EVERY 500 HOURS MAINTENANCE

LUBRICATING

Lubricating Swing Components

WARNING
When lubricating the swing circle and the swing pinion, do not swing the upper structure while
carrying out the lubricating.

NOTICE
For the first 100 hours on new machines where the parts are settling in, carry out greasing
every 10 hours.

Prepare a grease pump

1. Using a grease pump, pump in grease through the grease

fittings shown by arrows.
2. After greasing, wipe off any old grease that was pushed out.

(1) Swing pinion (1 place)

(2) Swing circle (1 place)

When lubricating the swing circle and swing pinion, turn the
chassis little by little to change the position while carrying out
the lubrication.

REMARK
Greasing the boom swing cylinder foot pin is an item of
servicing that is to be carried out on an ad-hoc basis.
(See"LUBRICATING (PAGE 4-46)")
Lubricating Work Equipment

NOTICE
When breaking in a new machine, carry out lubrication
every 10 hours for the first 100 hours of operation.
If any abnormal sound comes from the greasing point,
carry out greasing regardless of the inspection and
maintenance interval.
After carrying out digging work in water, always lubricate
the pins that were under water.

Prepare a grease pump

1. Set the machine to the greasing posture shown on the right

diagram, lower the work equipment to the ground, then stop
the engine.
2. Using a grease pump, pump in grease through the grease
fittings shown by arrows.
3. After greasing, wipe off any old grease that was pushed out.

(1) Bucket - Link connecting pins (1 place)

(2) Arm - Bucket connection pin (1 place)
(3) Arm - Link coupling pin (1 place)
(4) Bucket cylinder rod end (1 place)
(5) Link coupling pin (1 place)

(6) Blade cylinder foot pin (1 place)

(7) Blade cylinder rod end (1 place)
(8) Blade foot pin (2 places)
(9) Boom cylinder foot pin (1 place)

(10) Boom swing bracket pin (2 places)

(11) Boom swing cylinder rod end pin (1 place)
(12) Boom foot pin (2 places)
(13) Boom cylinder rod end (1 place)
(14) Arm cylinder foot pin (1 place)

(15) Arm cylinder rod end (1 place)

(16) Boom - Arm connecting pins (1 place)
(17) Bucket cylinder foot pin (1 place)
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER
CARTRIDGE
WARNING
Parts and oil are at high temperature immediately after the engine is stopped and may cause
serious burns. Wait for the oil temperature to go down before performing this operation.

Engine oil pan capacity : 7.5 liters (1.98 US gal)

Prepare a filter wrench

Change the oil and replace the cartridge once every 6 months, even if the engine has not been
operated for 500 hours.
In the same way, change the oil and replace the cartridge once every 500 hours, even if the engine
has not been operated for 6 months.

1. (Applicable only to PC55MR)

Remove the undercover on the engine underside.
2. Set a container to catch the oil immediately under the drain
plug (P) at the bottom of the machine.
3. Remove drain plug (P) slowly to avoid getting oil on
yourself, and drain the oil.
4. Check the drained oil, and if there are excessive metal
particles or foreign material, please contact your Komatsu
distributor.
5. Install drain plug (P).
6. Open the engine rear cover.
7. Using a filter wrench, turn filter cartridge (1)
counterclockwise to remove it.
8. Clean the filter holder,coat the new filter cartridgepacking
and threadedportionwith clean oil (or coat thinly with
grease),then install.

REMARK
Check that there is no old packing stuck to the filter holder. If
there is any old packing stuck to the filter, it will cause leakage of oil.

9. When installing; tighten until the packing surface contacts the seal surface of the filter holder, then
tighten it up 1/2 to 3/4 of a turn.
10. After replacing the filter cartridge, add oil through oil filler (F) until the oil level is between the H
and L marks on the dipstick (G).
11. Run the engine idle for a while, then stop the engine and confirm that the oil level is between the
H and L lines according to "Check Oil Level in Engine Oil Pan, Add Oil (PAGE 3-44)".
REPLACE FUEL FILTER CARTRIDGE
WARNING
Theengineis at hightemperature
immediately
afterthemachine
hasbeenoperated.
Waitfortheengineto cooldownbefore
replacing
thefilter.
Donotbringfireor sparksnearthefuel.

Prepare a filter wrench

Prepare for cloth.

1. Open the engine rear cover.

2. Spread the cloth beneath the filter cartridge.
3. Using a filter wrench, turn filter cartridge (1) counterclockwise
to remove it.
If any fuel spills, wipe it up immediately with a cloth.
4. Clean the filter holder, fill the new filter cartridge with fuel,
then
coatthepackingsurfacewithfuel,andinstalltothefilterholder.
5. When installing, turn to the right to tighten until the packing
surface contacts the seal surface of the filter holder, then use
a filter wrench to tighten approx. 1 turn.
Tightening torque: 19.6 to 23.5 Nm (2.0 to 2.4 kgm , 14.5 to
17.4 lbft)

6. After replacing the fuel filter cartridge, bleed air.

For details of the procedure, see "Air Bleeding (PAGE 4-55)".

