SK1020-5 | SN: 37CF00004-UP | Komatsu | Heavy Equipment Manual PDF

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LISTOFREVISEDPAGES

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IMPORTANTSAFETYNOTICE

Properserviceandrepairisextremelyimportantforthesafeoperationofyourmachine. TheserviceandrepairtechniquesrecommendedbyKomatsuUtilityanddescribeinthismanualarebotheffectiveandsafemethodsofoperation.Someoftheseoperationsrequiretheuseoftoolsspeciallydesigned byKomatsuUtilityforthepurpose.

Topreventinjurytoworkers,thesymbolsandareusedtomarksafetyprecautionsinthismanual. Thecautionsaccompanyingthesesymbolsshouldalwaysbecarefullyfollowed.Ifanydangerarisesormay possiblyarise,firstconsidersafety,andtakenecessarystepstoface.

SAFETY

GENERALPRECAUTIONS

Mistakesinoperationextremelydangerous. ReadalltheOperationandMaintenanceManualcarefullyBEFOREoperatingthemachine.

1.Beforecarryingoutanygreasingorrepairs,readall theprecautionswrittenonthedecalswhicharesuck onthemachine.

2.Whencarryingoutanyoperation,alwayswearsafetyshoesandhelmet.Donotwearloosework clothes,orclotheswithbuttonsmissing.

•Alwayswearsafetyglasseswhenhittingparts withahammer.

•Alwayswearsafetyglasseswhengrinding partswithagrinder,etc.

3.Ifweldingrepairsareneeded,alwayshavea trained,experiencedweldercarryoutthework. Whencarryingoutweldingwork,alwayswearweldinggloves,apron,glasses,capandotherclothes suitedforweldingwork.

4.Whencarryingoutanyoperationwithtwoormore workers,alwaysagreeontheoperatingprocedure beforestarting.Alwaysinformyourfellowworkers beforestartinganystepoftheoperation.Before startingwork,hangUNDERREPAIRsignsonthe controlsintheoperator’scompartment.

5.Keepalltoolsingoodconditionandlearnthecorrect waytousethem.

6.Decideaplaceintherepairworkshoptokeeptools andremovedparts.Alwayskeepthetoolsandparts intheircorrectplaces.Alwayskeeptheworkarea cleanandmakesurethatthereisnodirtoroilonthe floor.

Smokeonlyintheareasprovidedforsmoking.Neversmokewhileworking.

PREPARATIONSFORWORK

7.Beforeaddingormakinganyrepairs,parkthemachineonhard,levelground,andblockthewheelsto preventthemachinefrommoving.

8.Beforestartingwork,loweroutrigger,bucketorany otherworkequipmenttotheground.Ifthisisnot possible,useblockstopreventtheworkequipment fromfallingdown.Inaddition,besuretolockallthe controlleversandhangwarningsignonthem.

9.Whendisassemblingorassembling,supportthe machinewithblocks,jacksorstandsbeforestarting work.

10.Removeallmudandoilfromthestepsorotherplacesusedtogetonandoffthemachine.Alwaysuse thehandrails,laddersorstepswhengettingonoroff themachine. Neverjumponoroffthemachine. Ifitisimpossibletousethehandrails,laddersor steps,useastandtoprovidesafefooting.

PRECAUTIONSDURINGWORK

11.Whenremovingtheoilfillercap,drainplugorhydraulicpressuremeasuringplugs,loosenthem slowlytopreventtheoilfromspurtingout. Beforedisconnectingorremovingcomponentsof thehydrauliccircuitandenginecoolingcircuit,first removethepressurecompletelyfromthecircuit.

12.Thewaterandoilinthecircuitsarenothotwhenthe engineinstopped,sobecarefulnottogetburned. Waitfortheoilwatertocoolbeforecarryingoutany workonthecoolingwatercircuits.

13.Beforestartingwork,removetheleadsfromthebattery.Alwaysremovetheleadfromthenegative(–) terminalfirst.

