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Komatsu SK820-5N Skid Steer Loader Operation & Maintenance Manual SN A40001 and up – PDF DOWNLOAD
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Komatsu SK820-5N Skid Steer Loader Operation & Maintenance Manual
SERIAL NUMBERS SK820-5N A40001 and up
Book Code: CEAM016201
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Description
Komatsu SK820-5N Skid Steer Loader Operation & Maintenance Manual
FILE DETAILS:
Komatsu SK820-5N Skid Steer Loader Operation & Maintenance Manual
Brands: Komatsu
Equipment Type: Skid Steer Loader
Manuals Type: Operation & Maintenance Manual
Machine Model: SK820-5N
Serial Number: A40001 and up
Book Code: CEAM016201
Language: English
Pages: 251
File Format: Portable Document Format (PDF)
KOMATSU SK820-5N SKID STEER LOADER OPERATION & MAINTENANCE MANUAL SN A40001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu SK820-5N Skid Steer Loader Operation & Maintenance Manual
FOREWORD:
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and maintenance.
- Keep the manual in the machine and have all operators and maintenance personnel read it periodically. If this manual is lost, damaged or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner.
- Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual. Consult your local KOMATSU distributor or for the latest available information on your machine or for questions regarding information in this manual. Also, consult your local KOMATSU Distributor for attachments and optional equipment identified in this manual or any other items you may require.
TABLE OF CONTENTS:
Komatsu SK820-5N Skid Steer Loader Operation & Maintenance Manual
COVER............................................................................................................................... 1 INTRODUCTION........................................................................................................................ 2 FOREWORD........................................................................................................................ 3 Operation and Maintenance Manual Storage.................................................................................... 3 SAFETY INFORMATION.............................................................................................................. 4 APPROVED AND NON APPROVED USES.................................................................................................. 6 Approved.................................................................................................................... 6 Non Approved................................................................................................................ 6 PRODUCT INFORMATION............................................................................................................. 7 Main Features............................................................................................................... 7 Break In Period............................................................................................................. 7 Synthetic Biodegradable Oil Types....................................................................................... 7 PRODUCT IDENTIFICATION.......................................................................................................... 8 Machine Serial Number....................................................................................................... 8 Machine Identification Plate................................................................................................ 8 Engine Serial Number And Emission Plate..................................................................................... 9 Travel Reduction Gear Serial Number......................................................................................... 9 Cab Serial Number........................................................................................................... 9 SERIAL NUMBERS AND DISTRIBUTOR INFORMATION...................................................................................... 10 Model: SK820-5N............................................................................................................. 10 TABLE OF CONTENTS............................................................................................................... 11 SAFETY.............................................................................................................................. 18 SAFETY LABELS................................................................................................................... 19 Safety Label Using Both Words And Pictorial Message......................................................................... 19 Hazard Panel................................................................................................................ 19 Avoidance Panel............................................................................................................. 19 Safety Label Using Pictograms............................................................................................... 19 Hazard Panel................................................................................................................ 19 Avoidance Panel............................................................................................................. 19 Safety Label Using Both Words And Pictorial Message......................................................................... 22 Decals Pictograms And Relevant Meanings..................................................................................... 33 SAFETY LOCKS.................................................................................................................... 39 Loader Locks................................................................................................................ 39 GENERAL PRECAUTIONS............................................................................................................. 41 Safety Rules................................................................................................................ 41 If Abnormalities Are Found.................................................................................................. 41 Clothing And Personal Protective Items...................................................................................... 42 Fire Extinguisher And First Aid Kit......................................................................................... 42 Keep Machine Clean.......................................................................................................... 42 Inside Operator's Compartment............................................................................................... 43 Precautions When Using ROPS................................................................................................. 43 Unauthorized Modifications.................................................................................................. 44 Leaving The Operator’s Seat................................................................................................. 44 Getting On And Off The Machine.............................................................................................. 45 Checking The Rear-view Mirrors.............................................................................................. 45 Preventing Fires Due To Fuel And Oil........................................................................................ 46 Preventing Burns............................................................................................................ 46 Preventing Injury Due To Asbestos Dust...................................................................................... 47 Preventing Injury Caused By The Work Equipment.............................................................................. 47 Precautions Concerning The Cab Structure.................................................................................... 47 Precautions Concerning The Equipment........................................................................................ 48 PRECAUTIONS TAKEN BEFORE STARTING THE ENGINE.................................................................................... 48 Safety On The Worksite...................................................................................................... 48 Fire Prevention............................................................................................................. 48 Precautions Taken In The Operator’s Cab..................................................................................... 48 Room Ventilation............................................................................................................ 49 Precautions Taken For Lights................................................................................................ 49 Cleaning Windows And Rear-view Mirrors - Checking Windshield Wiper Blades................................................... 49 PRECAUTIONS TAKEN WHEN WORKING.................................................................................................. 50 Starting The Engine......................................................................................................... 50 Rules Followed When Traveling On Roads...................................................................................... 50 Checks For Traveling In Reverse............................................................................................. 50 Moving The Machine.......................................................................................................... 51 Working On Slopes........................................................................................................... 51 Preventing Electrocution.................................................................................................... 