MAINTENANCE SCHEDULE MAINTENANCE MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE CHART INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) CLEAN PTO LUBRICATION OIL FILTER STRAINER INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) ‘CHANGE OIL IN SWING MACHINERY CASE CHANGE OIL IN PTO CASE CHANGE OIL IN FINAL DRIVE CASE INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS) CHECK WELDED STRUCTURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT CLEAN INSIDE OF COOLING SYSTEM CHECK AND TIGHTEN TRACK SHOE BOLTS - CHECK AND ADJUST TRACK TENSION- REPLACE BUCKET TEETH (XS) ‘(CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID - CHECK AND MAINTENANCE AIR CONDITIONER CLEAN LINE FILTER, REMOVE DIRT CHECK SEALS AROUND ENGINE COOLING BLEEDING AIR FROM FULE CIRCUIT BLEEDING AIR FROM HYDRAULIC SYSTEM METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT INSPECTION OF ADDITIONAL WATER SEPARATOR AND CLEANING OF CASING INTERIOR - ‘CHECKS BEFORE STARTING EVERY 250 HOURS MAINTENANCE CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL. CHECK LEVEL OF BATTERY ELECTROLYTE - CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST ~ CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER) EVERY 500 HOURS MAINTENANCE CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS - CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS CLEAN, REPLACE HYDRAULIC PUMP DRAIN FILTER - REPLACE SWING, TRAVEL MOTOR DRAIN FILTER CARTRIDGE - REPLACE PILOT FILTER CARTRIDGE CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL, REPLACE FUEL PREFILTER CARTRIDGE 22. 22 22. 22. 22 23 30 - 33 34 - 39 45 46 48 49 50 54 66 68 n 72 75 76 78 80 83 86 88 88 89 90 1MAINTENANCE MAINTENANCE SCHEDULE EVERY 1000 HOURS MAINTENANCE REPLACE FUEL MAIN FILTER CARTRIDGE REPLACE FUEL TANK BREATHER ELEMENT ~ CHANGE OIL IN SWING MACHINERY CASE CHANGE OIL IN PTO CASE CLEAN PTO LUBRICATION OIL FILTER STRAINER ~ REPLACE HYDRAULIC OIL FILTER ELEMENT REPLACE HYDRAULIC TANK BREATHER FILTER ELEMENT - INSPECTION OF ENGINE SUCTION HOSE CLAMP FOR LOOSENING CHECK FOR LOOSE CLAMPS OF AFTERCOOLER HOSE CHECK GAS PRESSURE IN ACCUMULATOR FOR OPERATION CONTROL CIRCUIT CHECK WELDED STRUCTURE CHECK EMERGENCY LADDER GREASING HYDRAULIC LADDER. REPLACE SWING MOTOR COOLING FILTER ELEMENT EVERY 2000 HOURS MAINTENANCE CHANGE OIL IN FINAL DRIVE CASE CHECK GREASE LEVEL IN SWING PINION, ADD GREASE CHECK ALTERNATOR, STARTING MOTOR CHECK ENGINE VALVE CLEARANCE, ADJUST EVERY 4000 HOURS MAINTENANCE GREASE ENGINE MOUNT (FRONT SIDE) CHECK WATER PUMP CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER -. REPLACE ACCUMULATOR IN OIL COOLER CIRCUIT EVERY 5000 HOURS MAINTENANCE CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER-- EVERY 8000 HOURS MAINTENANCE REPLACE INJECTOR NOZZLE ASSEMBLY REPLACE HIGH-PRESSURE PIPING CLAMP -. REPLACE FUEL SPRAY PREVENTION CAP 4 94 4.97 4 98 4-100 4-102 4-103 4-104 4-105 4-108 4.107 4-108 4a 4112 4113 4417 4118 4118 4118 4.122 4119 4-120 4121 4.122 4.123 4127 4127 4427MAINTENANCE PROCEDURE MAINTENANCE MAINTENANCE PROCEDURE INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS) Carry out the following maintenance only after the first 100 hours of operation on new machines. + Clean strainer of PTO lubricating oil fiter For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE. INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS) Perform the following maintenance only after the first 500 hours of operation on new machines. + Change olin swing machinery case + Change oil in PTO case + Change olin final drive case For details of the method of replacing or maintaining, see EVERY 1000 HOURS and EVERY 2000 HOURS SERVICE, INITIAL 4000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 4000 HOURS) Carry out the following maintenance only after the first 4000 hours of operation on new machines. + Check welded structure For details of the method of replacing or maintaining, see the section on EVERY 1000 HOURS SERVICE.MAINTENANCE MAINTENANCE PROCEDURE WHEN REQUIRED CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT WARNING ‘+ When using compressed air there is danger of dir flying and causing personal injury. Always wear protective glasses, dust mask, or other protective equipment. ‘+ When removing the outer element from the ar cleaner body, itis dangerous to pull tout by force. When working in high places ‘or where the foothold is poor, be careful not to fall because of the reaction when pulling out the outer element. NOTICE * Do not clean the air cleaner element until the air cleaner clogging monitor on the machine monitor light up. Ifthe element is, cleaned frequently before the ar cleaner clogging monitor light up, the air cleaner will not be able to display its performance fully, and the cleaning efficiency will also go down. In addition, during the cleaning operation, more dirt stuck to the element will fall inside the inner element. * If inspection, cleaning, or maintenance is performed with the engine running, dirt wil enter the engine and cause damage to the engine. Always stop the engine before performing these operations. Checking Ifaircleaner clogging monitor (1) of the machine monitor lights up, clean the air cleaner element.MAINTENANCE PROCEDURE MAINTENANCE Replace element, O-ring ‘When one year has passed since the element was installed, orf air cleaner clogging monitor (1) on the monitor panel lights up immediately after it has been cleaned, replace external element (6), internal element (6), and O-ring (8). REMARK Use dust indicator (4) as a guideline for the cleaning interval for the air cleaner element. If tip (D) of the yellow piston enters the red range (7.5 kPa) (E), it is time to clean the element, + There are 2 dust indicators (4): they can be seen when the door of the power container at the front of the machine is opened.MAINTENANCE MAINTENANCE PROCEDURE Cleaning Outer Element NOTICE Before and after cleaning the element, do not leave or keep It in direct sunlight. 