14.Whenraisingheavycomponents,useahoistor crane.Checkthatthewirerope,chainsandhooks arefreefromdamage. Alwaysuseliftingequipmentwhichhasamplecapacity.Installtheliftingequipmentatthecorrect places.

Useahoistorcraneandoperateslowlytoprevent thecomponentfromhittinganyotherpart. Donotworkwithanypartstillraisedbythehoistor crane.

15.Whenremovingcoverswhichareunderinternal pressureorunderpressurefromaspring,always leavetwoboltsinpositiononoppositesides.Slowly releasethepressure,thenslowlyloosentheboltsto remove.

16.Whenremovingcomponents,becarefulnotto breakordamagethewiring. Damagewiringmaycauseelectricalfires.

17.Whenremovingpiping,stopthefueloroilfromspillingout.Ifanyfueloroildripsontothefloor,wipeitup immediately.

Fueloroilonthefloorcancauseyoutoslip,orcan evenstartfires.

18.Asageneralrule,donotusegasolinetowashparts. Inparticular,useonlytheminimumofgasoline whenwashingelectricalparts.

19.Besuretoassembleallpartsagainintheiroriginal places.Replaceanydamagepartswithnewparts. Wheninstallinghosesandwires,besurethatthey willnotbedamagedbycontactwithotherparts whenthemachineisbeingoperated.

20.Wheninstallinghighpressurehoses,makesure thattheyarenottwisted.Damagedtubesaredangerous,sobeextremelycarefulwheninstalling tubesforhighpressurecircuits.Also,checkthat connectingpartsarecorrectlytightened.

21.Whenassemblingorinstallingparts,alwaysuse specifiedtighteningtorques. Wheninstallingthepartswhichvibrateviolentlyor rotateathighspeed,beparticularycarefultocheck thattheyarecorrectlyinstalled.

22.Whenaligningtwoholes,neverinsertyourfingers orhand.

23.Whenmeasuringhydraulicpressure,checkthatthe measuringtooliscorrectlyassembledbeforetaking anymeasurement.

24.Takesurewhenremovingorinstallingwheels.

FOREWORD

Thisshopmanualhasbeenpreparedasanaidtoimprovethequalityofrepairsbygivingtheoperatoranaccurate understandingoftheproductandbyshowinghimthecorrectwaytoperformrepairsandmakejudgements.Makesure youunderstandthecontentsofthismanualanduseittofulleffectateveryopportunity.

Thisshopmanualmainlycontainsthenecessarytechnicalinformationforoperationsperformedinaserviceworkshop.

Themanualisdividedintochaptersoneachmaingroupofcomponents;thesechaptersarefurtherdividedintothe followingsections.

STRUCTUREANDFUNCTION

Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding ofthestructure,butalsoservesasreferencematerialfortroubleshooting.

TESTINGANDADJUSTING

Thissectionsexplainscheckstobemadebeforeandafterperformingrepairs,aswellasadjustmentstobe madeatcompletionofthechecksandrepairs.

Troubleshootingchartscorrelating«Problems»to«Causes»arealsoincludedinthissection.

DISASSEMBLYANDASSEMBLY

Thissectionexplainstheordertobefollowedwhenremoving,installing,disassemblingorassemblingeach component,aswellasprecautionstobetakenfortheseoperations.

MAINTENANCESTANDARD

Thissectiongivesthejudgementstandardswheninspectingdisassembledparts.

NOTE

Thespecificationscontainedinthisshopmanualaresubjecttochangeatanytimeandwithoutanynotice.

ContactyourKomatsuUtilitydistributorforthelatestinformation.

HOWTOREADTHESHOPMANUAL

VOLUMES

Shopmanualareissuedasaguidetocarryoutrepairs. Thesevariousvolumesaredesignedtoavoidduplicatingthesameinformation.

DISTRIBUTIONANDUPDATING

Anyadditions,amendmentsorotherchangeswillbe senttoKomatsuUtilitydistributors. Getthemostup-to-dateinformationbeforeyoustartany work.

