E0 – VEAM400102 1-1
1. Foreword

1.1 Foreword Foreword
1-2 PW180-7E0 – VEAM400102
1.1 Foreword
This manual provides rules and guidelines which will help you
use this machine safely and effectively. Keep this manual handy
and have all personnel read it periodically. If this manual has
been lost or has become dirty and can not be read, request a
replacement manual from KOMATSU or your KOMATSU distrib-
utor.
If you sell the machine, be sure to give this manual to the new
owners.
Continuing improvements in the design of this machine can lead
to changes in detail which may not be reflected in this manual.
Consult KOMATSU or your KOMATSU distributor for the latest
available information for your machine or for questions regarding
information in this manual.
WARNING
z This Operation and Maintenance Manual may contain
attachments and optional equipment that are not available in
your area. Please consult your local KOMATSU distributor
for those items you require.
z This machine complies with EC directive (89/392/EEC).
z Machines complying with this directive display the CE mark
z Improper operation and maintenance of this machine can be
hazardous and could result in serious injury or death.
z Operators and maintenance personnel should read this
manual thoroughly before beginning operation or mainte-
nance.
z Some actions involved in operation and maintenance of the
machine can cause a serious accident, if they are not done
in a manner described in this manual.
z The procedures and precautions given in this manual apply
only to intended uses of the machine. If you use your
machine for any unintended uses that are not specifically
prohibited, you must be sure that it is safe for you and oth-
ers. In no event should you or others engage in prohibited
uses or actions as described in this manual.
z KOMATSU delivers machines that comply with all applicable
regulations and standards of the country to which it has
been shipped. If this machine has been purchased in
another country or purchased from someone in another
country, it may lack certain safety devices and specifications
that are necessary for use in your country. If there is any
question about whether your product complies with the
applicable standards and regulations of your country, consult
KOMATSU or your KOMATSU distributor before operating
the machine.
z For further information, see "Safety information (1-3)" and
"Safety (2-1)".

Foreword 1.2 Safety information
PW180-7E0 – VEAM400102 1-3
1.2 Safety information
1.2.1 Safety messages
Most accidents are caused by the failure to follow fundamental
safety rules for the operation and maintenance of machines.
To avoid accidents, read, understand and follow all precautions
and warnings in this manual and on the machine before perform-
ing operation and maintenance.
To identify hazards on the machine pictorial decals are used,
see "Position for attaching safety labels (2-36)".
Red warning triangle
This is used on safety labels where there is a high probability of
serious injury or death if the hazard is not avoided. These safety
messages or labels usually describe precautions that must be
taken to avoid the hazard. Failure to avoid this hazard may also
result in serious damage to the machine.
Orange warning triangle
This is used on safety labels where there is a potentially danger-
ous situation which could result in serious injury or death if the
hazard is not avoided. These safety messages or labels usually
describe precautions that must be taken to avoid the hazard.
Failure to avoid this hazard may also result in serious damage of
the machine
Yellow safety triangle
This is used on safety labels for hazards which could result in
minor or moderate injury if the hazard is not avoided. This word
might also be used for a hazard where the only result could be
damage to the machine.
NOTE
This word is used for precautions that must be taken to avoid
actions which could shorten the life of the machine.
Safety precautions are described in "Safety (2-1)".
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 pro-
cedures and actions safely and without damaging the machine.
If you are unsure about the safety of some procedures, contact
KOMATSU or your KOMATSU distributor.

1.3 Noise emission levels Foreword
1-4 PW180-7E0 – VEAM400102
1.3 Noise emission levels
Two labels indicating the machine noise level are affixed on the
machine.
z Sound pressure level at the operator’s station, measured
according to ISO6396 (Dynamic test method, simulated
working cycle).
z Sound power level emitted by the machine, measured
according to ISO 6395 (Dynamic test method, simulated
working cycle). This is the guaranteed value as specified in
European directive 2000/14/EC.
GK018001
GK018002

