WEBM009100
SKID-STEER LOADER
SK820-5E0 SERIAL NUMBER
SK820-5E0
F60003 and up
SK820-5E0
SKID-STEER LOADER SK820-5E0
Machine Model
Serial number
SK820-5E0
F60003 and up
00 Index and foreword
SK820-5E0
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00 Index and foreword
Index
Index
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00 Index and foreword Index ........................................................................................................................................................... 2 Foreword and general information .............................................................................................................. 6 Safety notice ............................................................................................................................................ 6 How to read the shop manual ................................................................................................................ 11 Explanation of terms for maintenance standard .................................................................................... 13 Handling of hydraulic components ......................................................................................................... 15 Method of disconnecting and connecting push-pull type coupler .......................................................... 17 Handling of electric equipment............................................................................................................... 20 How to read electric wire code............................................................................................................... 30 Precautions when performing work........................................................................................................ 33 Standard tightening torque table ............................................................................................................ 36 List of abbreviation................................................................................................................................. 40 Conversion table .................................................................................................................................... 44 01 Specification Specification................................................................................................................................................ 4 Dimensions (with bucket)......................................................................................................................... 4 Dimensions (with pallet forks) .................................................................................................................. 6 Specification............................................................................................................................................. 8 Table of weight......................................................................................................................................... 9 Fuel, coolant and lubricants ................................................................................................................... 10 10 Structure, function and maintenance standard PTO.......................................................................................................................................................... 3 Power train ............................................................................................................................................... 5 Transmission............................................................................................................................................ 6 Final drive ................................................................................................................................................ 9 Hydraulic pump ...................................................................................................................................... 16 Control valve (3-spool) ........................................................................................................................... 37 CLSS...................................................................................................................................................... 53 Solenoid valves ...................................................................................................................................... 60 Accumulator ........................................................................................................................................... 62 R.H. PPC valve ...................................................................................................................................... 63 L.H. PPC valve....................................................................................................................................... 68 Cylinders ................................................................................................................................................ 74 Work equipment..................................................................................................................................... 76 20 Standard value table Standard value table ................................................................................................................................... 3 Engine...................................................................................................................................................... 3 Machine ................................................................................................................................................... 4 30 Testing and adjusting Testing and adjusting .................................................................................................................................. 3 Special tools............................................................................................................................................. 3 Checking the engine speed ..................................................................................................................... 4 Adjustment of valve clearance ................................................................................................................. 5 Measurement of the compression pressure............................................................................................. 7 Control and adjustment of the fan belt tension ........................................................................................ 8 Control and adjustment of the injection timing ......................................................................................... 9 00-2
SK820-5E0
Index
00 Index and foreword
Checking engine oil pressure ................................................................................................................ 11 Adjusting the stroke of the accelerator cables ....................................................................................... 12 Regulation of PPC valves’ drive pressure.............................................................................................. 15 Adjustment of the PPC valve clearances............................................................................................... 17 Adjusting the position of the servo-control. ............................................................................................ 18 Testing and adjustment of gearing chain tension .................................................................................. 19 Control and regulation of the pressures in the hydraulic circuits ........................................................... 20 Testing the hydraulic pump.................................................................................................................... 21 Valve calibration .................................................................................................................................... 22 Checking the travel deviation................................................................................................................. 24 SSC device (Slow speed control) calibration ......................................................................................... 25 Control valve .......................................................................................................................................... 26 Control and regulation of the servo-control power supply...................................................................... 28 Elimination of residual pressures - pressurisation of the tank................................................................ 30 Bleeding air from the hydraulic circuits .................................................................................................. 31 50 Disassembly and assembly How to read the manual........................................................................................................................... 3 Coating materials list ............................................................................................................................... 5 Removal and installation of engine hood ................................................................................................. 6 Tilting and lowering of cab ....................................................................................................................... 7 Removal and installation of battery........................................................................................................ 10 Removal and installation of starting motor............................................................................................. 11 Removal and installation of alternator ................................................................................................... 