FILINGMETHOD

1.Seethepagenumberonthebottomofthepage. Filethepagesincorrectorder.

2.Followingexamplesshowyouhowtoreadthepage number.

Example:

3.Additionalpages:additionalpagesareindicatedby ahyphen(–)andnumberafterthepagenumber. Fleasintheexample. Example:

REVISEDEDITIONMARK (....)

Whenamanualisrevised,aneditionmarkisrecorded onthebottomoutsidecornerofthepages.

REVISIONS

RevisedpagesareshownontheLISTOFREVISED PAGESbetweenthetitlepageandSAFETYpage.

SYMBOLS

Inordertomaketheshopmanualgreatlychelpful,importantpointsaboutsafetyandqualityaremarkedwith thefollowingsymbols.

SymbolItemRemarks

Safety

Caution

Weight

Tightening torque

Specialsafetyprecautions arenecessarywhen performingthework.

Extraspecialsafetyprecautions arenecessarywhenperforming theworkbecauseitisunderinternalpressure.

Specialtechnicalprecautionsor otherprecautionsforpreserving standardsarenecessarywhen performingthework.

Weightofpartsorsystems.

Cautionnecessarywhenselectinghoistingwire,orwhenworkingpostureisimportant,etc.

Partsthatrequirespecialattentionforthetighteningtorqueduringassembly.

CoatPartstobecoatedwithadhesivesandlubricantsetc.

Oil,water

Placeswhereoil,waterorfuel mustbeadded,andtheirquantity.

Drain

Placeswhereoilorwatermust bedrained,andquantitytobe drained.

HOISTINGINSTRUCTIONS

Heavyparts(25kgormore)mustbelifted withahoistetc.IntheDisassemblyandAssemblysection,everypartweighing25kgormoreis clearlyindicatedwiththesymbol

1.Ifapartcannotbesmoothlyremovedfromthemachinebyhoisting,thefollowingchecksshouldbe made:

•Checkforremovalofallboltsfasteningthepart totherelativeparts.

•Checkforanypartcausinginterferencewith theparttoberemoved.

2.Wireropes

1)Useadequateropesdependingontheweightof partstobehoisted,referringtothetablebelow:

WIREROPES

(Standard«S»or«Z»twistropes withoutgalvanizing)

Theallowableloadvalueisestimatedtobeonesixthorone-seventhofthebreakingstrengthofthe ropeused.

2)Slingwireropesfromthemiddleportionofthehook. Slingingneartheedgeofthehookmaycausethe ropetoslipoffthehookduringhoistg,andaseriousaccidentcanresult.

SK1020-5SK1020-5turbo

Hookshavemaximumstrengthatthemiddleportion.

3)Donotslingaheavyloadwithoneropealone,but slingwithtwoormoreropessymmetricallywound ontotheload.

Slingingwithoneropemaycauseturningoftheload duringhoisting,untwistingoftherope,orslippingof theropefromitsoriginalwindingpositiononthe load,whichcancausedangerousaccidents.

4)Donotslingaheavyloadwithropesformingawide hanginganglefromthehook.

Whenhoistingaloadwithtwoormoreropes,the forcesubjectedtoeachropewillincreasewiththe hangingangles.

Thetablebelowshowsthevariationofallowable load(kg)whenhoistingismadewithtworopes, eachofwhichisallowedtoslingupto1000kgvertically,atvarioushandingangles.

Whentworopesslingaloadvertically,upto2000kg oftotalweightcanbesuspended.

Thisweightbecomes1000kgwhentworopes makea120°hangingangle.

Ontheotherhand,tworopesaresubjectedtoanexcessiveforceaslargeas4000kgiftheyslinga2000 kgloadataliftingangleof150°.

STANDARDTIGHTENINGTORQUE

Thefollowingchartsgivethestandardtighteningtorquesofboltsandnuts. Exceptionsaregiveninsectionof«DisassemblyandAssembly».

