Komatsu's planned maintenance system follows the same tiered hour-based structure as the broader heavy equipment industry — PM services at 250, 500, 1,000, and 2,000 hours — but adds Komatsu-specific programs that no other OEM matches. Komatsu CARE provides complimentary factory-scheduled maintenance for the first 3 years or 2,000 hours on all eligible Tier 4 construction equipment, including a 50-point inspection by factory-trained certified technicians at each interval. KOMTRAX telematics monitors every machine remotely — tracking hours, fuel consumption, load frequency, fault codes, and DEF levels — and automatically notifies your distributor when service is due. KOWA (Komatsu Oil Wear Analysis) provides laboratory-grade fluid analysis at each major service interval. Together, these programs create a maintenance ecosystem that other manufacturers require you to build yourself. This guide covers daily checks, all four PM tiers, equipment-specific schedules for Komatsu's most common construction models, KOWA fluid analysis, KOMTRAX integration, Komatsu CARE and CARE PLUS programs, and environment-based interval adjustments. Always consult your specific Operation and Maintenance Manual for model-exact requirements. Book a demo to see automated Komatsu PM scheduling in HVI.
Komatsu PM Service Tiers
250 Hr
Engine oil and filter, grease all points, fluid levels, air filter check, belt/hose inspection, visual walk-around
500 Hr
All 250-hr + fuel filter, hydraulic return filter, battery service, coolant test (SCA), KOWA oil sample, detailed undercarriage
1,000 Hr
All 500-hr + hydraulic oil sample, final drive oil, turbo inspection, wear measurements, valve adjustment check, structural inspection
2,000 Hr
All 1,000-hr + hydraulic oil change, coolant flush/replace, transmission service, comprehensive component evaluation, KDPF check (4,500hr)
Komatsu CARE & CARE PLUS Programs
New Komatsu Tier 4 equipment comes with complimentary factory-scheduled maintenance that no aftermarket provider can replicate. Understanding these programs is essential for warranty protection and cost management.
Komatsu CARE (Complimentary)
Coverage: First 3 years or 2,000 hours, whichever comes first
Includes: Service at 250, 500, 1,000, 1,500, and 2,000 hours
Inspection: 50-point inspection by factory-trained certified technicians at each interval
Fluids: Komatsu Genuine Lubricants with OEM-formulated additive packages
Analysis: KOWA oil sampling and analysis at each service
KDPF: 2 complimentary exchange units for first 5 years/unlimited hours (at ~4,500 and ~9,000 hrs)
SCR: 2 complimentary SCR system maintenance services for first 5 years/unlimited hours
Komatsu CARE PLUS (Extended)
Coverage: Starts after CARE ends (or overlapping from 0 SMR)
Includes: All manufacturer-outlined maintenance items
Pricing: Upfront national pricing — fixed costs, no surprises
Scheduling: KOMTRAX auto-schedules maintenance; no manual tracking
Certification: Data retention certification increases resale value
Components: 100% core guarantee on all major components
Service: Any authorized Komatsu dealer nationwide
Daily Pre-Operation Checks (Every 10 Service Hours)
Before every shift — regardless of PM tier or Komatsu CARE status. These checks take 10-15 minutes and prevent 80% of common failures.
Fluids & Engine
Engine oil level and condition
Hydraulic fluid level (sight glass)
Coolant level and cap secure
Fuel level; drain water separator
DEF level (Tier 4 machines)
Air filter restriction indicator
Exterior & Undercarriage
Track tension and shoe/pad condition
Tire condition and inflation (wheeled)
Hydraulic hose condition — cracks, leaks
Pins, bushings, attachment points
Radiator/oil cooler — clear debris from fins
Check for fluid leaks under machine
Cab & Operational
ROPS/FOPS integrity, seat belt
Horn, backup alarm, lights
Emergency shutoff accessible
Start engine — gauges, KOMTRAX display normal
Test all controls — smooth response
Brakes — service and parking
PM Schedules by Equipment Type
Komatsu uses the same tiered structure across equipment types, but specific tasks, fluid capacities, and filter part numbers vary by model. These schedules cover the most common Komatsu construction machines.