53 Visibility.................................................................................................................. 53 Working On Icy Or Snow-Covered Surfaces..................................................................................... 54 Preventing Damage Caused By Work Equipment.................................................................................. 54 Working On Loose Ground..................................................................................................... 54 Parking The Machine......................................................................................................... 55 TRANSPORTING THE MACHINE ON OTHER VEHICLES...................................................................................... 56 Loading And Unloading The Machine........................................................................................... 56 The Route................................................................................................................... 56 BATTERY......................................................................................................................... 57 Safety Precautions For Work On Batteries.................................................................................... 57 Starting With Booster Cables................................................................................................ 57 PRECAUTIONS FOR EMERGENCY RECOVERY.............................................................................................. 58 PRECAUTIONS DURING MAINTENANCE.................................................................................................. 60 Warning Plates.............................................................................................................. 60 Tools....................................................................................................................... 60 Personnel................................................................................................................... 61 Equipment................................................................................................................... 61 Working Under The Machine................................................................................................... 61 Keeping The Machine Clean................................................................................................... 61 Use Of The Engine During Maintenance........................................................................................ 62 Periodical Replacement Of Parts That Are Critical For Safety................................................................ 62 Stop The Engine Before Carrying Out Any Maintenance Operation Or Inspection................................................. 62 Rules For Refuelling And Adding Oil......................................................................................... 63 Checking The Coolant Level In The Radiator.................................................................................. 63 Using Lamps................................................................................................................. 63 Precautions Concerning The Battery And Alternator........................................................................... 64 Precautions Concerning The Starter.......................................................................................... 65 Precautions Concerning High-Pressure Hoses.................................................................................. 66 Precautions When Working On High-Pressure Hoses............................................................................. 66 Precautions For Maintenance Work Involving High Temperatures And Pressures.................................................. 66 Cooling Fan And Fan Belt.................................................................................................... 67 Waste Materials............................................................................................................. 67 Precautions When Inflating The Tires........................................................................................ 67 Precautions When Using Synthetic Biodegradable Oil Type (HEES).............................................................. 68 OPERATION........................................................................................................................... 70 GENERAL VIEWS................................................................................................................... 71 Front General View.......................................................................................................... 71 Rear general view........................................................................................................... 72 Cab Inside General View..................................................................................................... 73 INSTRUMENTS AND CONTROLS........................................................................................................ 75 Instruments................................................................................................................. 75 Warning Lights.............................................................................................................. 77 Switches And Push Buttons................................................................................................... 82 Electrical Accessories...................................................................................................... 87 Machine Controls............................................................................................................ 90 ISO Pattern Control System.............................................................................................. 91 Optional Pattern Control System......................................................................................... 93 Optional Pattern Control System............................................................................................. 97 FUSES AND RELAYS................................................................................................................108 Machine Function Fuses......................................................................................................108 Version With Optionals......................................................................................................109 Main Fuse...................................................................................................................109 Relays......................................................................................................................110 GUARDS AND DRIVER’S SEAT........................................................................................................112 Engine Hood.................................................................................................................112 Rear Panel..................................................................................................................113 Cab.........................................................................................................................114 Raising The Cab.........................................................................................................115 Standard Seat...............................................................................................................117 Cushioned Seat..............................................................................................................117 Seat Safety Switch..........................................................................................................118 Safety Belt.................................................................................................................119 Emergency Exit..............................................................................................................119 Technical Documentation Case................................................................................................120 Fire Extinguisher...........................................................................................................120 First Aid Kit...............................................................................................................120 Battery Disconnect Switch...................................................................................................121 OPERATING THE MACHINE...........................................................................................................122 Checks Before Starting The Engine...........................................................................................122 Visual Checks...........................................................................................................122 Daily Checks............................................................................................................122 Operational Checks......................................................................................................123 Starting The Engine.........................................................................................................124 Starting With Warm Engine Or In Temperate Climates......................................................................124 Starting With Cold Engine Or In Cold Climates...........................................................................125 Warming The Engine..........................................................................................................126 Heating The Hydraulic Oil...................................................................................................126 Travel Circuit Hydraulic Oil Warm-Up....................................................................................127 How To Move The Machine (ISO Pattern Control