1.STANDARDTIGHTENINGTORQUEOFBOLTSANDNUT

Thistorquetabledoesnotapplytoboltsornutswhichhavetofastennylonorotherpartsnon-ferrousmetalwasher. Nm(newtonmeter):1Nm=0.102kgm

2.TIGHTENINGTORQUEFORNUTSOFFLARED

Usethesetorquesfornutpartofflared.

Threaddiameter ofnutpart (mm)

1/2”-20

9/16”-18

3/4”-16

7/8”-14

1.1/16-12

1.5/16-12

Widthacrossflats ofnutpart

Threaddiameter ofnutpart (mm)

9/16”-18

11/16”-16

13/16”-16

1”-14

1.3/16-12

1.7/16-12

1.11/16-12

2”-12

Widthacrossflats ofnutpart (mm)

Sealingsurface STANDARDTIGHTENINGTORQUE

2.3–2.5

3.4–3.9 5.2–5.8

COATINGMATERIALS

TherecommendedcoatingmaterialsprescribedinKomatsuUtilityShopManualsarelistedbelow:

NomenclatureCodeApplications

Bostik99Usedtoapplyrubberpads,rubbergasketsandcorkplugs.

Loctite406Usedtoapplyresin,rubber,metallicandnon-metallicpartswhenafast,strong sealisneeded.

Loctite222Usedforlowresistancelockingofscrews,checknutsandadjustmentnuts.

Loctite242 Topreventthelooseningofbolts,nutsandplugsandtheleakageofoil.Usedfor mediumresistancelockingofscrewsandnutsofeverytype,andforlocking keysandbearings.

Loctite262Usedforhighresistantofthreadedpartsthatcanberemovedwithnormaltools.

Adhesives

Loctite270Usedforhighresistantlockingandforsealingthreadedparts,boltsandstud bolts.

Loctite542Usedforsealingtheunionthreadsforhydraulictubes.

Loctite573Usedforsealingratherexactplanesurfaceswhentheoptionofpossiblefuture dismantlingisrequired.

Loctite601Usedforhighresistantlockingofmechanicalcomponentsthatcanberemoved onlyafterheating

Loctite675Usedtolockcylindricalcouplingsandforthepermanentlockingofthreaded parts,andalsotolockshaftstobearings,gears,pulleys,pins,bushings,etc.

Loctite542Usedbyitselftosealgreasefittings,taperedscrewfittingsandtaperedscrew fittingsinhydrauliccircuitsoflessthan50mmindiameter.

Gasketsealant

Antifrictioncompound (Lubricantincluding Molybdenumdisulfide)

Grease (Lithiumgrease)

Loctite510Usedbyitselfonmountingflatsurface(Clearancebetweensurfaceswithin0.2mm)

Loctite518Usedbyitselfonmountingflatsurface(Clearancebetweensurfaceswithin0.5mm

LitioEPMS2 NLGI2

LitioEP NLGI2

Appliedtobearingsandtapershafttofacilitatepress-fittingandtoprevent sticking,burningorrusting.

Appliedtobearings,slidingpartsandoilsealsforlubrication,rustprevention andfacilitationofassemblingwork.

Vaseline Usedforprotectingbatteryelectrodeterminalsfromcorrosion

Inthewiringdiagramsvariouscolourandsymbolsareemployedtoindicatethethicknessofwires. ThiswirecodetablewillhelpyouunderstandWIRINGDIAGRAMS.

Example:R–N1.5indicatesacablehavinganominalnumber1.5andredcoatingwithblackstripe.