1, Remove hooks (2) of each air cleaner (6 places), then remove cover (3), NOTICE * Never remove the inner element (6). It will allow dirt to enter and cause failure of the engine. *+ Do not use a screwdriver or other tool. 2. Hold the outer element (5), rock it lightly up and down and to the left and right, and rotate the element to the left and right to pullit out 3, When the outer element (5) has been removed, check that the inner element has not come out of position and is not at an angle. Ifis at an angle, insert your hand and push itn straight. 4, Alter removing the outer element (5), cover the inner element (6) with a clean cloth or tape to prevent dirt or dust from entering, 5, Wipe off or brush off the dirt stuck to cover (3) and the inside of the air cleaner body (7). NOTICE When cl ing th ment, do not hit or beat it against anything, 6. Direct dry compressed air (less than 0.2MPa (2.1 kg/em?, 30.0 PSI}) to the outer element from inside along its pleats, then direct it rom outside along its pleats and again from inside. 1) Replace the outer element which has been cleaned 6 times repeatedly or used throughout t year. Replace the inner element at the same time. 2) Replace both inner and outer elements when the air cleaner clogging monitor (1) lights up soon after installing the cleaned outer element even though it has not been cleaned 6 times.MAINTENANCE PROCEDURE MAINTENANCE 7. small holes or thinner parts are found on the element when itis checked by shining a light through it ater cleaning, replace the element. 8, Remove the cloth or tape covering inner element (6). NOTICE * Donot use an element whose pleats or gasket or seal are damaged. “= Ifthe element or O-ring are cleaned and used again after they have been used for more than 1 year, itwill cause problems, Do not use them again, 9. Check that there is no dirt or oll stuck to the seal portion of the new element or cleaned element. Wipe off any dirt or oil 10. Push the outer element in straight with your hand when installing it to the air cleaner body. Ifthe outer element is held and rocked lightly up and down and to the left and right while pushing it in, the outer element can be inserted easily. NOTICE Be sure to instal the air cleaner element facing in the correct direction, Install so that the bottom ofthe ar cleaner element cylinder (face where no hole is drilled) (B), (C) is at cover (3) end. Hf the direction of installation is. mistaken, there is danger that it will cause breakage of the air cleaner @ element or serious damage to the engine. C YMAINTENANCE NOTICE When inserting the element, ifthe rubber atthe tip is swollen or the outer clement is not pushed in straight, and cover (3) is assembled by force to hhook (2), there Is danger that the hook and air cleaner body may be damaged, so be careful when assembling, 11. Install cover (3) as follows. 41) Align cover (3) with the element, 2) Hook the tip of hook (2) to the protruding part of the air cleaner body and lock it in position. 3) When locking hooks (2) in position, apply the hooks in turn on opposite sides (top, bottom, left, right) in the same way as when tightening bolts. 4) When cover (3) is installed, check that the clearance between the air cleaner body and cover (3) is not too large. It itis too large, install again, 12. After cleaning and replacing the element, press the reset button of dust indicator (4). The yellow piston will etur to its original place. MAINTENANCE PROCEDURE A) )¢MAINTENANCE PROCEDURE MAINTENANCE Replacing Element 1. Remove hooks (2) of each air cleaner (6 places), then remove cover (3) 2. Hold the outer element (5), rock it lightly up and down and to the loft and right, and rotate the element to the left and right to pull it out, Do not remove inner element (6) when doing this. 3. When the outer element (5) has been removed, check that the inner element has not come out of position and is not at an angle. fis at an angle, insert your hand and push itn straight. 