Foreword 1.4 Vibration levels
PW180-7E0 – VEAM400102 1-5
1.4 Vibration levels
When used for its intended purpose, levels of vibration for the
earth-moving machine transmitted from the operator’s seat are
lower than or equal to the tested vibrations for the relative
machinery class in compliance with ISO 7096.
The actual acceleration value for the hands and arms is less
than or equal to 2.5 m/s². The actual acceleration value for the
body is less than or equal to 0.5 m/s².
These values were determined using a representative machine
and measured during the typical operating condition indicated
below according to the measurement procedures that are
defined in the standards ISO 2631/1 and ISO 5349.
Operating condition:
Excavating (Digging-loading-rotating-unloading-rotating)
1.4.1 Guide to reduce vibration levels on machine
The following guides can help an operator of this machine to
reduce the whole body vibration levels:
1. Use the correct equipment and attachments.
2. Maintain the machine according to this manual
 Tire pressures (for wheeled machines), tension of
crawler (for crawler machines)
 Brake and steering systems
 Controls, hydraulic system and linkages
3. Keep the terrain where the machine is working and traveling
in good condition
 Remove any large rocks or obstacles
 Fill any ditches and holes
 Site manager should provide machine operators with
machine and schedule time to maintain terrain condi-
tions
4. Use a seat that meets ISO 7096 and keep the seat main-
tained and adjusted
 Adjust the seat and suspension for the weight and size
of the operator
 Wear seat belt
 Inspect and maintain the seat suspension and adjust-
ment mechanisms

1.4 Vibration levels Foreword
1-6 PW180-7E0 – VEAM400102
5. Steer, brake, accelerate, shift gears (for wheeled machines),
and move the attachment levers and pedals slowly so that
the machine moves smoothly
6. Adjust the machine speed and travel path to minimize the
vibration level
 When pushing with bucket or blade, avoid sudden load-
ing; load gradually
 Drive around obstacles and rough terrain conditions
 Slow down when it is necessary to go over rough terrain
 Make the curve radius of traveling path as large as pos-
sible
 Travel at low speed when traveling around sharp curves
7. Minimize vibrations for long work cycle or long distance trav-
eling
 Reduce speed to prevent bounce
 Transport machines long distances between worksites
8. The following guidelines can be effective to minimize risks of
low back pain
 Operate the machine only when you are in good health.
 Provide breaks to reduce long periods of sitting in the
same posture
 Do not jump down from the cab or machine
 Do not repeatedly handle and lift loads

Foreword 1.5 Emergency steering
PW180-7E0 – VEAM400102 1-7
1.5 Emergency steering
This machine is equipped with an emergency steering system
and complies to ISO 5010 (BSEN 12643). In the event of failure
of the source of power for the steering system (engine failure)
whilst travelling, the machine can be steered allowing the
machine to be safely stopped.
In such a case, the effort required at the steering wheel and the
number of turns to steer the machine will increase. To confirm
function of emergency steering system, raise the front wheels off
the ground (using the work equipment) and with the engine off,
turn the steering wheel and check movement of the wheels.
1.6 Emergency braking
This machine is equipped with an emergency braking system
and complies to ISO 3450. In the event of failure of the source of
power for the braking system (engine failure) whilst travelling,
the brakes can be actuated from stored energy in the accumula-
tors to bring the machine safely to a stop.
In such a case, five brake applications can be made before
exhausting the energy in the accumulators. In the event of ser-
vice brake failure, the park brake can be used as an emergency
brake to bring the machine to a stop.

1.7 Introduction Foreword
1-8 PW180-7E0 – VEAM400102
1.7 Introduction
1.7.1 Intended use
This KOMATSU HYDRAULIC EXCAVATOR is designed to be
used mainly for the following work:
z Digging
z Smoothing work
z Ditching work
z Loading work
See the section "Work possible using hydraulic excavator
(3-141)" for further details.
1.7.2 Features
z This KOMATSU HYDRAULIC EXCAVATOR is equipped with
various controls based on an advanced electronics system.
z The monitor panel greatly facilitates daily maintenance and
self-diagnosis.
z Working mode and travel speed are selectable.
z Digging and lifting force can be increased by light-touch con-
trol. (For details, see operation section.)
z Adjustable wrist control levers make operations smooth and
easy.
z Fresh filtered air conditioner assures comfortable operation.
z Low noise level and smart urban style design and coloring.
z Superb operation performance provided by powerful engine
(to European stage 3a regulations and EPA tier 3) and high-
performance hydraulic pump.
z Low fuel consumption controlled by an electronic control
system provides an environment-friendly machine.
z Sophisticated drive train provides fast and smooth travelling
on the highway and off road.
z Proportional control HCU circuits.
z Quick coupler facility.

