Komatsu SK820-5N Skid Steer Loader Shop Manual CEBM016001 PDF

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Komatsu SK820-5N Skid Steer Loader Shop Manual CEBM016001 – PDF DOWNLOAD

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Komatsu SK820-5N Skid Steer Loader Shop Manual CEBM016001 – PDF DOWNLOAD 

Language : English
Pages : 365
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu SK820-5N Skid Steer Loader Shop Manual CEBM016001 – PDF DOWNLOAD 

SERIAL NUMBERS SK820-5N A40001 and up
ENGINE 4D84E-1

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu SK820-5N Skid Steer Loader Shop Manual CEBM016001 – PDF DOWNLOAD 

SERIAL NUMBERS SK820-5N A40001 and up
ENGINE 4D84E-1

COVER 1
FOREWORD 3
CONTENTS 3
SAFETY 8
Safety Notice 8
IMPORTANT SAFETY NOTICE 8
General Precautions 8
Preparations For Work 8
Precautions During Work 8
GENERAL 10
HOW TO READ THE SHOP MANUAL 11
Volumes 11
Distribution And Updating 11
Filing Method 11
Revised Edition Mark 11
Revisions 11
Symbols 11
HOISTING INSTRUCTIONS 12
Hoisting 12
Wire Ropes 12
COATING MATERIALS 13
STANDARD TIGHTENING TORQUE 15
Bolts And Nuts Standard Tightening Torque 15
Hose Nuts Tightening Torque 16
Split Flange Bolts Tightening Torque 16
Tightening Torque For Flared Nuts 16
Tightening Torque For Flared Nuts 17
O-ring Boss Piping Joints Tightening Torque 17
O-ring Boss Plugs Tightening Torque 17
Hoses (Taper Seal Type And Face Seal Type) Tightening Torque 18
SPECIFIC DRIVING TORQUE 18
ELECTRIC WIRE CODE 19
Classification By Thickness 19
Classification By Color And Code 19
CONVERSION TABLES 20
Method Of Using The Conversion Table 20
PUSH-PULL TYPE COUPLER 26
01 GENERAL 28
WEIGHT TABLE 30
FUEL COOLANT AND LUBRICANTS 31
SERVICE NOTES 32
Homologated Synthetic Biodegradable Lubricants Type HEES 33
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 34
P T O 35
POWER TRAIN 37
TRANSMISSION 38
FINAL DRIVE 41
HYDAULIC PUMP 49
HST pump LPV40 + 40 (Standard) 49
HST pump LPV40 + 40 (High Flow) 51
Suction Safety Valve 59
Charge Safety Valve 63
Charge Pump 65
ANTI-ENGINE STALL CONTROL VALVE (AS VALVE) 67
SHUTTLE VALVE 70
CONTROL VALVE 71
Standard (3-Spool) 71
Super High-flow (4-Spool) 85
CLSS 93
SOLENOID VALVE 101
Solenoid Valve Group ST1 101
Solenoid Valve ST2 102
ACCUMULATOR 103
PATTERN CHANGE VALVE 104
Pattern ISO 107
Pattern Optional 107
R H PPC VALVE (STANDARD) 108
Equipment Control 108
R H PPC VALVE (PATTERN CHANGE) 115
Equipment And Travel Control 115
L H PPC VALVE (STANDARD) 119
Travel Control 119
L H PPC VALVE (PATTERN CHANGE) 125
Work Equipment and Travel Control 125
CYLINDER 131
Lift Arm 131
Bucket 131
WORKING EQUIPMENT 133
20 STANDARD VALUE TABLES 136
STANDARD TECHNICAL DATA 137
Engine 137
Machine 138
30 TESTING AND ADJUSTING 144
T-ADAPTER PROCEDURES AND KITS 146
SPECIAL TOOLS 147
ENGINE 148
Engine Speed 148
Valve Clearance 149
Compression Pressure 151
Fan Belt 152
Injection Timing 153
Checking 153
Adjusting 154
Oil Pressure 155
ACCELERATOR CABLES 156
Adjusting The Stroke 156
PPC VALVES 157
Drive Pressure 157
Valve Clearance Adjustment 159
SERVO-CONTROL SAFETY SENSOR 160
Adjusting The Engagement Position 160
GEARING CHAIN 161
Testing And Adjusting Tension 161
HYDRAULIC CIRCUITS 162
Control And Regulation Of Pressures 162
Hydraulic Pump 163
Valve Calibration 164
HST Valve 164
AS Valve 165
Travel Deviation 166
Control Valve 168
Servo-Control Power Supply 170
Elimination Of Residual Pressures 172
Hydraulic Tank Pressurization 172
Bleeding Air From The Hydraulic Circuits 173
Bleeding air from the pump 173
Bleeding air from the cylinders 174
Bleeding air from any optional equipment 174
40 TROUBLESHOOTING 176
POINTS TO REMEMBER WHEN TROUBLESHOOTING 178
SEQUENCE OF EVENTS IN TROUBLESHOOTING 180
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 181
Precautions When Handling Electrical Equipment 181
Handling Control Box 186
Points To Remember When Troubleshooting Electrical Circuits 187
Points To Remember When Handling Hydraulic Equipment 188
CHECKS BEFORE TROUBLESHOOTING 190
Using Troubleshooting Charts 191
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 192
