CEBM016001
Shop Manual
SKID STEER LOADER SERIAL NUMBERS SK820-5N A40001 and up
ENGINE
4D84E-1
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
Copyright 2010 Komatsu Printed in U.S.A. Komatsu America Corp. January 2010
FOREWORD 12
CONTENTS
CONTENTS
00
00
FORWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1
20
STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
90
DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
SK820-5N
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SK820-5N
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This is the sample of the manual Click on the download link for complete manual
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SK820-5N
FOREWORD
SAFETY
12 SAFETY
Safety Notice
00
00
IMPORTANT SAFETY NOTICE
00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
General Precautions
00
Preparations For Work
00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.
2.
When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
3.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting 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.
If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4.
When carrying out 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" signs on the controls in the operator's compartment.
5.
Keep all tools in good condition and learn the correct way to use them.
6.
Decide 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 or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
SK820-5N
Precautions During Work
00
1.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
2.
The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
00-3
FOREWORD
SAFETY
12 4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane and always stand clear from what you are raising. 5.
When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6.
When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7.
When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
8.
Never use flammable liquids to clean parts, always use approved non-flammable solvents to clean parts.
9.
Be sure to assemble all parts in their original locations. Replace any damaged part 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 being operated.
10. When installing high pressure hoses, be sure that they are not twisted. Damaged tubbing dangerous, be extremely careful when installing tubes for high pressure circuits. Also make sure parts are correctly installed. 11. When assembling or installing parts, always use the specified tightening torques and sequences. When installing protective parts such as guards, or parts that may vibrate or rotate at high speeds, be particularly careful to check their installation carefully. 12. When aligning two holes, never insert your fingers or hand. Use appropriate tools to align parts. 13. When measuring hydraulic pressure, be sure the measuring tool is correctly assembled before taking any measurements. 14. Take care when removing or installing the tracks on track-type machines. When removing the track, the track separates suddenly, never let anyone stand at either end of the track. 15. When making repairs or adjustments on electronically controlled engines, avoid any physical contact with the injection systems wiring harness while the engine is running. Due to the high voltage and amperage in this system, serious injury may occur. 16. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-4
SK820-5N
FOREWORD
GENERAL
12 GENERAL
00
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE, FUNCTION AND MAINTENENCE STANDARD This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also gives the judgement standards when inspecting, dissembled parts and serves as reference material for troubleshooting. TESTING ANDADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. TROUBLESHOOTING Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. DIAGRAMS AND DRAWINGS This section has the hydraulic and electrical schematics.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
SK820-5N
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
12 HOW TO READ THE SHOP MANUAL
Volumes
00
00
Revisions
00
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page.
Chassis volume: Engine volume:
Symbols
Issued for every machine model Issued for each engine series
Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available.
Distribution And Updating
Filing Method 1. 2.
So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Item
Remarks
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
Tightening torque
Places that require special attention for tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
00
Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. 00
See the page number on the bottom of the page. File the pages in correct order. Following examples show how to read the page number: Example: 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item
3.
Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example:
00
10-4 10-4-1 10-4-2
Added pages
10-5
Revised Edition Mark
00
When a manual is revised, an edition mark ( …) is recorded on the bottom outside corner of the pages.
00-6
SK820-5N
FOREWORD
HOISTING INSTRUCTIONS
12 HOISTING INSTRUCTIONS
00
Hoisting
00
WARNING! Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
• 1. 2.
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: Check for removal of all bolts fastening the part to the relative parts. Check for existence of another part causing interface with the part to be removed.
Wire Ropes 1.
3.
WARNING! 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.
00
Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter
2.
Allowable load
mm
kg
tons
10
907
1.0
11.2
1270
1.4
12.5
1451
1.6
14
1995
2.2
16
2540
2.8
18
3265
3.6
20
3992
4.4
22.4
5080
5.6
30
9072
10.0
40
16329
18.0
50
25401
28.0
60
36287
40.0
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
4.
Do not sling a heavy load 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 angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.
The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
SK820-5N
00-7
FOREWORD
COATING MATERIALS
12 COATING MATERIALS
00
The recommended coating materials prescribed in the shop manuals are listed below. Category
Code
Adhesives
LT-1A
Part No.
Quantity
Container
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pieces)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardening agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 179-129-9140 1735
Gasket sealant
2g
Polyethylene container
Aron-alpha 790-129-9130 201
50 g
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
LG-3
790-129-9070
1 kg
Polyethylene container
Main applications, features •
Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out
•
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
•
• •
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
•
Used as adhesive or sealant for metal, glass or plastic.
•
Used as sealant for machined holes.
•
Used as heat-resisting sealant for repairing engine.
• • •
Quick hardening type adhesive. Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
• •
Quick hardening type adhesive. Quick cure type (max. strength after 30 minutes). Used mainly for adhesion of rubbers, plastics and metals.
• • •
Features: Resistance to heat, chemicals Used at joint portions subject to high temperature.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
• •
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe.
Can •
00-8
SK820-5N
FOREWORD Category
Code
LG-4
COATING MATERIALS Part No.
790-129-9020
Quantity
200 g
Container
Tube
Main applications, features • • • • •
LG-5
790-129-9080
1 kg
Polyethylene container
Gasket sealant
• •
LG-6
09940-00011
250 g
Tube
• • •
Molybdenum disulphide lubricant
LG-7
150 g
Tube
Three bond 790-129-9090 1211
100 g
Tube
LM-G
09940-00051
60 g
Can
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA160CNLI
Various
Various
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYG2160CNCA
Various
Various
400 g (10 per case)
Belows type
Molybdenum disulphide lubricant
Grease
09920-00150
SK820-5N
SYG2-400M
•
Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
•
Used as heat-resisting sealant for repairing engines.
•
Used as lubricant for sliding parts (to prevent squeaking).
• •
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load.
00-9
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
00
Bolts And Nuts Standard Tightening Torque
00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY. Thread diameter of bolt
Width across flats
mm
mm
N•m
lbf ft
6
10
11.8 - 14.7
8.70 - 10.84
8
13
27 - 34
19.91 - 25.07
10
17
59 - 74
43.51 - 54.57
12
19
98 - 123
72.28 - 90.72
14
22
153 - 190
112.84 - 140.13
16
24
235 - 285
173.32 - 210.20
18
27
320 - 400
236.02 - 295.02
20
30
455 - 565
335.59 - 416.72
22
32
610 - 765
449.91 - 564.23
24
36
785 - 980
578.98 - 722.81
27
41
1150 - 1440
848.19 - 1062.09
30
46
1520 - 1910
1121.09 - 1408.74
33
50
1960 - 2450
1445.62 - 1807.02
36
55
2450 - 3040
1807.02 - 2242.19
39
60
2890 - 3630
2131.55 - 2677.35
Thread diameter of bolt
Width across flats
mm
mm
N•m
lbf ft
6
10
5.9 - 9.8
4.35 - 7.22
8
13
13.7 - 23.5
10.10 - 17.23
10
14
34.3 - 46.1
25.29 - 34.00
12
27
74.5 - 90.2
54.94 - 66.52
00-10
SK820-5N