CLASSIFICATIONBYTHICKNESS

Nominal number

Copperwire CableO.D. (mm) Currentrating (A) Number strands Øofstrands (mm) Crosssection (mm)

0.5160.200.351.553.5 1140.300.992.8011 1.5210.301.483.3514 2.5350.302.473.8020 4560.303.954.6028 6840.305.935.2037

CLASSIFICATIONBYCOLOURANDCODE

PrimaryAuxiliary

CodeAA–BA/BA–G–A–NA/NA–RA–VA/V

ColourLightBlueLightBlue–WhiteLightBlue–YellowLightBlue–BlackLightBlue–RedLightBlue–Green CodeBB–G–B–NB/NB–RB/R

ColourWhiteWhite–YellowWhite–BlackWhite–Red CodeCC–BC/BC–L–C–NC/N

ColourOrangeOrange–WhiteOrange–BlueOrange–Black CodeGG–NG/N–G/R

ColourYellowYellow–BlackYellow–Red CodeHH–GH–L–H–N–H–RH/R

ColourGreyGrey-YellowGrey–BlueGrey–BlackGrey–Red CodeL–L/BL–GL/GL–NL/NL–RL/R

ColourBlueBlue–WhiteBlue–YellowBlue–BlackBlue–Red CodeMM–BM/BM–N–M–V–

ColourBrownBrown–WhiteBrown–BlackBrown–Green CodeN

ColourBlack

CodeRR–G–R–NR/NR–V–

ColourRedRed–YellowRed–BlackRed–Green CodeSS–G–S–NS/N

ColourPinkPink–YellowPink–Black CodeVV–BV/BV–N–

ColourGreenGreen–WhiteGreen–Black CodeZZ–B–Z–NZ/N

ColourVioletViolet–WhiteViolet–Black

COMPOSITIONOFTHECOLOURS

Thecolorationoftwo-colourwiresisindicatedbythecompositionofthesymbollisted.

Example:G–V=Yellow-Greenwithlongitudinalcolouring G/V=Yellow-Greenwithtransversalcolouring

SK1020-5SK1020-5turbo

WEIGHTTABLE

Thisweighttableisaguideforusewhentransportingorhandlingcomponents.

Unit:kg

MachinemodelSK1020-5SK1020-5turbo

Engineassembly-Muffler-Exhaustpipe235235

Radiator3538

Hydraulicoiltank(withoutoil)2525

Enginehood18.518.5

Cabin(withoutseat)215215 Seat:

Engine-pumpgroup328–335328–335

Wheel,assy.(standard)5252

Controlvalve: •3-spool(standard)

Workequipment(withoutbucket)

•Arm

•Workequipmentsupport

•Bucket

•Tiltcylinder

TABLEOFOILANDCOOLANTQUANTITIES

RESERVOIRKINDOF FLUID

SAE10W

Hydraulicsystem andhydrostatic trasmissione

Hydrauliccircuit with biodegradableoil

SAE30

SAE40

SAE10W-30

SAE5W-30

SAE10W

SAE5W-30

SAE10W-30 ASTMD975N.2

ASTMD975N.

IMPORTANT:

(1)Whenthedieseloilsulphurcontentislessthen0.5%,changetheengineoilaccordingtotheperiodicmaintenance intervalsindicatedintheoperationandmaintenancemanual.Inthedieseloilsulphurcontentexceeds0.5%change theengineoilaccordingtothefollowingtable:

SulphurcontentEngineoilchangeinterval from0.5to1.0%1/2fregularinterval over1.0%1/4fregularinterval

(2)Whenstartingtheengineattemperaturesbelow0°C,useengineoilSAE10W,20W-20and10W-30,evenifduring thedaythetemperatureincreasesby10°C.

(3)UseengineoilwithCDclassification;ifoilwithCDclassificationisused,reducetheengineoilchangeintervalbya half.

(4)Useoriginalproducts,whichhavecharacteristicsspecificallyformulatedandapprovedfortheengine,thehydraulic circuitofequipmentandforreductions.

Firstfillingquantity: totalquantityofoil,includingtheoilforthecomponentsandpipes.

Oilchangequantity: quantityofoilnecessarytofillthesystemorunitduringthenormalinspectionandmaintenanceoperations.

ASTM:AmericanSocietyofTestingandMaterials

SAE:SocietyofAutomotiveEngineers

API:AmericanPetroleumInstitute

SK1020-5SK1020-5turbo