12 Removal and installation of muffler........................................................................................................ 13 Removal and installation of turbocharger .............................................................................................. 14 Removal and installation of air intake filter ............................................................................................ 15 Removal and installation of valve cover ................................................................................................ 16 Removal and installation of nozzle holder ............................................................................................. 17 Removal and installation of injection pump ........................................................................................... 18 Removal and installation of cylinder head ............................................................................................. 21 Removal and installation of coolant liquid pump.................................................................................... 23 Removal and installation of radiator group ............................................................................................ 24 Removal and installation of fuel tank ..................................................................................................... 26 Removal and installation of cab ............................................................................................................. 28 Removal and installation of engine-pump group ................................................................................... 32 Removal and installation of hydraulic pump assembly .......................................................................... 35 Removal and installation of gear pump ................................................................................................. 37 Removal and installation of engine-pump coupling ............................................................................... 38 Removal and installation of control valve .............................................................................................. 39 Removal and installation of PPC valve.................................................................................................. 40 Removal and installation of hub wheel .................................................................................................. 41 Removal and installation of final drive ................................................................................................... 45 Removal and installation of lift cylinder.................................................................................................. 46 Removal and installation of bucket cylinder........................................................................................... 48 Disassembly and assembly of work equipment cylinders...................................................................... 50 Removal and installation work equipment assembly ............................................................................. 55 Removal and installation of fulcrum lever .............................................................................................. 57 Removal and installation of lift lever ...................................................................................................... 58 Removal and installation of equipment support frame........................................................................... 60 90 Diagrams and drawings Hydraulic diagrams ..................................................................................................................................... 3 Hydraulic diagram (float).......................................................................................................................... 3 SK820-5E0
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00 Index and foreword
Index
Hydraulic diagram (float - road homologation)......................................................................................... 5 Hydraulic diagram (float - road homologation - Slow Speed control)....................................................... 7 Hydraulic diagram (High-flow).................................................................................................................. 9 Hydraulic diagram (High-flow - road homologation)............................................................................... 11 Hydraulic diagram (High-flow - road homologation - Slow Speed control) ............................................ 13 Electrical circuit diagrams ......................................................................................................................... 15 Electrical circuit diagram (1/2)................................................................................................................ 15 Electrical circuit diagram (2/2)................................................................................................................ 17
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SK820-5E0
This is the sample of the manual Click on the download link for complete manual
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Index
SK820-5E0
00 Index and foreword
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00 Index and foreword
Foreword and general information Safety notice
Foreword and general information
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Safety notice
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(Rev. 2010/03)
Important safety notice Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes. The symbol mark "k" is indicated for such matters that require special precautions. The work indicated with the warning mark should be performed according to the instructions with special attention to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure to keep safe first and take every necessary measure. 1. General precautions k Inappropriate handling creates an extreme danger. Read and understand what is described in the Operation and Maintenance Manual before operating the machine. Read and understand what is described in this manual before starting work. 1) Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) Locate a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When performing any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear the safety glasses when hitting parts with a hammer. q Always wear the safety glasses when grinding parts with a grinder, etc. 4) When performing any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the operator's compartment. 5) Only qualified workers must perform the work and operation which require license or qualification.
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6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Before starting work, thoroughly check the tools, machine, forklift truck, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condition. 9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition and at the provided place. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signals 5 Prohibition of operation and handling by unlicensed workers 6 Safety check before starting work 7 Wearing protective goggles (for cleaning or grinding work) 8 Wearing shielding goggles and protectors (for welding work) 9 Good physical condition and preparation 10 Precautions against work which you are not used to or you are used to too much
2. Preparation work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving.
SK820-5E0
Foreword and general information Safety notice
2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning tag on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting the work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing components for the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is shut down, so be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or water circuits. 3) Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts. 4) Before starting work, remove the cables from the battery. Always remove the cable from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure by a spring, always leave two bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. SK820-5E0
00 Index and foreword
7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11)When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that connections of them are correct. 12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speeds, be particularly careful to check that they are installed correctly. 13)When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14)When measuring hydraulic pressure, check that the measuring tools are correctly installed. 15)Take care when removing or installing the wheels. 16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
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00 Index and foreword
4. Precautions for slinging work and making signals 1) Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaller must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaller must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its centre of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with one wire rope alone. If it is slung so, It may rotate and may slip out of the rope. Install two or more wire ropes symmetrically. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60 degree, as a rule. Do not sling a heavy load (25 kg or more) with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When the two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1000 kg} when the two ropes make a hanging angle of 120 degree. If the two ropes sling a 19.6 kN {2000 kg} load at a lifting angle of 150 degree, each of them is subjected to a force as large as 39.2 kN {4000 kg}.
