Komatsu — CONTENTS

FOREWORD CONTENTS FUEL, COOLANT AND LUBRICANTS ................................................................................................................ 4-8 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ................................................................ 4-8 STANDARD TIGHTENING TORQUES .............................................................................................................. 4-13 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-14 MAINTENANCE SCHEDULE CHART ...............................................................................................................

4-16 MAINTENANCE SCHEDULE CHART........................................................................................................... 4-16 SERVICE PROCEDURE .................................................................................................................................... 4-18 INITIAL 250 HOURS SERVICE..................................................................................................................... 4-18 INITIAL 1000 HOURS SERVICE...................................................................................................................

4-18 WHEN REQUIRED........................................................................................................................................ 4-19 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ................................................................... 4-19 CLEAN INSIDE OF COOLING SYSTEM.................................................................................................. 4-22 CHECK WATER SEPARATOR ................................................................................................................ 4-25 CHECK TRANSMISSION OIL LEVEL, ADD OIL......................................................................................

4-26 CHECK AXLE OIL LEVEL, ADD OIL........................................................................................................ 4-27 CLEAN AXLE CASE BREATHER ............................................................................................................ 4-28 CLEAN CONDENSER OF AIR CONDITIONER....................................................................................... 4-28 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...................................................................... 4-29 CLEAN RADIATOR FINS AND COOLER FINS .......................................................................................

4-29 CHECK ELECTRICAL INTAKE AIR HEATER.......................................................................................... 4-32 REPLACE BOLT ON CUTTING EDGE .................................................................................................... 4-32 REPLACE BUCKET TEETH..................................................................................................................... 4-33 CHECK AIR CONDITIONER .................................................................................................................... 4-34 REPLACE SLOW-BLOW FUSE ...............................................................................................................

4-35 SELECTION AND INSPECTION OF TIRES ............................................................................................ 4-36 CHECK BEFORE STARTING ....................................................................................................................... 4-38 EVERY 50 HOURS SERVICE....................................................................................................................... 4-39 DRAIN WATER, SEDIMENT FROM FUEL TANK.................................................................................... 4-39 EVERY 100 HOURS SERVICE.....................................................................................................................

4-40 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL............................................................................. 4-40 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER............................................................. 4-41 EVERY 250 HOURS SERVICE..................................................................................................................... 4-42 CHECK BATTERY ELECTROLYTE LEVEL............................................................................................. 4-42 CHECK PARKING BRAKE.......................................................................................................................

4-44 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST .............................................. 4-44 CHECK FOR LOOSE WHEEL HUB NUTS, TIGHTEN ............................................................................ 4-45 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER .................................................. 4-45 EVERY 500 HOURS SERVICE..................................................................................................................... 4-46 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE .............................

4-46 REPLACE FUEL FILTER CARTRIDGE ................................................................................................... 4-47 EVERY 1000 HOURS SERVICE................................................................................................................... 4-48 CHANGE TRANSMISSION OIL AND FILTER, CLEAN STRAINER ........................................................ 4-48 CLEAN TRANSMISSION CASE BREATHER .......................................................................................... 4-49 CHECK TIGHTENING PARTS OF TURBOCHARGER............................................................................

4-49 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................ 4-49 CHECK ALTERNATOR DRIVING BELT TENSION AND REPLACEMENT............................................. 4-49 REPLACE CORROSION RESISTOR CARTRIDGE ................................................................................ 4-49 EVERY 2000 HOURS SERVICE................................................................................................................... 4-50 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT...............................

4-50 REPLACE HYDRAULIC TANK BREATHER ELEMENT .......................................................................... 4-52 CHANGE AXLE OIL.................................................................................................................................. 4-53 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER.... 4-53 CLEAN PPC CIRCUIT STRAINER........................................................................................................... 4-54 CLEAN ENGINE BREATHER ELEMENT.................................................................................................

4-54 CHEK ALTERNATOR, STARTING MOTOR ............................................................................................ 4-54 CHECK ENGINE VALVE CLEARANCE, ADJUST................................................................................... 4-54 CLEAN AND CHECK TURBOCHARGER ................................................................................................ 4-54 CHECK INJECTOR .................................................................................................................................. 4-55 CHECK ACCUMULATOR GAS PRESSURE ........................................................................................... 4-55 1-11