4, Wipe off or brush off the dirt stuck to cover (3) and the inside of the air cleaner body (7). NOTICE * The inner element must not be cleaned and used again. When replacing the outer element, replace the inner element at the same time. * Ifthe inner element isnot installed properly and the outer element and cover are installed, there Is danger thatthe outer element will be damaged. + The seal portion on improper parts lacks precision, and allows the entry of dust, which leads to damage of the engi use such improper parts. Donat 5, Remove inner element (6), then quickly install the new inner element. Insert the inner element securely so that it does not move. 6. Push the new outer element (6) in straight with your hand when installing it to the air cleaner body. Ifthe element is held and rocked lightly up and down and to the left and right while pushing itin, the element can be inserted easily.MAINTENANCE MAINTENANCE PROCEDURE NOTICE Be sure to instal the air cleaner element facing in te correct direction Insta s0 thatthe bottom of the air cleaner element cylinder face where no hole is dried (B),(C) is at cover (3) end. ithe direction of installation is ASI mistaken, there is danger that it will cause breakage of the air cleaner ce element or serious damage tothe engine. Q @® 7. Replace O-ring (8) of cover (3) with anew part ® Z NO Q)~- o\ Z NOTICE When inserting the element, if the rubber atthe tip is swollen or the outer clement is not pushed in stright, and cover (3) is assembled by force to hhook (2), there is danger that the hook and air cleaner body may be damaged, so be careful when assembling. 8. Install cover (3) as follows. 41) Align cover (3) with the element. 2) Hook the tip of hook (2) to the protruding part of the air cleaner body and lock it in position. 3) When locking hooks (2) in position, apply the hooks in turn on opposite sides (top, bottom, let, right) in the same way as when tightening bolts. 4) When cover (3) is installed, check that the clearance between the air cleaner body and cover (3) is not too large. Ititis too large, install again. 9. Alter cleaning and replacing the element, press the reset button of dust indicator (4). The yellow piston will tum to its original place.MAINTENANCE PROCEDURE MAINTENANCE CLEAN INSIDE OF COOLING SYSTEM WARNING * Immediately after the engine Is stopped, the coolant is at high temperature. In addition, the radiator Is under high internal Pressure. Ifthe cap is opened under these conditions, it will cause burns. Wait for the temperature to go down, then open the cap slowly to release the pressure, * When cleaning the cooling system with the engine running, set the lock lever to LOCK position to prevent the machine from moving. * For details of the procedure for starting the engine, see "BEFORE STARTING ENGINE (PAGE 3-180)" and "STARTING ENGINE (PAGE 3.214)". Stop the machine on level ground when cleaning or changing the coolant. Clean the inside of the cooling system, change the coolant according to the table below. Interval for cleaning inside of cooling system Coolant and changing antifreeze coolant Komatsu genuine SUPERCOOLANT (AF-NAC) Every 2 years or every 4000 hours whichever comes sooner Komatsu genuine SUPERCOOLANT (AF-NAC) has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with SUPERCOOLANT (AF-NAC). SUPERCOOLANT (AF-NAC) has excellent anticorrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4000 hours. As a basic rule, we do not recommend the use of any coolant other than SUPERCOOLANT (AF-NAC). If you use another coolant, it may cause serious problems, such as corrosion of the engine and aluminum parts of the cooling system. To maintain the anticorrosion properties of coolant, always keep the density of coolant between 30% and 64%. When selecting coolant, investigate the lowest temperature in the past and decide the density for the coolant from the coolant density table below. When actually deciding the density for the coolant, set it approximately 10°C (18° F} below lowest temperature. The density must be over 30% at least. If the density of obtained coolant is higher than the necessary density for lowest temperature, dilute it with adequate distilled water, and then flit into the tank. It there is any unclear point, contact your Komatsu distributor. Coolant density table [Above-0| 15 | -20 | -25 | 30 | 35 | 40 | -45 | -50 SF [Above 14[ 5 4 | 13 | 22 | 31 [ 40 | 49 | 58 Density (%) 30 ae | 41 | 46 [| so | 54 | se | ot | 64 Minimum TempMAINTENANCE MAINTENANCE PROCEDURE WARNING * Coolant is toxic. Be careful not to get coolant on you when opening the drain valve. Itit gets in your eyes, flush your eyes with large amount of fresh water and see a doctor at once. ‘+ Aska specialist company or contact your Komatsu distributor for performing the change of coolant or disposal of the cooling water containing coolant thathas been drained during repair of radiator. Coolantis toxic, Do not ett flow into drainage ditches ‘or spray it onto the ground surface. REMARK For details of the method of draining and adding coolant to machines equipped with a service center (option), see "Method of Draining, Adding Coolant (PAGE 6-24)". Coolant is already diluted with distiled water, so itis not flammable. (For details of the distilled water, see "COOLANT AND WATER FOR DILUTION (PAGE 4-7)"). Check the density with a coolant tester. Prepare a container whose capacity is larger than the specified coolant volume to catch drained coolant. Prepare a hose to use when refiling with coolant. 1. Stop the machine on level ground, then stop the engine. 2. Open cover (1) at the front of the power container on the right side of the machine. 3. Check that the surface temperature of the cap of reservoir tank. (2)is cool enough to be touched by hand, then raise cap lever (4) of cap (3) at the top of the reservoir tank, and release the pressure inside the reservoir tank. 4, Remove water filler cap (5).MAINTENANCE PROCEDURE MAINTENANCE 5. Set a container under drain valve (7) under the machine to catch the coolant and water mix. 6. Install a drain hose (approximately 2 m (6 ft 7in)) to drain valve . 