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Foreword and general information Safety notice
8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10)Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11)Do not use twisted or kinked wire ropes. 12)When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
SK820-5E0
Foreword and general information Safety notice
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load at an angle. 13)When lowering a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. q
5. Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead traveling crane k A hoist crane or similar device must be used for lifting a heavy load (25 kg or more). The weight of a part that is 25 kg or more is indicated with the symbol "4" in "Disassembly and assembly". 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, ground fault circuit interrupter, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signals for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load at an angle. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10)Place the control switch in a position where it will not be an obstacle to work and passage. 11)After operating the hoist, do not swing the control switch. 12)Remember the position of the main switch so that you can turn off the power immediately in an emergency.
SK820-5E0
00 Index and foreword
13)If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition. 14)If you find an obstacle around the hoist, stop the operation. 15)After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below Wire ropes (Standard "Z" twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal diameter Allowable load of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a The allowable load is one-sixth of the breaking strength of the rope to be used (Safety coefficient: 6).
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8. Precautions for disconnecting and connecting hoses and tubes in an air conditioner circuit 1) Disconnection k Although the refrigerant (refrigerant gas: R134a) used on the machine's air conditioner is less destructive to the ozone layer for environmentally friendliness, it is not allowed to be released into the atmosphere as is. Whenever disconnecting the air conditioner gas circuit, be sure to recover the refrigerant gas to reuse it. a Ask a qualified person for collection and charge of the refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight or your skin may be frozen. Whenever recovering or adding refrigerant gas, you must put on safety glasses, safety gloves and long sleeved clothes. The refrigerant gas must be recovered and added by a qualified person.
Foreword and general information Safety notice
a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that O-ring (1) is free from flaw and deterioration. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VALEO THERMAL SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings. a Example of O-ring (Fitted to every joint of hoses and tubes)
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SK820-5E0
Foreword and general information How to read the shop manual
00 Index and foreword
How to read the shop manual
0 -17 (Rev. 2010/03)
q q q
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine volume of the engine model mounted on the machine.
1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added. 01. Specification This section explains the specifications of the machine. 10. Structure and function This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are explained in "Standard value table". 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 60. Maintenance standard This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 80. Appendix This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections. 90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume) Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of re manufacturing and repairing engine and replacing parts. q
SK820-5E0
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00 Index and foreword
Foreword and general information How to read the shop manual
2. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. 3. Filing method File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED PAGES. q
Revision number When a manual is revised, revision number of each page is increased by 1. (Example: (01), (02), (03)...)
q
Revisions The revised pages are shown in the LIST OF REVISED PAGES.
4. Symbol Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
Description
k
Safety
Special safety precautions which are necessary when performing work are described.
a
Caution
Special technical precautions or other precautions for preserving standards which are necessary when performing work are described.
4
Weight
Weight of parts of component or parts are indicated. Caution necessary when selecting hoisting wire, or when working posture is important, etc. are described.
3
Tightening torque
Places that require special attention for tightening torque during assembly are indicated.
2
Coat
5
Oil, coolant
6
Drain
Places to be coated with adhesives, etc. during assembly are indicated.
Places where oil, etc. must be added, and capacity are indicated.
Places where oil, etc. must be drained, and quantity to be drained are indicated.
5. Unit In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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SK820-5E0
Foreword and general information Explanation of terms for maintenance standard
00 Index and foreword
Explanation of terms for maintenance standard
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(Rev. 2010/03) The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1. Standard dimension and tolerance q To be accurate, the finished dimension of parts is slightly different from one to another. q To specify the finished dimension of a part, a certain dimension is set for the part and an allowable difference from that dimension is indicated. q The above dimension set is called the "standard dimension" and the range of difference from the standard dimension is called the "tolerance". q The tolerance with the symbols of + or – is indicated on the right side of the standard dimension. Example: Standard dimension 120
q
When some parts are repaired, the value of performance/function is set to the standard value.
Tolerance -0.022 -0.126
a The tolerance may be indicated in the text and a table as [standard dimension (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) q
q
Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of dimension of rotating shaft and hole and their related drawing.
Example: Standard dimension 60
Tolerance Shaft Hole -0.030 +0.046 -0.076 0
2. Standard clearance and standard value q The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q The values indicating performance and function of new products or equivalent are called the "standard value", which is indicated by a range or a target value.
SK820-5E0
3. Standard interference q When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called the "interference". q The range (between A and B) from the difference (A) between the minimum dimension of the shaft and the maximum dimension of the hole to the difference (B) between the maximum dimension of the shaft and the minimum dimension of the hole is the “standard interference”. q After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.
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