Komatsu — CONTENTS

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

4-6 FILTERS ..................................................................................................................................................... 4-6 OUTLINE OF ELECTRIC SYSTEM................................................................................................................. 4-6 WEAR PARTS LIST ............................................................................................................................................. 4-7 THE PARTS IN PARENTHESES ARE TO BE REPLACED AT THE SAME TIME. ........................................

4-7 LUBRICANTS AND OPERATING MEANS .......................................................................................................... 4-8 LUBRICATION CHART ................................................................................................................................... 4-8 LUBRICANTS, FUELS AND FILLING CAPACITIES ....................................................................................... 4-9 STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS .....................................................................

4-13 TORQUE LIST............................................................................................................................................... 4-13 PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS .......................................................................... 4-14 MAINTENANCE SCHEDULE CHART ............................................................................................................... 4-15 MAINTENANCE SCHEDULE CHART...........................................................................................................

4-15 SERVICE PROCEDURE .................................................................................................................................... 4-17 INITIAL 250 HOURS SERVICE..................................................................................................................... 4-17 WHEN REQUIRED........................................................................................................................................ 4-18 CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT ...................................................................

4-18 CLEAN INSIDE OF COOLING SYSTEM.................................................................................................. 4-21 CHECK TRANSMISSION OIL LEVEL, ADD OIL...................................................................................... 4-24 CHECK AXLE OIL LEVEL, ADD OIL........................................................................................................ 4-25 CHECK AXLE CASE BREATHER............................................................................................................ 4-26 CLEAN CONDENSER OF AIR CONDENSER.........................................................................................

4-26 CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID...................................................................... 4-27 CLEAN RADIATOR FINS AND COOLER FINS ....................................................................................... 4-28 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 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL............................................................................. 4-39 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.............................................................

4-40 EVERY 250 HOURS SERVICE..................................................................................................................... 4-41 CHECK ENGINE ELECTROLYTE LEVEL ............................................................................................... 4-41 CHECK PARKING BRAKE....................................................................................................................... 4-42 CHECK ALTERNATOR BELT TENSION, ADJUST ................................................................................. 4-43 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST ..............................................

4-44 CHECK FOR LOOSE WHEEL HAB NUTS, TIGHTEN............................................................................. 4-44 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 CLEAN FUEL STRAINER......................................................................................................................... 4-49 EVERY 1000 HOURS SERVICE ................................................................................................................... 4-50 CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER................................................................................................................................................ 4-50 CLEAN TRANSMISSION CASE BREATHER ..........................................................................................

4-51 CHECK TIGTENING PARTS OF TURBOCHARGER .............................................................................. 4-51 CHECK PLAY OF TURBOCHARGER ROTOR........................................................................................ 4-51 REPLACE CORROSION RESISTOR CARTRIDGE ................................................................................ 4-51 EVERY 2000 HOURS SERVICE ................................................................................................................... 4-52 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT............................... 4-52 1-13