7. Open drain valve (6). 8. Open drain valve (7) and drain the water. 9. After draining the water, close drain valves (6) and (7). 10. Remove cover (8) at the top of the power container, then turn radiator cap (9) slowly to remove it 41. Fill with city water through the water filer port of radiator cap (9) Until water overflows from the radiator. 12. Add city water to the reservoir tank through the water filer of reservoir tank cap (5) to fill up to the FULL line. 18. Close radiator cap (9). Leave reservoir tank cap (5) off. 14, Start the engine and run for approximately 10 minutes at low idl. 15. Stop the engine and open drain valves (6) and (7) to drain the water. 16. After draining the water, use a detergent to wash the tank. For details of the method of washing, see the method of use provided with the detergent. 17. Close drain vaives (6) and (7), 18. Remove drain plug (10) under reservoir tank (2) to drain all detergent liquid in reservoir tank (2) 19. install drain plug (10). 20. Add coolant through the water filer port up to the mouth of the port. For details of the coolant density, see "COOLANT DENSITY TABLE". 21. Close radiator cap (2). 22. Add coolant to the reservoir tank (2) up to the H level. 2. To bleed the air from the coolant, run the engine at low idle for § minutes, then run for a further § minutes at high idle. When doing this, leave cap (5) of the reservoir tank removed. 24. Close cap (6) of the reservoir tank.MAINTENANCE. MAINTENANCE PROCEDURE CHECK AND TIGHTEN TRACK SHOE BOLTS If the machine is used with track shoe bolts (1) loose, they will break, so tighten any loose bolts immediately. Tightening 1. Tighten first to a tightening torque of 686 + 69 Nm (70 # 7 kgm, 506.3 + 50.6 Ib), then check that the nut and shoe are in tight contact with the link mating surface. 2. Alter checking, further tighten to the tightening torque of 150 deg. + 10 deg. Order for Tightening Tighten the bolts in the order shown in the figure on the right. After tightening, check that the nut and shoe are in close contact with the link mating surface.MAINTENANCE PROCEDURE MAINTENANCE CHECK AND ADJUST TRACK TENSION WARNING * For detalls of the method of starting the engine and operating the work equipment, see "BEFORE STARTING ENGINE (PAGE 3180)", “STARTING ENGINE (PAGE 3.214)", "AFTER STARTING ENGINE (PAGE 3-217)', and "WORK EQUIPMENT CONTROLS AND OPERATIONS (PAGE 3-245)", * Before carrying out this operation, always bleed the air from the circuit. For details of the procedure for bleeding air from the hydraulic circuit, see "BLEEDING AIR FROM IDLER CUSHION CIRCUIT (PAGE 4-58)". ‘The wear of the pins and bushings on the undercarriage will vary with the working conditions and type of soil, so inspect the track tension frequently in order to maintain the standard tension. Stop the machine on firm, horizontal ground when carrying out the inspection and maintenance. Checking 41. Run the engine at Low idle (MIN), then move the machine forward fora distance equal to the track length on ground, and slowly stop the machine. 2, Place wooden bar (3) on top of the track from No. 2 roller (1) to No. 3 roller (2). 3. Measure the maximum deflection between bottom surface of the wooden bar and top surface of the track shoe. Deflection "a" should be 10 to 30 mm {0.4 to 1.2 in}.MAINTENANCE MAINTENANCE PROCEDURE Adjustment Ifthe track tension is not atthe standard valu, adjust it in the following manner. ‘Adjusting Hydraulic Cushion (HIC) Cylinder 1, Check that drain valve (1) is fully close. (R) Machine's rear side 2. Set the fuel control dial to a point midway between low idle (MIN) and full speed (MAX), and run the engine at a mid-range speed.MAINTENANCE PROCEDURE MAINTENANCE 3. Thrust bucket teeth into the ground to prevent the machine to travel, then relief hydraulic valve (4 to 5 seconds) with forward / reverse operation of right travel lever (2). Repeat this operation 5 to 6 times. NOTICE + Do not carry out this forward / reverse operation on a slippery surface (such as steel plates). = Even if protrusion (A) of the hydraulic cushion cylinder plunger (3) is snsae8 within the specified value, HIC circuit charge pressure may be low, $0 carry out Step 3 correctly. 4, Check that protrusion (A) of hydraulic cushion cylinder plunger ~———__—— (3) is within the specified value on both the left and right. 5. Ifprotrusion (A) is not within the specified value, carry out Step 3 again to obtain the correct value for dimension (A). If protrusion cannot be within the specified value, there is possibly too much grease in grease cylinder (4). In this case, release some of the grease. For details of the procedure, see “Adjust Grease Cylinder (PAGE 4-37)". + Specified value: 195 + 5 mm (5.3 £ 0.2 in) REMARK If the end of hydraulic cushion cylinder plunger (3) is located around center of inspection hole of crawler frame, the protrusion is almost within the specified value. 