Maintenance & Service Schedules
Komatsu Dump Trucks not only transport heavy loads quickly and easily, but also cost effectively. They are exceptionally strong machines, built around a powerful Komatsu engine, guaranteeing driving safety even at high speeds.
Despite all the components being designed to handle daily stresses for maximum reliability, it is important to perform maintenance and service on your machine to keep it running to its best.
See below a helpful guide to when certain components should be replaced in your Komatsu Dump Truck. This is a rough guide and should treated as such. Always refer to the manufacturers machine manual for instructions.
WEAR PARTS
Wear parts such as the filter element, air cleaner element, etc. are to be replaced at the time of periodic maintenance or before their abrasion limits. Changing the wear parts correctly will help the machine run more economically.
The parts in parentheses should be replaced at the same time.
| ITEM | PART DESCRIPTION | QTY | REPLACEMENT FREQUENCY |
|---|---|---|---|
| Engine oil filter | Cartridge | 1 | Every 500 hours |
| Fuel prefilter | Cartridge | 1 | Every 500 hours |
| Fuel main filter | Cartridge | 1 | Every 1000 hours |
| Corrosion resistor | Cartridge | 1 | Every 1000 hours |
| Transmission oil filter (Valve side) | Cartridge | 1 | Every 1000 hours |
| Transmission oil filter (Brake cooling side) | Element (O-ring) | 1 | Every 1000 hours |
| Brake oil filter | Element (O-ring) (Back-up ring) | 1 | Every 1000 hours |
| Hydraulic filter | Element (O-ring) | 1 | Every 2000 hours |
| Air cleaner | Element Ass’y Outer element | 1 1 | Every 2000 hours |
MAINTENANCE SCHEDULE
INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)
- Change oil in engine oil pan, replace engine oil filter cartridge
- Replace fuel prefilter cartridge
- Replace fuel main filter cartridge
- Replace transmission filter element (valve side, brake cooling side)
- Change oil in transmission case
- Change oil in brake oil tank, replace brake oil filter element
- Change oil in final drive case
- Change oil in differential case
- Replace hydraulic filter element
- Change oil in hydraulic tank
WHEN REQUIRED
- Check, clean or replace air cleaner
- Clean inside of cooling system
- Check level of window washer fluid, add fluid
- Clean air conditioner air filter
- Check refrigerant (gas) level
- Check dump body
- Check length of suspension cylinder
- Bleed air from front brake
- Bleed air from centre brake
- Check play of output coupling of output shaft
- Selection and inspection of tires
- Adjust parking brake
- Cleaning hydraulic tank strainer
CHECK BEFORE STARTING EVERY 50 HOURS SERVICE
- Lubrication
EVERY 250 HOURS SERVICE
- Lubrication
- Check drive shaft
- Clean overflow hose
- Check level of battery electrolyte
- Check fan belt and alternator belt tension, adjust
- Check air conditioner compressor belt tension, adjust
- Check frame, A-arm
- Check braking capacity of foot brake
- Check braking capacity of retarder brake
- Check braking capacity of parking brake
- Check wear of parking brake pads
- Check of accumulator gas pressure
EVERY 500 HOURS SERVICE
- Change oil in engine oil pan, replace engine oil filter cartridge
- Replace fuel prefilter cartridge
- Lubricate cab mount pin (left and right: 1 place each)
- Check oil level in final drive case, add oil
- Check oil level in differential case, add oil
- Clean, check radiator fins and after cooler fins
- Recover oil leaking from floating seal
EVERY 1000 HOURS SERVICE
- Replace fuel main filter cartridge
- Replace corrosion resistor cartridge
- Replace transmission filter element
- Change oil in transmission case
- Change oil in brake oil tank, replace brake oil filter element
- Lubrication
- Check wear of brake disc
- Check of engine air intake piping clamps for looseness
EVERY 2000 HOURS SERVICE
- Change oil in final drive case
- Change oil in differential case
- Replace hydraulic filter element
- Clean transmission case strainer
- Clean breather
- Check accumulator gas pressure
- Check alternator
- Check, adjust engine valve clearance
- Check vibration damper
EVERY 4000 HOURS SERVICE
- Change oil in hydraulic tank
- Check starting motor
- Check water pump
- Check air compressor
- Check fan pulley and tension pulley
- Checking for looseness of high-pressure clamp, hardening of rubber
- Checking for missing fuel spray prevention cap, hardening of rubber
EVERY 6000 HOURS SERVICE
- Lubricate drive shaft
EVERY 8000 HOURS SERVICE
- Replace high-pressure piping clamp
- Replace fuel spray prevention cap
- Overhaul starting motor and alternator
CONTACT US
Plant Parts can supply service packages and key components for the Komatsu HD and HM range.
Speak to a member of the team about your requirements.
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