System)........................................................................128 Steering (Changing Direction)...............................................................................................130 How To Move The Machine (Optional Pattern Control System)...................................................................132 Steering (Changing Direction)...............................................................................................134 Moving On Slopes............................................................................................................136 CHANGING THE OPERATING PATTERN..................................................................................................137 How To Change The Operating Pattern.........................................................................................139 Maximum Immersion Depth.....................................................................................................140 HAND & FOOT CONTROL SYSTEM......................................................................................................141 Machine Controls............................................................................................................141 Travel And Steering Control Levers..........................................................................................142 Work Equipment Control Pedals (Loader Arm And Bucket).......................................................................144 Auxiliary Hydraulic Kit Control.............................................................................................147 How To Move The Machine (Hand & Foot Control System)........................................................................150 Steering (Changing Direction)...............................................................................................152 PARKING THE MACHINE.............................................................................................................154 Parking On Level Ground.....................................................................................................154 STOPPING THE ENGINE.............................................................................................................155 TRANSPORTING THE MACHINE ON OTHER VEHICLES......................................................................................156 Loading And Unloading The Machine...........................................................................................156 Transport...................................................................................................................157 HOW TO LIFT THE MACHINE.........................................................................................................158 PRECAUTIONS IN THE COLD SEASON..................................................................................................159 Fuel And Lubricants.........................................................................................................159 Coolant.....................................................................................................................159 Battery.....................................................................................................................160 Other Precautions...........................................................................................................160 Precautions At The End Of Work..............................................................................................160 Precautions In The Warm Season..............................................................................................161 USING THE WORK EQUIPMENT........................................................................................................162 Lowering The Equipment In Case Of Machine Failure...........................................................................162 Organizing The Work Area....................................................................................................163 Loading Material On Heaps And On Level Surfaces.............................................................................164 Loading Material On Slopes..................................................................................................165 Digging Method..............................................................................................................166 Changing The Bucket Or The Equipment With Standard Rapid Coupling...........................................................167 Releasing The Bucket........................................................................................................168 Coupling The Bucket.........................................................................................................168 Changing The Bucket Or The Equipment With Optional Rapid Coupling...........................................................170 Removing The Bucket Or The Equipment........................................................................................171 Connecting The Bucket.......................................................................................................172 Checking The Position Of The Locking Pins...................................................................................173 Adjusting The Locking Pins..................................................................................................174 LONG PERIODS OF INACTIVITY......................................................................................................175 Before The Period Of Inactivity.............................................................................................175 During The Period Of Inactivity.............................................................................................176 After The Period Of Inactivity..............................................................................................176 TROUBLESHOOTING.................................................................................................................177 How To Remove The Machine...................................................................................................177 If The Fuel Has Been Completely Depleted....................................................................................177 If The Battery Is Depleted..................................................................................................178 Starting With Booster Cables................................................................................................179 Other Troubles..............................................................................................................181 Electrical Circuit......................................................................................................181 Hydraulic System........................................................................................................181 Engine..................................................................................................................182 Hydrostatic Transmission................................................................................................183 MAINTENANCE.........................................................................................................................186 GUIDE TO MAINTENANCE............................................................................................................187 MAINTENANCE NOTES...............................................................................................................188 NOTES REGARDING THE ENGINE......................................................................................................188 Engine Oil..................................................................................................................188 Coolant.....................................................................................................................188 Fuel........................................................................................................................189 Notes Regarding The Hydraulic System........................................................................................189 Notes Regarding The Electrical System.......................................................................................189 Notes Regarding Lubrication.................................................................................................190 Parts Subject To Wear That Periodically Need Changing.......................................................................190 FUEL, COOLANT AND LUBRICANTS....................................................................................................191 Homologated Synthetic Biodegradable Lubricants Type HEES....................................................................192 TORQUE FOR SCREWS AND NUTS......................................................................................................193 Standard Torques............................................................................................................193 Specific Torques............................................................................................................193 LUBRICATION.....................................................................................................................194 Lubrication Diagram.........................................................................................................194 PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY...................................................................................195 Critical Parts For Safety...................................................................................................196 Fuel Supply System......................................................................................................196 Standard Hydraulic System...............................................................................................197 