Handling the fuel system

To maximize the service life of your equipment’s engine, using high-quality fuel is essential. It is very important to know how to assess the quality of the fuel being used in your equipment to ensure proper combustion and, above all, to prevent impurities from entering the system.

More than 85% of engine fuel system failures are caused by water and dust in the system.

Most of these impurities are trapped by the fuel filter, which is responsible for trapping dirt and impurities present in the fuel, in the fuel tank, or that enter the system when refueling in dusty areas; it also blocks moisture from the air in the tank and prevents rust from forming there.

A clogged or malfunctioning filter causes symptoms that can be noticed during operation:

• Abnormal exhaust smoke color;
• Poor performance and lack of engine power;
• Excessive fuel consumption;
• Overheating;
• Difficulty to start the engine;
• Poor acceleration.

Therefore, it is recommended that you perform certain daily checks at the beginning and end of the workday, as well as during fueling and storage. These steps, combined with the use of genuine Komatsu filters, will certainly drastically reduce the occurrence of failures or malfunctions related to the fuel injection and filtration system and make your operation more efficient.

Inspection tips:

• At the start of the workday, check to make sure that all water and sediment in the water separator and fuel tank have been drained;
• When refueling the machine during operation, drain the water and sediment from the tank approximately 10 minutes after refueling;
• Make sure the tank has been completely filled after the end of the daily operation. Otherwise, water droplets caused by condensation will form inside the tank;
• During refueling, check that the nozzle and hoses are clean to prevent dirt from entering the tank;
• Clean the inside of the fuel tank whenever you identify a system malfunction or if the screen filter becomes clogged;
• To prevent dust from entering the fuel, do not fill the main filter with fuel; instead, fill the pre-filter without removing the cap;
• Store fuel drums in a horizontal position and in a covered area. 

Using the right lubricating oil

To comply with exhaust emission standards, it is necessary to use high-quality engine oil; therefore, we recommend genuine Komatsu lubricants. Using the right lubricant, combined with proper operation and maintenance, helps extend the service life of your Komatsu equipment:

• Follow the recommended oil change intervals, as the oil’s properties may deteriorate over time, potentially causing engine damage. When changing the oil, be sure to replace the filters as well;
•  It is recommended to warm up the engine before operation; otherwise, internal engine parts may be damaged, compromising components such as the cylinder liner, piston rings, and turbocharger. Always monitor the oil level and temperature, as low oil levels or high oil temperatures can mask issues such as excessive oil consumption or a malfunction in the oil pump;
• Before starting the engine, always check the engine oil level, ensuring the oil is between the L and H marks on the dipstick.

Always use multi-viscosity oil appropriate for the ambient temperature at the worksite. This type of oil withstands temperature changes and maintains its viscosity. In addition, it prevents component wear. When changing the type of oil, replace the entire specified capacity. The oil mixture remaining in the lines will not cause problems. Perform oil changes according to the intervals described in the Operation and Maintenance Manual for your Komatsu equipment.

Be careful not to allow water or any dirt to enter the reservoir while refilling with oil, and do not use dirty containers or hoses to perform this procedure.

• Avoid performing oil changes or refills on rainy days or in dusty/windy environments.

Handling the coolant (water)

Coolant is used to prevent engine damage that can be caused by water freezing at low temperatures. Water freezes at 0 °C, but when coolant is mixed with water, the freezing point is lowered. The freezing point varies depending on the amount of coolant mixed with the water.

Komatsu coolant can be used for 2 years or 4,000 hours, whichever comes first, and has the following characteristics:

• Prevents corrosion and rust on iron, brass, and aluminum;
• Prevents cavitation and erosion;
• Prevents the formation of scale or deposits;
• Antifreeze;
• No need to add water.

After using the correct coolant, maintenance should be performed periodically, as specified in the Operation and Maintenance Manual for your Komatsu equipment.

It is recommended that some of these checks be performed daily, before starting work:

• Check for coolant leaks around the engine or in the system;
• Check the coolant level, and if necessary, add genuine Komatsu coolant.

Important: Whenever you need to remove the coolant reservoir cap, wait for the engine to cool down.

It is also recommended to periodically check the radiator fins: Clean them from time to time. If they become clogged, the engine will overheat.

Handling the air system

When the engine draws in dust suspended in the air, various problems can arise, including wear on the cylinders and piston rings, which results in a loss of power and the emission of dark smoke, increased oil consumption, reduced engine power, and overheating of the turbocharger and exhaust manifold.

The air system filters out all these dust particles and impurities, supplying clean air to the engine and thereby ensuring its optimal performance and extending the service life of your Komatsu equipment.

To avoid these problems, periodic inspection and maintenance of the equipment’s air system is necessary:

• At the start of each workday, it is recommended to check the air obstruction indicator. It allows you to monitor the gradual dust build-up and plan for the next cleaning;
• Do not remove the internal filter while cleaning the external filter. This prevents dust and other impurities from entering the engine.
•  Check the system’s hoses and clamps.
•  When maintaining and cleaning the external air filter, use compressed air to clean it from the inside out. Do not attempt to remove dust by tapping the filter or striking it directly against other objects;
•  Each time you clean the filters, make a mark on the sticker on the filter to keep track of the number of cleanings.