6. Check that drain vaive (1) is fully closed.MAINTENANCE MAINTENANCE PROCEDURE Adjust Grease Cylinder Carry out this adjustment after adjusting the hydraulic cushion cylinder. WARNING There is danger of plug (1) flying out under the high internal pressure of the grease, Never loosen plug (1) more than 1 tur. Never loosen any part other than plug (1). Never put your face in the mounting direction of plug (1). It the track tension cannot be loosened with the procedure given here, contact your Komatsu distributor. Before pumping in grease, check that protrusion (A) of hydraulic cushion right. Check the protrusion of the hydraulic cushion cylinder again after + cushion cylinder cannot be within the specified value, please ask your Loo Komatsu distributor to carry out adjustment. @ @ + Specified value: 135 + § mm (5.3 + 0.2 in) Do not simply pump grease into the grease cylinder to adjust the track tension without adjusting with the hydraulic cushion cylinder. An excessive load will be brought to bear on the undercarriage, and there is danger of damage to the undercarriage. When increasing Tension Prepare a grease pump. 1. Pump in grease through plug (1) with a grease gun 2. To check that the tension is correct, move the machine slowly forward. 3. Check the track tension again, and ifthe tension is not correct, adjust it againMAINTENANCE PROCEDURE MAINTENANCE 4. When adjusting the track tension, itis possible to pump in grease until protrusion (B) of grease cylinder plunger(4) is 35 ©=35190e8 to 190 mm (1.4t0 7.5 in). If the tension is stil weak, there is - excessive wear ofthe pins and bushings, sotum or replace the pins and bushings. Please ask your Komatsu distributor to carry out repairs REMARK ¢ The protrusion of grease cylinder plunger s set between 30 to 45 mm (1.210 1.8 in) at shipment from factory, WARNING ‘Always use the following procedure. Its extremely dangerous to use any other procedure to release the grease. If the track link does not become loose, ask your Komatsu distributor to carry out repairs. 1. Loosen plug (1) a litle at atime to release the grease. 2. Loosen plug (1) a maximum of turn 3. Ifthe grease does not come out smoothly, move the machine forwards and backwards a short distance. 4, Tighten plug (1). 5, To check that the correct tension has been achieved, move the machine backwards and forwards. 6. Check the track tension again, and i the tension is not correct, adjust it again. Releasing internal pressure in Hydraulic Idler Cushion (HIC) circuit Hydraulic Idler Cushion (HIC) circuit is closed circuit with high pressure grease. When removing HIC equipment or detaching piping, please release internal pressure in the circuit in accordance with "RELEASING INTERNAL PRESSURE IN HYDRAULIC IDLER CUSHION (PAGE 4-67)".MAINTENANCE MAINTENANCE PROCEDURE REPLACE BUCKET TEETH (XS) Replace teeth Replace the bucket teeth before the adapter starts to wear. WARNING itis dangerous ifthe work equipment moves by mistake when the teth are being replaced Set the work equipment in a stable condition, then stop the engine and set the lock lever securely to LOCK position. * There isa hazard that fragments wil fy curing the replacement work, so always wear protective equipment lke safety glasses and gloves. + Ifthe tooth pins cannot be removed inthis procedure, for safety's sake, be sure to ask your Komatsu distributor forthe replacement. NOTICE + When replacing the bucket teeth, be sure to replace all of them at once. Should al the bucket teeth be not replaced at atime, the bucket will ikely be deformed. * In order to prevent a tooth from slipping off, also replace the pins with new ones when replacing the teeth. Prepare for a socket wrench for 16 mm- width across flats. 1. Set the bucket with the bottom of the bucket on black (3) sothat pin (1) can be removed, then stop the engine. 2. Within 15 seconds after stopping the engine, move each control lever (for work equipment and travel) to the full stroke in all directions to release the internal pressure. 3. Check that the work equipmentis in a stable condition, then set the lock lever to LOCK position (L). Oa nineMAINTENANCE PROCEDURE MAINTENANCE 4.Fit a socket wrench to the head of pin (1), then tum it counterclockwise 90 deg. to release the lock of the pin. 5. Push pin (1) out by hand or with a hammer in the direction of the arrow to remove the tooth (2). 6. Clean the mounting surface, fit new tooth (2) to the adapter, insert new pin (1), then tighten 90 deg. clockwise with the socket wrench to lock the pin and complete the installation. REMARK Turn the tooth upside down and rotate the installation positions. Such practice allows wear on the teeth to develop evenly, the lifetime to be extended, and the replacement frequency to be reduced, NOTICE Inorderto prevent atooth from a sip-of, insert apin from the inside (in the direction indicated with an arrow) for tooth (4) and (5) on both edges of the bucket.MAINTENANCE MAINTENANCE PROCEDURE Replace wear cap Replace the woar cap before the adaptor starts to wear. WARNING * Itis dangerous if the work equipment moves by mistake when the wear cap are being replaced, ‘Set the work equipment ina stable condition, then stop the engine and set the lock lever securely to LOCK position. * Theres ahazard that fragments will ly during the replacement work, so always wear protective equipment like safety glasses and gloves. * Ifthe tooth pins cannot be removed in this procedure, for safety's sake, be sure to ask your Komatsu distributor for the replacement. Prepare for a socket wrench for 16 mm- width across flats. 1. Set the bucket with the bottom of the bucket on block (3) so that pin (1) can be removed, then stop the engine. 