Foreword 1.7 Introduction
PW180-7E0 – VEAM400102 1-9
1.7.3 Running in your new 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 run in the machine for the initial 100 hours (as indi-
cated by the hour meter).
During running in:
z Idle the engine for 5 minutes after starting it up.
z Avoid operation with heavy loads or at high speeds.
z Sudden starting or acceleration, unnecessarily abrupt brak-
ing and sharp turning should be avoided except in cases of
emergency.
Additionally for the first 20 hours:
z Avoid operating engine for prolonged periods at constant
speed (including idle).
z Avoid high speed travelling for periods of more than 5 min-
utes.
Pay particular attention to oil pressure and temperature indica-
tors and check coolant and oil levels frequently during breaking
in.
The precautions given in this manual for operating, mainte-
nance, and safety procedures are only those that apply when
this product is used for the specified purpose. If the machine is
used for a purpose that is not listed in this manual, KOMATSU
cannot bear any responsibility for safety. All consideration of
safety in such operations is the responsibility of the user.
Operations that are prohibited in this manual must never be car-
ried out under any circumstances.

1.8 Locations of plates, table to enter serial no. and distributor Foreword
1-10 PW180-7E0 – VEAM400102
1.8 Locations of plates, table to enter serial no. and
distributor
1.8.1 Machine serial no. plate position
On the front right of the undercarriage.
1.8.2 Engine serial no. plate position
On the top of the engine.
1.8.3 Table to enter serial no. and distributor
Machine serial No.
Engine serial No.
Product identification number
Manufacturer’s name
Address
KOMATSU Hanomag GmbH
Hanomagstr. 9
D-30449 Hannover
Germany
Distributor
Address
Phone

Foreword 1.8 Locations of plates, table to enter serial no. and distributor
PW180-7E0 – VEAM400102 1-11
1.8.4 Machine serial plates
Model
Serial number
Manufacturing year
Manufactured by KOMATSU Hanomag GmbH for KOMATSU Ltd.
Weight
Engine power
Product
Identification Number

1.9 Contents Foreword
1-12 PW180-7E0 – VEAM400102
1.9 Contents
1. Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2.1 Safety messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3 Noise emission levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.4 Vibration levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4.1 Guide to reduce vibration levels on machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.5 Emergency steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.6 Emergency braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.7 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.7.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.7.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1.7.3 Running in your new machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.8 Locations of plates, table to enter serial no. and distributor . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8.1 Machine serial no. plate position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8.2 Engine serial no. plate position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8.3 Table to enter serial no. and distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.8.4 Machine serial plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.9 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Safety features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Clothing and personal protective items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Unauthorised modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Always apply (raise) safety lock lever when leaving operator’s seat. . . . . . . . . . . . . . . . 2-3
Always chock the wheels before going under the machine. . . . . . . . . . . . . . . . . . . . . . . 2-4
Mounting and dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Fire prevention for fuel and oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Precautions when handling at high temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Machines fitted with wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Asbestos dust hazard prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Crushing or cutting prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Fire extinguisher and first aid kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Protection against falling or flying objects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Precautions for attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Precautions for accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Rotating beacon (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Electromagnetic interference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Foreword 1.9 Contents
PW180-7E0 – VEAM400102 1-13
2.2 Precaution during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
2.2.1 Before starting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Safety at worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
In operator’s cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Ventilation for enclosed areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Precautions for mirrors, windows and lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.2.2 Operating machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
When starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Check direction before starting machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Check that no one is in the area before swinging or travelling in reverse . . . . . . . . . . 2-14
Precautions when travelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Travelling on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Prohibited operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Do not go close to high-voltage cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Do not hit work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Ensure good visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Operate carefully on snow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Working on loose ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Do not hit the operator cab (for two piece boom only) . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Operations on slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Parking the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2.2.3 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Loading and unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2.2.4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Battery hazard prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Starting with booster cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2.2.5 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
When towing, attach wire to frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
View on transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2.2.6 Bucket with hook or bucket link with lifting eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
General precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Precautions for lifting operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2.2.7 Handling of fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Handling of used engine oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Handling of oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Handling of fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2.3 Precautions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2.3.1 Before carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Warning tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Proper tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Periodic replacement of safety critical parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Stop the engine before carrying out inspection and maintenance . . . . . . . . . . . . . . . . 2-31
Rules to follow when adding fuel or oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Radiator water level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Use of lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