Air Bleeding
1. Fill the fuel tank with fuel.
2. Set handle (1) of the water separator to OPEN position (B).
3. Loosen air bleed bolt (2) of the water separator 2 or 3 turns.
4. When no more bubbles come out with the fuel from air bleed
bolt (2), tighten air bleed bolt (2).

5. Turn the starting switch to the ON position (B), hold it there

for 10 to 15 seconds, then return it to the OFF position (A).
Air bleeding is carried out automatically by the automatic air
bleed device. REMARK
When the machine has run out of fuel, carry out the same
procedure, to bleed the air.
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL

WARNING
The parts and oil are at high temperature immediately after the engine is stopped, and may
cause serious burns. Wait for the temperature to go down before starting the operation.
If there is still pressure remaining inside the case, the oil or
plug may fly out. Loosen the plug slowly to release the
pressure.

Prepare a container to catch drained

oil. Prepare a hexagon wrench.

1. Set so that plug (G) is at the top, with plug (G) and plug (P)
perpendicular to the ground.
2. Set the container to catch oil under plug (P).
3. Remove plug (G) with a hexagonalwrench. Oil level
shouldbe near the bottom of the plug hole (G).
4. If the oillevelislow, addoil throughthe holein plug(G) untilthe
oil overflows.
5. After checking, install plug (G).
CLEAN,CHECK RADIATOR FINS,OIL COOLER FINS,FUEL COOLER
FINS
WARNING
If compressed air, high-pressure water, or steam hits your body directly or dirt is sent flying by
the compressed air, high-pressure water, or steam, there is danger of personal injury. Always
wear protective glasses, dust mask, and other protective equipment.

NOTICE
When use the compressed air, keep a distance from air nozzle, to prevents damage to the fins.
To prevent damage to the fins, apply compressed air from and appropriate distance. Damaged
fins may cause water leakage or overheating. In a dusty site, check the fins daily, irrespective
of the maintenance interval.

1. Open the engine rear cover and cooling cover. For details, see "COOLING COVER (PAGE 3-27)".
2. Use compressed air, steam, or water to blow off the mud, dirt, and leaves clogging radiator fins, oil
cooler fins and fuel cooler fins (1).

CHECK AND ADJUST COOLING FAN BELT TENSION

Checking
1. The deflection should be approx. 9 to 13 mm (0.355 to 0.5
in) whenpressedata pointmidwaybetweenthe
crankshaftpulley and the fan pulley with a finger pressure of
approx. 98 N (10 kg).
REMARK
As a guideline, there is no problem if the deflection is approx.
10 mm (0.4 in).

Adjustment
WARNING
When this maintenance is carried out, it is necessary to open (tilt) the floor.
Before starting the operation to open the floor, read the precautions in "CAUTIONS FOR
OPENING (TILTING) FLOOR (PAGE 2-35)" in the safety and maintenance sections
thoroughly, and refer to the explanation for each part in "METHOD OF OPENING (TILTING)
 FLOOR (PAGE 3-29)" when carrying out the operation. Or ask your Komatsu distributor to
carry out the maintenance.
Immediately after the engine is stopped, the parts and oil are at a high temperature, and will
cause burns. Wait for the temperature to go down before starting the operation.

Prepare a pinch bar.

Prepare a wooden block.

1. Open up the floor, seeing "When Opening (tilt open) (PAGE 3-29)".
2. Insert a bar between alternator (1) and the cylinder block to
fix alternator(1) in position. When fixing alternator(1) in
position, insert a wooden block between the bar and
alternator (1) to prevent any damage to the alternator.
3. Loosen alternator adjustment bolt (2) and mounting bolts (3).
4. Move alternator (1) to adjust so that the belt tension is
approx. 7 to 10 mm (0.276 to 0.4 in) when pressed at a point
midway between the alternator pulley and the fan pulley with
a finger pressure of approx. 98 N (10 kg).

5. Tighten adjustment bolt (2), then tighten mounting bolts (3) to secure alternator (1) in position.
6. Check for damage to the pulleys, and wear of the V-groove and V-belt. Be particularly careful to
check that the V-belt is not in contact with the bottom of the V-groove.
7. If the belt is stretched, leaving no allowance for adjustment, or if it is cut or cracked, contact your
Komatsu distributor for replacement.
8. After completing the adjustment, close the floor. For details, see "When Closing (tilt close) (PAGE
3-33)".