LUBRICANTS, COOLANT AND FILTERS

HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC OIL

● Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), and is deteriorates with use.

Always use oil that matches the grade and temperature for use given in the Operation and Maintenance Manual.

Even if the oil is not dirty, always change the oil after the specified interval.

● Oil corresponds to blood in the human body, so always be careful when handling it to prevent any impurities (water, metal particles, dirt, etc.) from getting in.

The majority of problems with machine are caused by the entry of such impurities.

Take particular care not to let any impurities get in when storing or adding oil.

● Never mix oils of different grades or brands.

● Always add the specified amount of oil.

Having too much oil or too little oil are both causes of problems.

● If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases, please contact your Komatsu distributor.

● When changing the oil, always replace the related filters. In particular, when replacing the engine oil filter, fill the new filter with fresh, clean specified oil before installing.

● We recommend you to have an analysis made of the oil periodically to check the condition of the machine. For those who wish to use this service, please contact your Komatsu distributor.

Fuel

● The fuel pump is a precision instrument, and if fuel containing water or dirt is used, it cannot work properly.

● Be extremely careful not to let impurities get in when storing or adding fuel.

● Always use the fuel specified in the Operation and Maintenance Manual.

Fuel may congeal depending on the temperature when it is used (particularly in low temperature below –15°C), so it is necessary to change to a fuel that matches the temperature.

● To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day’s work.

● Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from the fuel tank.

● If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

Cooling System Coolant

● River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine and radiator, and this will cause defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

● When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

● Komatsu machines are supplied with Komatsu specified anti-freeze in the coolant.

This anti-freeze is effective in preventing corrosion of the cooling system.

The anti-freeze can be used continuously for 2 years or 4000 hours. Therefore, it can be used as it is even in hot areas.

● Anti-freeze is flammable, so be extremely careful not to expose it to flame or fire.

● The ratio for the mixture of water and anti-freeze differs according to the ambient temperature. For details of the ratio, see “CLEAN INSIDE OF COOLING SYSTEM (PAGE 4-25)”.

● If the engine overheats, wait for the engine to cool before adding coolant.

● In addition to causing overheating, lack of cooling water also causes corrosion of the cooling circuit due to entry of air.

Grease

● Grease is used to prevent twisting and noise at the joints.

● The nipples not included in the MAINTENANCE section are nipples used when overhauling, so they do not need grease.

If any part becomes stiff or generates noise after being used for a long time, grease it.

● Always wipe off all of the old grease that is pushed out when greasing.

Be particularly careful to wipe off the old grease in places where sand or dirt sticking in the grease would cause wear of the rotating parts.

CARRYING OUT KOWA (Komatsu Oil Wear Analysis)

KOWA is a maintenance service that makes it possible to prevent machine failures and down-time. With KOWA, the oil is periodically sampled and analyzed. This enables early detection of wear of the machine drive parts and other abnormalities.

Periodic use of KOWA makes the following possible:

● It enables abnormalities to be detected early, leading to reduction of repair costs and machine downtime.

● It enables repair schedules to be planned, leading to improved machine availability.

Kowa Analysis Items

● Analysis of metal wear particles

This uses an ICP (Inductively Coupled Plasma) analyzer to measure the density of metal wear particles in the oil.

● Measurement of particle quantity

This uses a PQI (Particle Quantifier Index) measurer to measure the quantity of large iron particles in the oil.

● Others

Measurements are made of items such as the ratio of water or fuel in the oil, and the dynamic viscosity.

Oil Sampling

● Sampling interval

250 hours: Engine 500 hours: Other components

● Precautions when sampling

● Make sure that the oil is well mixed before sampling.

● Carry out sampling regularly at fixed intervals.

● Do not carry out sampling on rainy or windy days when water or dust can get into the oil. For further details of KOWA, please contact your Komatsu distributor.

Oil And Fuel Storage

● Keep indoors to prevent any water, dirt, or other impurities from getting in.

● When keeping drum cans for a long period, put the drum on its side so that the filler port of the drum can is at the side. (To prevent moisture from being sucked in) If drum cans have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.

● To prevent any change in quality during long-term storage, be sure to use in the order of first in - first out (use the oldest oil or fuel first).

LUBRICANTS, COOLANT AND FILTERS MAINTENANCE

Filters

● Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering important equipment and causing problems.

Replace all filters periodically. For details, see the Operation and Maintenance Manual. However, when working in severe conditions, replace the filters at shorter intervals according to the oil and fuel (sulfur content) being used.

● Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.

● When replacing oil filters, check if any metal particles are affixed to the old filter. If any metal particles are found, please contact your Komatsu distributor.

● Do not open packs of spare filters until just before they are to be used.

● Always use Komatsu genuine filters.

Electric System Maintenance

● It is extremely dangerous if the electrical equipment becomes wet or the covering of the wiring is damaged. This will cause electrical leakage and may lead to malfunction of the machine. Do not wash the inside of the operator's cab with water. When washing the machine, be careful not to let water get into the electrical components.

● Service relating to the electric system is check of fan be lt tension, check of damage or wear in the fan belt and check of battery fluid level.

● Never install any electric components other than there specified by Komatsu.

● External electrical interference may cause malfunction of the control system controller, so before installing a radio receiver or other wireless equipment, please contact your Komatsu distributor.

● When working at the seashore, carefully clean the electric system to prevent corrosion.

● When installing an operator's cab cooler or any other electrical equipment, connect it to an independent power source connector. The optional power source must never be connected to the fuse, starting switch, or battery relay.