1.9 Contents Foreword
1-14 PW180-7E0 – VEAM400102
2.3.2 During maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Work under the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Keep the machine clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Precautions with battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Handling high-pressure hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Precautions with high pressure oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Precautions when carrying out maintenance at high temperature or
high pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Rotating fan and belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Waste materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.4 Position for attaching safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.4.1 Position for attaching safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
2.5 Lifting capacity chart PW180-7E0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2.5.1 One piece boom – Lift capacity tables for 2.5 metre undercarriage . . . . . . . . . . . . . . . 2-44
2.5.2 One piece boom – Lift capacity tables for 2.75 metre undercarriage . . . . . . . . . . . . . . 2-50
2.5.3 Two piece boom – Lift capacity tables for 2.5 metre undercarriage . . . . . . . . . . . . . . . 2-56
2.5.4 Two piece boom – Lift capacity tables for 2.75 metre undercarriage . . . . . . . . . . . . . . 2-62
2.6 Overload caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
2.6.1 Monoboom – Overload caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
2.6.2 Two piece boom – Overload caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
3. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 General view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.1 General view of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.2 General view of controls and gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2 Explanation of components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.1 Machine monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.2.2 Basic operation of machine monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
If there is abnormality when starting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
If any abnormality occurs during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.3 Basic check items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.3.1 Caution items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.3.2 Emergency stop items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.3.3 Meter display portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Monitor switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Adjustment screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
3.4 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
3.5 Control levers, pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54

Foreword 1.9 Contents
PW180-7E0 – VEAM400102 1-15
3.6 Front window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
When opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
When closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64
Removing front bottom window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-65
3.7 Emergency exit from operator’s cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Ceiling window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Clear rain visor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
Pull down sun visor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
Door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
3.8 Cap, cover with lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
3.8.1 Method of opening and closing cap with lock (for the fuel tank filler port) . . . . . . . . . . 3-68
3.8.2 Method of opening and closing cover with lock (cover with lock). . . . . . . . . . . . . . . . . 3-69
3.9 Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3.9.1 Fuse box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
3.9.2 Fuse Box 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
3.10 Luggage tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3.11 Ashtray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3.12 Cup holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
3.13 Hot and cool box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3.14 Cab radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3.15 Power pick-up port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-74
3.16 Handling air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.16.1 General locations of control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-75
3.16.2 Method of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Automatic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Stopping automatic operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Stopping manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Operation with cold air to face and warm air to feet. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-84
Defroster operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-85
3.16.3 Precautions when using air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-87
3.16.4 Check, maintain machine equipped with air conditioner . . . . . . . . . . . . . . . . . . . . . . . 3-88
3.16.5 Other functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Self-diagnostic function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-88
Switch set temperature display between °F and °C . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-89
3.17 Fusible link. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3.18 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90
3.19 Tool box (chassis) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-90

