Komatsu — Contents

FOREWORD Contents Table to enter serial No. and distributor Grease ........................................................................................................................................................ 4-4 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 .............................................................................................

4-11 Torque list ...................................................................................................................................................... 4-11 Periodic replacement of safety critical parts .................................................................................................. 4-13 Safety critical parts......................................................................................................................................... 4-13 Maintenance schedule chart ............................................................................................................................

4-15 Maintenance schedule chart.......................................................................................................................... 4-15 Service procedure ............................................................................................................................................. 4-17 Initial 50 hours service (only after the first 50 hours) ..................................................................................... 4-17 Check for loose wheel hub bolts, tighten ..................................................................................................

4-17 Initial 250 hours service (only after the first 250 hours) ................................................................................. 4-17 When required ............................................................................................................................................... 4-18 Check, clean, or replace air cleaner element............................................................................................ 4-18 Dust pre-extractor "Turbo II": check, clean ...............................................................................................

4-21 Clean inside of cooling system ................................................................................................................. 4-22 Check oil level in transfer case, add oil..................................................................................................... 4-25 Check axle oil level, add oil....................................................................................................................... 4-26 Clean axle case breather..........................................................................................................................

4-27 Clean air conditioner condenser ............................................................................................................... 4-27 Check window washing fluid level, add fluid............................................................................................. 4-28 Clean radiator fins and cooler fins ............................................................................................................ 4-28 Clean transfer oil cooler fins .....................................................................................................................

4-29 Check electrical intake air heater.............................................................................................................. 4-29 Replace bolt on cutting edge .................................................................................................................... 4-29 Replace bucket teeth ................................................................................................................................ 4-30 Check air conditioner ................................................................................................................................

4-31 Replace slow blow fuse ............................................................................................................................ 4-32 Selection and inspection of tires ............................................................................................................... 4-33 Check before starting..................................................................................................................................... 4-35 Every 50 hours service ..................................................................................................................................

4-35 Drain water, sediment from fuel tank ........................................................................................................ 4-35 Every 100 hours service ................................................................................................................................ 4-36 Lubricate rear axle pivot pin...................................................................................................................... 4-36 Clean element in air conditioner fresh air filter..........................................................................................

4-36 Check oil level in hydraulic tank, add oil ................................................................................................... 4-37 Every 250 hours service ................................................................................................................................ 4-38 Check battery electrolyte level.................................................................................................................. 4-38 Check parking brake.................................................................................................................................

4-40 Check air conditioner compressor belt tension, adjust ............................................................................. 4-40 Check for loose wheel hub bolts, tighten .................................................................................................. 4-41 Clean element in air conditioner recirculation filter ................................................................................... 4-42 Lubricating ................................................................................................................................................

4-43 Every 500 hours service ................................................................................................................................ 4-44 Change oil in engine oil pan, replace engine oil filter cartridge................................................................. 4-44 Replace fuel filter cartridge ....................................................................................................................... 4-45 Clean water separator strainer..................................................................................................................

4-46 Every 1000 hours service .............................................................................................................................. 4-47 Change oil in transfer case ....................................................................................................................... 4-47 1-13