Excavators
Common Models: PC200, PC210, PC228, PC300, PC350, PC360, PC390, PC490 (and LC/NLC variants)
Service Task
250 Hr
500 Hr
1,000 Hr
2,000 Hr
Engine oil and filter
Change
Change
Change
Change
Grease — boom, stick, bucket, swing bearing
All points
All points
All points
All points
Fuel filter / water separator
Drain daily
Replace
Replace
Replace
Air filter (outer element)
Check
Check
Clean/Replace
Replace
Hydraulic return filter
—
Replace
Replace
Replace
KOWA hydraulic oil sample
—
Sample
Sample
Sample
Hydraulic system oil change
—
—
—
Change
Coolant SCA test / flush
Level
Test SCA
Test SCA
Flush/Replace
Final drive oil (both sides)
Level
Level
Change
Change
Swing machinery oil
—
Level
Check/Change
Change
Undercarriage wear measurement
Visual
Visual
Measure
Measure
Belts, hoses, clamps
Inspect
Inspect
Inspect/Replace
Replace worn
Battery and alternator
Terminals
Load test
Load test
Load test
Structural (boom/stick welds)
—
Visual
Visual
Comprehensive
Dozers
Common Models: D37, D39, D51, D61, D65, D85, D155, D375 (and EX/PX/WX variants)
Service Task
250 Hr
500 Hr
1,000 Hr
2,000 Hr
Engine oil and filter
Change
Change
Change
Change
Grease — blade, ripper, push arms, pivots
All points
All points
All points
All points
Fuel filter / water separator
Drain
Replace
Replace
Replace
Air filter (outer element)
Check
Check
Clean/Replace
Replace
Hydraulic return filter
—
Replace
Replace
Replace
Hydraulic oil sample / change
—
KOWA sample
Sample
Change
Transmission / torque converter oil
Level
Level
Sample/Change
Change
Final drive oil (both sides)
Level
Level
Change
Change
Coolant SCA test / flush
Level
Test SCA
Test SCA
Flush/Replace
Undercarriage wear measurement
Visual
Visual
Measure
Measure
ROPS bolt torque
—
—
Torque check
Torque check
Cutting edge / end bit bolt torque
Check
Check
Check
Check
Turbocharger inspection
—
—
Inspect
Inspect
Wheel Loaders
Common Models: WA150, WA200, WA270, WA320, WA380, WA470, WA480, WA500, WA600
Service Task
250 Hr
500 Hr
1,000 Hr
2,000 Hr
Engine oil and filter
Change
Change
Change
Change
Grease — bucket, Z-bar/linkage, steering, axle
All points
All points
All points
All points
Fuel filter / water separator
Drain
Replace
Replace
Replace
Air filter (outer element)
Check
Check
Clean/Replace
Replace
Hydraulic return filter
—
Replace
Replace
Replace
Hydraulic oil sample / change
—
KOWA sample
Sample
Change
Transmission oil and filter
Level
Filter replace
Sample + filter
Change all
Axle oil (front and rear)
Level
Level
Sample
Change
Differential oil
—
—
Check
Change
Tire condition / inflation
Check
Check
Check
Check
Brake system inspection
Function test
Inspect pads
Measure
Comprehensive
Articulation / steering pins
Grease
Grease + check
Measure play
Replace worn
Coolant SCA test / flush
Level
Test SCA
Test SCA
Flush/Replace
Dump Trucks
Common Models: HD325, HD405, HD465, HD605, HD785 (rigid) + HM300, HM400 (articulated)
Service Task
250 Hr
500 Hr
1,000 Hr
2,000 Hr
Engine oil and filter
Change
Change
Change
Change
Grease — body pivot, suspension, steering
All points
All points
All points
All points
Fuel filter / water separator
Drain
Replace
Replace
Replace
Air filter (outer element)
Check
Check
Clean/Replace
Replace
Hydraulic return filter
—
Replace
Replace
Replace
Hydraulic oil sample / change
—
KOWA sample
Sample
Change
Transmission oil and filter
Level
Filter replace
Change
Change
Differential / final drive oil
Level
Level
Change
Change
Tire condition / inflation / wheel nuts
Check all
Check + torque
Check + torque
Check + torque
Brake system (wet disc / retarder)
Function test
Inspect
Measure
Comprehensive
Dump body / hoist cylinder / tailgate
Inspect
Inspect
Detailed
Comprehensive
Suspension system
Visual
Inspect
Measure
Replace worn
Coolant SCA test / flush
Level
Test SCA
Test SCA
Flush/Replace
KOWA: Komatsu Oil Wear Analysis
KOWA is Komatsu's laboratory fluid analysis program — equivalent to Cat's S.O.S but integrated into the Komatsu CARE service ecosystem. Every major service includes KOWA sampling, and results are tracked by your Komatsu distributor through KOMTRAX.
Engine Oil
Wear metals (iron, copper, lead, aluminum), contaminants (silicon = dirt, sodium = coolant), fuel dilution, soot, viscosity, oxidation
Hydraulic Fluid
Particle count (ISO cleanliness), wear metals from pumps/valves, water content, viscosity change, oxidation level
Coolant
pH, SCA concentration, glycol content, conductivity, nitrite/molybdate levels, contamination indicators
Transmission / Final Drive
Gear wear metals (iron = gear teeth, copper = bushings/washers), particle contamination, viscosity, water content
Track Every Komatsu PM Interval Automatically
HVI integrates with KOMTRAX telematics for automatic hour updates, schedules PM services with the correct tasks per model, and generates work orders 90 hours before each interval.