1.9 Contents Foreword
1-16 PW180-7E0 – VEAM400102
3.20 Refuelling pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3.20.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3.20.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91
3.20.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-92
3.21 Warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-93
3.22 Handling accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.22.1 Control circuit accumulator (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94
3.22.2 Clutch control accumulator (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.22.3 Brake circuit accumulators (C) × 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-95
3.23 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.23.1 Check before starting engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
Walk-around check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-96
3.23.2 Check before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Check coolant level, add water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-98
Check oil level in engine oil pan, add oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-99
Check fuel level, add fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-100
Check oil level in hydraulic tank, add oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-101
Check air cleaner for clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
Check electric wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-102
Check function of horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103
Check for water and sediment in water separator, drain water . . . . . . . . . . . . . . . . . . 3-103
3.23.3 Adjustment of operator’s seat (air suspension seat) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-105
3.23.4 Rearview mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-107
3.23.5 Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
Fastening and removing seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-108
3.23.6 Adjustment of operator’s seat (mechanical seat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
Seat belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-109
3.23.7 Operations and checks before starting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-110
3.23.8 Starting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-112
Starting in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-113
Operations and checks after starting engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-114
Warming up operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-115
In cold areas (automatic warming-up operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-118
3.23.9 Moving machine off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
Moving machine forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-122
3.23.10 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-125
3.23.11 Travelling on public highway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-126
3.23.12 Stopping and parking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-127
Stopping machine (emergency). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-128
3.23.13 Swinging (slewing the upper carriage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-129
3.23.14 Operation of work equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-130
Operation of dozer and outriggers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-132
Precautions for using the dozer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133
3.23.15 Working mode selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
Working mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134
One touch power max switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-134

Foreword 1.9 Contents
PW180-7E0 – VEAM400102 1-17
3.23.16 Prohibitions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-135
3.23.17 Precautions for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-137
3.23.18 Recommendations for travelling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-138
3.23.19 Precautions when travelling up or down hills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-139
3.23.20 How to escape from mud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
When one side is stuck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
When both sides are stuck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-140
3.23.21 Work possible using hydraulic excavator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
Backhoe work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
Shovel work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
Ditching work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-141
Loading work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
Levelling work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-142
3.23.22 Replacement and inversion of bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-143
Inversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-144
3.23.23 Stopping engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
Check after finishing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-145
3.23.24 Check after stopping engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
Locking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
Handling the wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-146
3.24 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
3.24.1 Transportation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
3.24.2 Loading, unloading work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-151
3.24.3 Securing machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154
3.24.4 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-155
3.24.5 How to lift the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-157
3.24.6 Precautions for transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-159
3.24.7 Travelling posture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-161
3.25 Cold weather operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
3.25.1 Precautions for low temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
Fuel and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-164
3.25.2 Precautions after completion of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-165
3.25.3 After cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-165
3.26 Long-term storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
3.26.1 Before storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
3.26.2 During storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-166
3.26.3 After storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-167
3.26.4 Starting machine after long-term storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-167
3.27 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168
3.27.1 Phenomena that are not failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-168
3.28 Method of towing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-169
3.29 Precautions on particular jobsites. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-170

1.9 Contents Foreword
1-18 PW180-7E0 – VEAM400102
3.30 Discharged battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-171
3.30.1 Removal and installation of battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-172
3.30.2 Battery charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-172
3.30.3 Starting engine with booster cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-173
Connecting and disconnecting booster cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-173
Booster cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-174
Starting the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-174
Booster cable disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-175
3.31 Other trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-176
3.31.1 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-176
3.31.2 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-177
3.31.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-178
3.31.4 Electronic control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-180
4. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Guides to maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2 Outline of service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.2.1 Outline of oil, fuel, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Grease. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Carrying out KOWA (KOMATSU Oil Wear Analysis) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
KOWA analysis items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Oil sampling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Storing oil and fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.2.2 Outline of electric system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.2.3 Outline of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.3 Wear parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.4 Use fuel, coolant and lubricants according to ambient temperature . . . . . . . . . . . . . . . . . . 4-16
4.4.1 Proper selection of fuel, coolant and lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.5 Recommended brands, recommended quality for products other than KOMATSU
genuine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.6 Standard tightening torques for bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.6.1 Introduction of necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.6.2 Tightening torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Tightening torque list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.7 Periodic replacement of safety critical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.7.1 Safety critical parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.8 Maintenance schedule chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.9 Key to lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.10 Maintenance interval for hydraulic breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30