High-flow And Super Flow Hydraulic System...............................................................................199 MAINTENANCE SCHEDULE............................................................................................................202 Maintenance Schedule Chart..................................................................................................202 MAINTENANCE PROCEDURE...........................................................................................................204 When Required...............................................................................................................204 Checking, Cleaning Or Changing The Air Cleaner Cartridge................................................................204 Tire Rotation...........................................................................................................205 Draining The Fuel Tank..................................................................................................206 Releasing The Parking Brake.............................................................................................207 Checking The Battery Charge Level.......................................................................................208 Checks Before Starting......................................................................................................209 Various Checks..........................................................................................................209 Checking The Coolant Level..............................................................................................209 Checking The Fuel Level.................................................................................................210 Checking The Engine Oil Level...........................................................................................211 Checking The Oil Level In The Hydraulic Circuit.........................................................................212 Checking The Water Separator For Sediments And Water....................................................................213 Checking The Wiring System..............................................................................................213 Maintenance After The First 50 Hours Of Operation...........................................................................214 Maintenance Every 50 Hours Of Operation.....................................................................................214 Checking The Tire Pressure..............................................................................................214 Checking The Coolant Level In The Radiator..............................................................................214 Maintenance After The First 250 Hours Of Operation..........................................................................215 Maintenance Every 250 Hours Of Operation....................................................................................215 Adjusting The Fan Belt Tension..........................................................................................215 Checking The Gearing Chain Tension......................................................................................216 Cleaning The Outside Of The Radiators...................................................................................218 Checking The Wheel Nut Driving Torque...................................................................................218 Checking The Oil Level In The Final Transmissions.......................................................................219 Lubricating The Joints..................................................................................................220 Changing The Engine Oil.................................................................................................221 Changing The Engine Oil Filter..........................................................................................222 Maintenance After The First 500 Hours Of Operation (Only For Machines Filled With Synthetic Biodegradable Oil Type HEES)....223 Maintenance Every 500 Hours Of Operation....................................................................................223 Changing The Fuel Filter................................................................................................223 Changing The Hydraulic Oil Drain Filter.................................................................................225 Cleaning The Water Separator............................................................................................226 Draining The Hydraulic Oil Tank (Only For Machines Filled With Synthetic Biodegradable Oil Type HEES)...................228 Maintenance Every 1000 Hours Of Operation...................................................................................229 Changing The Oil In The Final Transmission..............................................................................229 Changing The Hydraulic System Oil And Cleaning The Suction Filter.......................................................230 Checking And Adjusting The Engine Valve Clearance.......................................................................231 Maintenance Every 2000 Hours Of Operation...................................................................................232 Changing The Coolant....................................................................................................232 Changing The Suction Filter.................................................................................................233 Checking The Alternator And The Starter.................................................................................234 SPECIFICATIONS......................................................................................................................236 TECHNICAL DATA..................................................................................................................237 Standard Machine Overall Dimensions.........................................................................................237 Overall Dimensions With Standard Bucket L 1730 mm (68.1 in) And Tires (10x16.5).........................................237 Overall Dimensions With Bucket L 1550 mm (61.0 in) And Tires (10x16.5)..................................................238 Overall Dimensions With Bucket L 1800 mm (70.8 in) And Tires (10x16.5)..................................................238 Machine Overall Dimensions With Optional Equipment..........................................................................239 Overall Dimensions With Pallet Forks....................................................................................239 Overall Dimensions With Snow Blade......................................................................................239 Overall Dimensions With Mixing Bucket...................................................................................240 Overall Dimensions With Sweeper.........................................................................................240 Overall Dimensions With Grapple Fork....................................................................................241 Technical Characteristics...................................................................................................242 Total Mass..............................................................................................................242 Bucket Capacity.........................................................................................................242 Engine..................................................................................................................242 Electrical System.......................................................................................................242 Speed...................................................................................................................242 Tires...................................................................................................................242 Solid Tires.............................................................................................................242 OPTIONS, ATTACHMENTS................................................................................................................244 AUTHORIZED OPTIONAL EQUIPMENT...................................................................................................245 Precautions Regarding Safety................................................................................................245 Precautions Regarding The Installation Of Equipment.........................................................................246 Characteristics Of The Standard Machine Optional Equipment..................................................................246 Characteristics Of The Optional Equipment Of The Machine Version With High-flow And Super-flow Hydraulic System.............247 CHANGING THE AUTHORIZED EQUIPMENT...............................................................................................248 Connecting The Excavator....................................................................................................248 Connecting The Hydraulic Circuit............................................................................................249 Connecting The Return Circuit With Direct Drainage Into The Tank............................................................251 Preparing The Machine For The Use Of The Excavator..........................................................................252 Using The Machine With The Excavator........................................................................................252 PALLET FORKS....................................................................................................................253
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