2. Within 15 seconds after stopping the engine, move each control lever (for work equipment and travel) to the full stroke in all directions to release the internal pressure. 3. Check that the work equipmentis in a stable condition, then set, the lock lever to LOCK position (L). 4. Fit a socket wrench to the head of pin (1), then turn it counterclockwise 90 deg. to release the lock ofthe pin.MAINTENANCE PROCEDURE MAINTENANCE 5. Push pin (1) out by hand or with a hammer in the direction of the arrow to remove the tooth (2). 6. Take off wear cap (6) after removing tooth (2), and then clean. the cap mounting face and mounting hole (7).. 7. Install new wear cap (6) by fiting it in adapter mounting hole a. 8. Clean the tooth mounting face, fittooth (2) in the adapter, insert pin (1) and then lock the pin by turning a socket wrench clockwise to 90 degrees to install the tooth. NOTICE Inorderto prevent atooth from a sip-of, insert apin from the inside (in the direction indicated with an arrow) for tooth (4) and (5) on both edges of the bucket.MAINTENANCE. How to Remove Slinging Loop WARNING * Ifthe slinging loop Is caught on any part of the bucket (tooth, lip shroud, wear cap, adapter, side shroud), remove it. If digging operations are carried out without removing the slinging loop, there is danger that the slinging loop may break and pieces may fly around. Itis dangerous if the machine begins to move while the slinging loop is being removed. Hold the work equipment in a stable posture, stop the engine and make sure to put the lock lever to LOCK position. ‘+ When removing the slinging loop, wear protective tools like safety glasses. There is a danger that metal pieces ofthe broken slinging loop are sent flying around. Never hit the tooth against a boulder for the purpose of removing the slinging loop. ‘There is the danger that the broken slinging loop will be sent flying around in pieces, causing a personal injury. NOTICE MAINTENANCE PROCEDURE the machine is operated without the slinging loop being removed, the following problems will possibly arise. ‘+ When the work equipment is pulled back, the slinging loop at the tip of the tooth interferes with the boom. ‘+ The cracks caused when the slinging loop breaks may extend to various parts of the main body (tooth, lip shroud, wear cap, ‘adapter, side shroud) and damage the main body ofthe parts. * The slinging loop may break during the digging work and its broken pieces are mixed in the sand, earth and stones to be loaded. Be sure to remove the slinging loop in the following steps. 1. Put block (3) under the bottom of the bucket and stop the engine. 2. Within 15 seconds after stopping the engine, move each contro! lever (for work equipment and travel) to the full stroke in all directions to release the internal pressure. 3. Check that the work equipmentis in a stable condition, then set the lock lever to LOCK position (L).MAINTENANCE PROCEDURE MAINTENANCE 4, Preheat the slinging loop to be cut to 100to 150 °C (212 to 302 *F) and use a gas cutter to cut the slinging loop at each part of the bucket * Tip of tooth (1), top of tooth (2), lip shroud (3), wear cap (4), adapter (5), side shroud (6). NOTICE ‘When cutting the slinging loop at each part of the bucket, cut at the following cutting positions (A) to (A) or (B) to (B), according to the shape of the loop. In addition, when doing this, be careful thatthe cutting surface does not cout into the main body of the bucket parts. + Cutting position (A) to (A) This applies to tip of tooth (1), lip shroud (3), wear cap (4), and side shroud (6). Cut at the bottom of the hole in the lifting loop. + Cutting position (B) to (B) This applies to top of tooth (2) and adapter (6). Cut at a position 10 to 20 mm (0.4 to 0.8 in) from the main body of the bucket part. 5. Finish the cutting surface smoothly, using a grinding machine. 6. Check that there is no crack on the cutting surface.MAINTENANCE MAINTENANCE PROCEDURE CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID If there is air in the window washer fluid, check the level of the fluid In window washer tank (1). Add automobile window washer fluid if necessary. When adding fluid, be careful not to let any dust get in. Mixture Ratio of Pure Washer Fluid and Water ‘The proportion differs according to the ambient temperature, so dilute the washer fluid with water to the following proportions before adding, Operation area _endacason | Mower | pears regen finer | 2764 Wirtrinextemel Toure washertuié | ~30°C (22°F) ‘There are 2 types depending on the freezing temperature: “10°C (14°F) (general use) and -30°C (-22"F) (cold area use), select according to the area and season.MAINTENANCE PROCEDURE MAINTENANCE CHECK AND MAINTENANCE AIR CONDITIONER Check Level of Refrigerant (gas) WARNING Ifthe refrigerant used in the air conditioner gets into your eyes or on your hands, it may cause loss of sight or frostbite. Do not touch the refrigerant. Never loosen any part ofthe refrigerant circuit. Do not bring any open flame close to any point where the refrigerant gas is leaking. Run the engine at full speed and operate the air conditioner at maximum airflow, then check the flow of refrigerant gas (Hydrofluorocarbons HFC -134a) in the refrigerant circuit through the sight glass (2) (inspection