MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE CHART

INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER 4- 61
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)
CHANGE OIL IN SWING MACHINERY CASE 4- 69
CHANGE OIL IN PTO CASE 4- 71
CHANGE OIL IN FINAL DRIVE CASE 4- 80
WHEN REQUIRED
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT 4- 18
CLEAN INSIDE OF COOLING SYSTEM 4- 21
CHECK AND TIGHTEN TRACK SHOE BOLTS 4- 25
CHECK AND ADJUST TRACK TENSION 4- 26
REPLACE BUCKET TEETH (XS) 4- 29
ADJUST BUCKET CREARANCE 4- 33
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID 4- 34
CHECK AND MAINTENANCE AIR CONDITIONER 4- 35
CLEAN LINE FILTER, REMOVE DIRT 4- 36
CHECK GAS SPRING 4- 37
BLEEDING AIR FROM HYDRAULIC SYSTEM 4- 38
BLEEDING AIR FROM FULE CIRCUIT 4- 42
CHECKS BEFORE STARTING
EVERY 10 HOURS MAINTENANCE
LUBRICATING 4- 46
EVERY 100 HOURS MAINTENANCE
LUBRICATING SWING CIRCLE 4- 48
EVERY 250 HOURS MAINTENANCE
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL 4- 49
CHECK LEVEL OF BATTERY ELECTROLYTE 4- 50
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS 4- 52

EVERY 500 HOURS MAINTENANCE

REPLACE FUEL PRE-FILTER CARTRIDGE 4- 53
REPLACE FULE MAIN FILTER CARTRIDGE 4- 55
CHECK SWING PINION GREASE LEVEL, ADD GREASE 4- 57
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS,FUEL COOLER FINS,
AFTERCOOLER FINS, CONDENSER FINS (machines equipped with air conditioner),
PTO OIL COOLER 4- 58
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER 4- 59
REPLACE PILOT FILTER ELEMENT 4- 60
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER 4- 61
CHECK, REPLACE ALTERNATOR, AIR CONDITIONER COMPRESSOR DRIVE BELTS 4- 61
REPLACE DRAIN FILTER CARTRIDGE 4- 62
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE 4- 63
EVERY 1000 HOURS MAINTENANCE
REPLACE HYDRAULIC OIL FILTER ELEMENT 4- 65
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK 4- 66
CLEAN HYDRAULIC TANK RETURN STRAINER 4- 67
REPLACE FUEL TANK BREATHER ELEMENT 4- 68
CHANGE OIL IN SWING MACHINERY CASE 4- 69
CHANGE OIL IN PTO CASE 4- 71
GREASE, CHECK TENSION PULLEY ASSEMBLY OF ALTERNATOR, AIR CONDITIONER
COMPRESSOR DRIVE BELT 4- 72
CHECK WELDED STRUCTURE 4- 73
REPLACE SWING MOTOR COOLING FILTER ELEMENT 4- 76
EVERY 2000 HOURS MAINTENANCE
CHANGE OIL IN FINAL DRIVE CASE 4- 80
CHECK BOOST PIPING HOSE CLAMPS 4- 80
CHECK ALTERNATOR 4- 80
CHECK ENGINE VALVE CLEARANCE, ADJUST 4- 80
CLEAN HYDRAULIC TANK STRAINER 4- 81
CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL
CIRCUIT) 4- 82
EVERY 4000 HOURS MAINTENANCE
CHECK WATER PUMP 4- 86
CHECK STARTING MOTOR 4- 86
CHECK AIR COMPRESSOR, ADJUST 4- 86
REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT) 4- 86
CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER 4-
87
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER 4- 88
EVERY 5000 HOURS MAINTENANCE
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER 4- 89
EVERY 8000 HOURS MAINTENANCE
REPLACE HIGH-PRESSURE PIPING CLAMP 4- 91
REPLACE FUEL SPRAY PREVENTION CAP 4- 91
OVERHAUL STARTING MOTOR AND ALTERNATOR 4- 91

MAINTENANCE PROCEDURE
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100
HOURS)
Perform the following maintenance only after the first 100 hours.
Clean strainer of PTO lubricating oil filter
For details of the method of maintaining, see EVERY 500 HOURS MAINTENANCE.
INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500
HOURS)
Carry out the following maintenance only after the first 500 hours of operation on new machines.
Change oil in swing machinery case
Change oil in PTO case
Change oil in final drive case
Special tools are needed for inspection and maintenance, so contact your Komatsu distributor.
For details of the method of replacing or maintaining, see EVERY 1000 HOURS and EVERY 2000
HOURS
SERVICE.
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