Komatsu — CONTENTS

FOREWORD CONTENTS GREASE................................................................................................................................................... 4-5 CARRYING OUT KOWA (Komatsu Oil Wear Analysis) ........................................................................... 4-5 STORING OIL AND FUEL........................................................................................................................ 4-6 FILTERS ...................................................................................................................................................

4-6 BIODEGRADABLE HYDRAULIC OIL AND LUBRICANTS ...................................................................... 4-7 OUTLINE OF ELECTRIC SYSTEM............................................................................................................... 4-7 WEAR PARTS .................................................................................................................................................... 4-8 WEAR PARTS LIST.......................................................................................................................................

4-8 FUEL, COOLANT AND LUBRICANTS .............................................................................................................. 4-9 LUBRICATION CHART ................................................................................................................................. 4-9 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS ............................................................ 4-10 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS ................................................................... 4-15 TORQUE LIST.............................................................................................................................................

4-15 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS ........................................................................ 4-16 MAINTENANCE SCHEDULE CHART ............................................................................................................. 4-17 MAINTENANCE SCHEDULE CHART......................................................................................................... 4-17 SERVICE PROCEDURE ..................................................................................................................................

4-19 INITIAL 250 HOURS SERVICE................................................................................................................... 4-19 WHEN REQUIRED...................................................................................................................................... 4-20 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ................................................................. 4-20 DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN....................................................................... 4-22 CLEAN INSIDE OF COOLING SYSTEM................................................................................................

4-23 CHECK OIL LEVEL IN TRANSFER CASE, ADD OIL ............................................................................ 4-26 CHECK AXLE OIL LEVEL, ADD OIL...................................................................................................... 4-27 CLEAN AXLE CASE BREATHER .......................................................................................................... 4-28 CLEAN AIR CONDITIONER CONDENSER........................................................................................... 4-29 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID....................................................................

4-29 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 .................................................................................................. 4-32 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 LUBRICATE REAR AXLE PIVOT PIN.................................................................................................... 4-40 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER........................................................... 4-40 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...........................................................................

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 BOLTS, TIGHTEN ........................................................................

4-45 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER ................................................ 4-46 LUBRICATING........................................................................................................................................ 4-46 EVERY 500 HOURS SERVICE................................................................................................................... 4-48 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE ........................... 4-48 REPLACE FUEL FILTER CARTRIDGE .................................................................................................

4-49 CLEAN WATER SEPARATOR STRAINER............................................................................................ 4-50 EVERY 1000 HOURS SERVICE ................................................................................................................. 4-51 CHANGE OIL IN TRANSFER CASE...................................................................................................... 4-51 CLEAN TRANSFER CASE BREATHER ................................................................................................ 4-52 REPLACE HST OIL FILTER ELEMENT.................................................................................................

4-53 LUBRICATING........................................................................................................................................ 4-54 CHECK TIGHTENING PARTS OF TURBOCHARGER.......................................................................... 4-54 1-13