window) of the receiver (1). (A) Intermittent bubbles in refrigerant flow: Suitable (8) Many bubbies in flow (bubbles pass continuously) Lack of refrigerant x (C) Transparent and colorless: overflled NG (The refrigerant may be colorless if isis insufficient.) REMARK SE RSSHSRAEE] ooo mon [Sen cone) + When bubbles appear, there is lack of refrigerant gas, so have @ lO xm! OC = your service shop add refrigerant immediately @ =| sax] O + Total volume of refrigerant: 960 9 (2.098 Ib)/each unit [total for 2 units: 1,900 g (4.19 Ib)] + Ifitis not replaced but refilled, refill it until bubbles disappear in sight glass, and add 200 9(0.441Ib) more (as a reserve). (ifitis insulicient, refill wil be needed in a short time.) a AC GAS PRESS hy = AC GAS AMOUNT)MAINTENANCE MAINTENANCE PROCEDURE Inspection During Off Season During the off-season, run the air conditioner once a month for 3 to § minutes at low idle to maintain the oil film at all parts of the compressor. Inspection and Maintenance Items Guideline for maintenance Check, maintenance items Content of check, maintenance ional Refrigerant (gas) (Charge amount Every 250 hours ‘Air conditioner condenser _|Clogged fins. Every 500 hours Compressor (Operating condition Every 4000 hours V-belt Damage, tension Every 250 hours ‘Operating condition (00s it make abnormal noise?) When required Control mechanism (Operating condition (does it function normally?) _|When required ‘Mounting condition, looseness at tightening or ‘connecting portions, leakage of gas, damage Blower motor, fan Piping mounts When requiredMAINTENANCE PROCEDURE MAINTENANCE CLEAN LINE FILTER, REMOVE DIRT If there is any abnormality in the pump or other hydraulic ‘equipment, remove the ditt from inside the line fiter as follows. + Before removing the dirt from the line fiter, remove the cap from oil filer port (F) at the top of the hydraulic tank to release the pressure inside the hydraulic circuit 1. Remove cover (1). 2. Install a bolt (10 mm, 0.4) in bolt hole (A) of element (2), then hold the bolt and pull out element (2) 3. Clean element (2). + When cleaning the element, clean the drt and dust stuck to side surface (8) ofthe fiter case 4, Replace O-ring (3) of element (2) with a new part, then insert element (2) into the fiter case, 5. Replace backup ring (4) and O-ring (5) of cover (1) with new parts, then install cover (1) to the filter case. Tightening torque of cover (1):181 Nm (18.5 kgm, 183.8 It) After assembling the line filter again, bleed the air. For details, see "BLEEDING AIR FROM HYDRAULIC SYSTEM (PAGE 4-54)"MAINTENANCE MAINTENANCE PROCEDURE CHECK SEALS AROUND ENGINE COOLING © @ @ . rl] os q & P BE ‘ 4 D @ \ AN _¥ R F: Area around radiator at front of engine R: Area around oll cooler at rear of engine (ight side of machine) (lett side of machine) Check from inside the engine room that there is no gap caused by deformation or peeling of the sponge sealing material around the engine cooling, Locations to check sealing material (A) Seal around radiator (8) Seal of attercooler hose (C) Seal of radiator upper hose (0) Seal of oil cooler hose (E) Seal of oil cooler upper hose NOTICE Hf thereis a change to high water temperature when operating the engine over several days when there is na change in the ambient temperature, a possible reason is peeling of the sealing material around the engine cooling or creation of a gap caused by deformation. If nothing is done to correct this problem, there willbe deterioration in the heat balance and increase in noise. Take action as soon as possible. When doing thi, please contact your Komatsu distributor.MAINTENANCE PROCEDURE MAINTENANCE BLEEDING AIR FROM FUEL CIRCUIT In the following cases, carry out the procedure given below to bleed the air from the fuel circuit, + When fuel flter has been replaced + When engine has run out of fuel + When starting the engine for the first time after replacing the supply pump or modifying the piping or any other parts WARNING * After the engine is stopped, all parts are at high temperature, so there is danger of suffering burns. Walt for al parts to cool down before starting the operation, * When the air breather ofthe supply pump or the air bleed plug atthe top of the fue! fiter head is opened, the residual pressure may spray out fuel. Loosen the plug and breather slowly before opening. NOTICE The common rail ype fue injection system used on this machine consists of higher precision parts than the conventional injection pump and nozzle, This means that problems ae more likely to occur when dust ordi gts. Hany drt shouldbe stuck to any part of the fuel system, use fuel to wash it off completely. For details of the poor fuel arrangement specification machines (if equipped), see "Bleeding air from fuel circuit with the electric priming pump (PAGE 4-52)’. 