Komatsu — Contents

Contents FOREWORD Carrying out KOWA (Komatsu Oil Wear Analysis) ..................................................................................... 4-5 Storing oil and fuel ...................................................................................................................................... 4-5 Filters .......................................................................................................................................................... 4-6 Biodegradable hydraulic oil and lubricants .................................................................................................

4-6 Outline of electric system................................................................................................................................. 4-6 Wear parts ............................................................................................................................................................ 4-7 Wear parts list .................................................................................................................................................. 4-7 Fuel, coolant and lubricants ..............................................................................................................................

4-8 Lubrication chart............................................................................................................................................... 4-8 Proper selection of fuel, coolant and lubricants ............................................................................................... 4-9 Standard tightening torques for bolts and nuts ............................................................................................. 4-13 Torque list ......................................................................................................................................................

4-13 Periodic replacement of safety critical parts .................................................................................................. 4-15 Safety critical parts......................................................................................................................................... 4-15 Maintenance schedule chart ............................................................................................................................ 4-17 Maintenance schedule chart ..........................................................................................................................

4-17 Service procedure ............................................................................................................................................. 4-19 Initial 250 hours service (only after the first 250 hours) ................................................................................. 4-19 When required................................................................................................................................................ 4-20 Check, clean, or replace air cleaner element............................................................................................ 4-20 Dust pre-extractor "Turbo II":

check, clean ............................................................................................... 4-23 Clean inside of cooling system ................................................................................................................. 4-24 Check oil level in transfer case, add oil..................................................................................................... 4-27 Check axle oil level, add oil.......................................................................................................................

4-28 Clean axle case breather .......................................................................................................................... 4-29 Clean air conditioner condenser ............................................................................................................... 4-29 Check window washing fluid level, add fluid ............................................................................................. 4-30 Clean radiator fins and cooler fins ............................................................................................................

4-30 Clean transfer oil cooler fins ..................................................................................................................... 4-31 Check electrical intake air heater.............................................................................................................. 4-31 Replace bolt on cutting edge .................................................................................................................... 4-31 Replace bucket teeth ................................................................................................................................

4-32 Check air conditioner ................................................................................................................................ 4-33 Replace slow blow fuse ............................................................................................................................ 4-34 Selection and inspection of tires ............................................................................................................... 4-35 Check before starting.....................................................................................................................................

4-37 Every 50 hours service................................................................................................................................... 4-38 Drain water, sediment from fuel tank ........................................................................................................ 4-38 Every 100 hours service................................................................................................................................. 4-39 Lubricate rear axle pivot pin......................................................................................................................

4-39 Clean element in air conditioner fresh air filter.......................................................................................... 4-39 Check oil level in hydraulic tank, add oil ................................................................................................... 4-40 Every 250 hours service................................................................................................................................. 4-41 Check battery electrolyte level ..................................................................................................................

4-41 Check parking brake ................................................................................................................................. 4-43 Check air conditioner compressor belt tension, adjust ............................................................................. 4-43 Check for loose wheel hub bolts, tighten .................................................................................................. 4-44 Clean element in air conditioner recirculation filter ...................................................................................

4-45 Lubricating ................................................................................................................................................ 4-46 Every 500 hours service................................................................................................................................. 4-47 Change oil in engine oil pan, replace engine oil filter cartridge................................................................. 4-47 Replace fuel filter cartridge .......................................................................................................................

4-48 Every 1000 hours service............................................................................................................................... 4-49 Change oil in transfer case ....................................................................................................................... 4-49 Clean transfer case breather .................................................................................................................... 4-50 Replace HST oil filter element ..................................................................................................................

4-51 Lubricating ................................................................................................................................................ 4-52 Check tightening parts of turbocharger..................................................................................................... 4-52 1-12