KOMTRAX: Remote Monitoring & PM Integration
Every Komatsu machine ships with KOMTRAX telematics — and it does far more than GPS tracking. KOMTRAX data feeds directly into maintenance scheduling and machine health management.
Engine Hours & PM Countdown
Countdown timers for each standard maintenance interval, customizable for application (e.g., hydraulic hammer = shorter intervals). On-screen messages and email alerts when service is due.
Load Frequency Data
Hours spent in four load levels based on pump pressure or engine torque. High-load machines may need shortened intervals. Fuel consumption data indicates load factor — a better wear indicator than hours alone.
Fault Codes & Warnings
Error codes and out-of-range alerts for high temperatures, low fluid/DEF levels, and system anomalies. Built-in diagnostics eliminate laptop need for most troubleshooting.
HVI Integration
Connect KOMTRAX data to HVI for unified fleet management — hours, fault codes, fuel consumption feed into PM scheduling alongside inspection records, work orders, and compliance documentation.
Using HVI to Automate Komatsu PM Scheduling
KOMTRAX Integration
Engine hours, fault codes, and fuel consumption from KOMTRAX feed directly into HVI. Automatic PM triggers. No manual hour logging for connected machines.
Pre-Built Komatsu Templates
Inspection and PM checklists for PC-series excavators, D-series dozers, WA-series loaders, and HD/HM-series trucks. Customizable per model.
Auto Work Orders
PM interval triggers → work order generated with all tasks, parts list, and assigned technician. Tracks from schedule through completion and sign-off.
KOWA Results Tracking
Log fluid analysis results per machine. Trend wear metals over time. Identify accelerating wear before the next sample is due.
Cost-Per-Hour Analytics
Maintenance cost per operating hour per machine. Compare across fleet. Identify outliers. Data-driven repair-vs-replace decisions.
Komatsu CARE Tracking
Track which machines are still under CARE coverage, when CARE expires, and whether to transition to CARE PLUS. Warranty protection through documented PM compliance.
Frequently Asked Questions
Q: What's included in Komatsu CARE and how long does it last?
Komatsu CARE covers the first 3 years or 2,000 hours (whichever first) on eligible Tier 4 construction equipment. You get factory-scheduled service at 250, 500, 1,000, 1,500, and 2,000 hours, a 50-point inspection at each interval, Komatsu Genuine Lubricants, KOWA oil analysis, plus 2 complimentary KDPF exchanges and 2 SCR services for 5 years/unlimited hours. After CARE ends, Komatsu CARE PLUS provides extended coverage at fixed national pricing.
Q: Are Komatsu PM intervals the same as Caterpillar?
The tier structure (250/500/1,000/2,000 hours) is standard across the industry, including both Komatsu and Cat. However, specific tasks, fluid specifications, and filter part numbers differ. Komatsu uses KOWA analysis (vs. Cat S.O.S) and includes KOMTRAX telematics on every machine (Cat charges separately for VisionLink). Always use OEM-specified fluids and filters for warranty compliance.
Q: Can I perform Komatsu CARE services myself?
Komatsu CARE services must be performed by authorized Komatsu distributors using factory-trained certified technicians and Komatsu Genuine Lubricants. Self-service during the CARE period may void the complimentary coverage. After CARE expires, you can self-service using Komatsu-specified fluids and filters — HVI helps track intervals and document services for warranty compliance.
Q: How does HVI integrate with KOMTRAX?
HVI connects to KOMTRAX data for automatic engine hour tracking, fault code alerts, and fuel consumption monitoring. This feeds directly into PM scheduling — no manual hour entry for connected machines. HVI adds what KOMTRAX doesn't: digital inspection records, photo-verified defects, work order management, and fleet compliance documentation on one platform. Book a demo to see the integration.
Q: What happens at 4,500 and 9,000 hours on Tier 4 Komatsu machines?
KDPF (Komatsu Diesel Particulate Filter) exchange is recommended at ~4,500 and ~9,000 hours. Komatsu CARE provides 2 complimentary KDPF exchanges within the first 5 years. SCR (Selective Catalytic Reduction) system maintenance is also recommended at these intervals. These are in addition to the standard PM schedule and are critical for emissions compliance and engine performance.
Q: Do these schedules apply to older pre-Tier 4 Komatsu equipment?
The core PM structure (250/500/1,000/2,000 hours) applies to all Komatsu equipment. Pre-Tier 4 machines won't have KDPF/SCR service requirements and aren't eligible for Komatsu CARE. Older machines benefit even more from systematic PM since they lack the telematics monitoring of newer models. HVI tracks PM for any Komatsu model regardless of age.
Never Miss a Komatsu PM Interval Again
HVI integrates with KOMTRAX, automates PM scheduling per model, generates work orders with the correct tasks, and tracks Komatsu CARE coverage — one platform for your entire Komatsu fleet.