1. Loosen airbleed plug (1) atthe top ofthe fue! iter head. (One place each on left and right sides of engine) jaMAINTENANCE MAINTENANCE PROCEDURE 2, Remove locknut (3) from priming pump lever (4), then pump priming pump lever (4) 50 to 100 times and check that fuel ‘comes out from air bleed plug (1). When fuel comes out, tighten plug (1). (One place each on left and right sides of engine) Tightening torque: 7.8 to 9.8 Nm (0.8 to 1 kgm, 5.8 to 7.2lbft} 3. Open air breather (6) at the side of supply pump (5), then pump. priming pump lever (4) approximately 5 to 15 times, With this operation, fuel will start to overfiow from air breather (6). When no more bubbles come outwith the fuel, tighten air breather (6). (One place each on left and right sides of engine) Tightening torque: 4.9 to 6.9 Nm {0.5 to 0.7 kgm, 3.610 5.1 Ibtt) 4, Pump priming pump lever (4) again several times until it becomes heavy. Then push in priming pump lever (4) and tighten locknut (3) to hold priming pump lever (4) in positon. =} tana 5. Ifthe air bleed operation does not go well, return to Step 3 and start again. 6. For normal stating, turn the key in the starting switch to START position. The engine will start. + When starting the engine, do not run the starting motor for more than 20 seconds continuously. + Ifitis necessary to keep it continuously running, provide a more than 2 minute interval between tials.MAINTENANCE PROCEDURE MAINTENANCE Bleeding air from fuel circuit with the electric priming pump (Only poor fuel arrangement specification machines) Poor fuel arrangement specification machines is equipped with an electric priming pump to bleed the air from the fuel circuit. n the following cases, use the procedure below to bleed the air. + When fuel fter has been replaced + When engine has run out of fuel + When starting the engine for the first time after replacing the supply pump or modifying the piping or any other parts WARNING * After the engine is stopped, all parts are at high temperature, so there is danger of suffering burns. Wait for al parts to cool down before starting the operation, * When using the electric priming pump, do not loosen the alr bleed plug forthe fuel circuit. When the electric priming pump is operated, pressure is applied to the fuel circuit, sof the air bleed plug is loosened, fuel will spurt out and create a dangerous situation. 1. Turn the key in starting switch to the OFF position (A) and stop the engine. ® 2. Open air bleeding valve (1) and (2). (Lett side) (Right side)MAINTENANCE MAINTENANCE PROCEDURE 3. Tum electric priming pump switch (3) to ON position (A). Lamp (4) flashes and the electric priming pump start. Release electric priming pump switch (3). Switch (3) will return automatically to the original position (N). REMARK ‘+ While lamp (4) s flashing, the electric priming pump is actuated for 30 seconds and then stops for 10 seconds. This action is repeated until lamp (4) goes out. + If this switch is turned to OFF position (B) when the lamp is flashing, the lamp will go out and the electric priming pump will stop. + When the lamp is flashing, the electric priming pump will stop, but this does not indicate any abnormality. ‘4, When the specified time (approximately 7 minutes) has passed, lamp (4) automatically goes out and the electric priming pump stops. 5. The electric priming pump automatically stops working (the monitor lamp goes off), when the fuel circuit is ‘emptied of fuel as in the instance that the engine stops due to fuel exhaustion, or in the instance that the fuel hose, tube or priming pump has been maintained or replaced, In that case, tt the electric priming pump switch back to the ON position (A) so as to allow the pump to work again. 8. When the lamp (4) goes out, the air bleed operation is completed. 7. Shut off the air bleeding valves on both right and left banks, 8. Start the engine, Ifthe engine does not start, the probable reason is that the air has not been completely bled. Do as follows, then start the engine again 41) Check that the air bleed valve is closed. 2) Turn electric priming pump switch (3) ON position (A) 3) Try to start the engine while the electric priming pump is in operation. f the engine still does not start, wait for approximately 2 minutes, and then repeat steps 2) and 3). 4) After the engine has started, run the engine for approximately 5 minutes to bleed air from the fuel system completely NOTICE Do not keep the starting motor rotating continuously for more than 20 seconds. Ht the engine will not start, wat for at least 2 minutes before trying to start the engine again.MAINTENANCE PROCEDURE MAINTENANCE BLEEDING AIR FROM HYDRAULIC SYSTEM For details, see "STARTING ENGINE (PAGE 3-214)’. If itis necessary to refer to the items for starting the engine, moving the machine off, steering, or stopping, see OPERATION section, NOTICE Bleed air from the hydra system in the following steps. 1. Hydraulic pump (those for work equipment and hydraulically driven cooling fan) 2. Hydraulic motor (those for swing and travel) 3, Swing holding brake circuit 4, Front idler cushion ircult 5. Pilot piping (those for pilot selector valve circuit and main valve PPC circuit) 6, Work equipment circuit ‘+ Run the engine at less than 1000 rpm and operate the cylinders slowly. * Domnot use sudden stopping and starting to raise the cylinder pressure; do not operate the cylinder to the end of its stroke. “+ Be particularly careful to operate slowiy forthe first operation of each cylinder (return stroke). * When a cylinder is operated forthe first time, there isa large amount of ai inside the circuit, so the work equipment will not move for more than 10 seconds. Do not operate the lever fully to make the work equipment move. + Fill the pumps and other equipment with clean oil of NAS 7 class or above, and use a clean container forthe il