T-ADAPTER TABLE 216
INFORMATION CONTAINED IN TESTING PROCEDURES 219
BASIC AIR CONDITIONING SYSTEM (TYPICAL) 222
Operator Cab Air Conditioning 223
Principles of Refrigeration 223
Air Conditioning 223
The Act of Cooling 223
The Refrigeration Cycle 224
Air Conditioner System Components 224
Compressor (Refrigerant Pump) 224
Service Valves 224
Condenser 225
Receiver-Drier 225
Thermostatic Expansion Valve 225
Evaporator 226
Electrical Circuit 226
Thermostat 227
Compressor Clutch 227
Safety Switches 227
System Servicing 228
R-134A Refrigerant Containers 229
Service Tools And Equipment 229
Recovery/Recycle Station 229
Leak Detector 230
Service Valves 230
Vacuum Pump 230
Manifold Gauge Set 231
Installing Manifold Gauge Set 232
Purging Air from Service Hoses 233
Adding Refrigerant to the System (Without a Charging Station) 234
Stabilizing the AC System 234
Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling Station) 235
Recovering and Recycling the Refrigerant 235
Performing the Recovery Cycle 235
Performing the Recycling Procedure 236
Evacuating and Charging the AC System 236
System Performance Test 237
System Leak Testing 238
Electronic Leak Detector 238
Tracer Dyes 238
Soap and Water 238
System Repair 239
Hoses and Fittings 239
Lines 239
Expansion Valve 239
Receiver-Drier 239
Thermostat 239
Clutch 240
Compressor 240
Checking Compressor Oil Level 240
Evacuating The System 241
Troubleshooting – Air Conditioning System 242
Pre-Diagnosis Checks 242
Preparing for Diagnosis 242
Preliminary Steps 242
System Performance Test 242
Diagnosis of Gauge Readings and System Performance 243
Troubleshooting by Manifold Gauge Set Readings 244
Preventive Maintenance Schedule for A/C System 249
50 DISASSEMBLY AND ASSEMBLY 252
METHOD OF USING MANUAL 256
PRECAUTIONS DURING OPERATION 257
Precautions When Carrying Out Removal Work 257
Precautions When Carrying Out Installation Work 258
Precautions When Completing The Operations 259
Other Precautions 259
CONNECTOR REPAIR PROCEDURES 260
Stripping Insulation 260
Wire Inspection 260
Contact Terminal Removal (HD30 Type) 261
Crimping Contact Terminal (HD30 Type) 262
Insertion Of Contact Terminal (HD30 Type) 263
Contact Terminal Removal (DT Type) 264
Crimping Contact Terminal (DT Type) 265
Insertion Of Contact Terminal (DT Type) 266
ENGINE HOOD 268
Removal 268
Installation 268
CAB 269
Tilting 269
Lowering 271
Removal 272
Installation 274
BATTERY 275
Removal 275
Installation 275
STARTER MOTOR 276
Removal 276
Installation 276
ALTERNATOR 277
Removal 277
Installation 277
MUFFLER 278
Removal 278
Installation 278
TURBOCHARGER 279
Removal 279
Installation 280
AIR INTAKE FILTER 281
Removal 281
Installation 281
VALVE COVER 282
Removal 282
Installation 283
NOZZLE HOLDER 284
Removal 284
Installation 284
INJECTION PUMP 285
Removal 285
Installation 287
CYLINDER HEAD 288
Removal 288
Installation 290
COOLANT LIQUID PUMP 291
Removal 291
Installation 291
RADIATOR GROUP 292
Removal 292
Installation 293
FUEL TANK 294
Removal 294
Installation 295
ENGINE PUMP GROUP 296
Removal 296
Installation 299
HYDRAULIC PUMP 300
Removal 300
Installation 302
GEAR PUMP 303
Removal 303
Installation 303
ENGINE-PUMP COUPLING 304
Removal 304
Installation 304
CONTROL VALVE 305
Removal 305
Installation 305
PPC VALVES 306
Removal 306
Installation 306
HEATING FAN 307
Removal 307
Installation 308
WHEEL HUB 309
Removal 309
Installation 310
Disassembly 311
Assembly 312
FINAL DRIVE 313
Removal 313
Installation 314
CYLINDER 315
Raising 315
Removal 315
Installation 316
Bucket 317
Removal 317
Installation 318
Work Equipment 319
Disassembly 319
Assembly 321
WORKING EQUIPMENT 325
Removal 325
Installation 327
FULCRUM LEVER 328
Removal 328
Installation 328
LIFT LEVER 329
Removal 329
Installation 330
WORKING EQUIPMENT COUPLER 331
Removal 331
Installation 331
90 DIAGRAMS AND SCHEMATICS 332
ELECTRICAL DIAGRAM 333
ENGINE LINE (1/2) 333
ENGINE LINE (2/2) 334
FRAME LINE STANDARD (1/2) 335
FRAME LINE STANDARD (2/2) 336
FRAME LINE OPTIONAL (1/2) 337
FRAME LINE OPTIONAL (2/2) 338
CABIN LINE STANDARD (1/4) 339
CABIN LINE STANDARD (2/4) 340
CABIN LINE STANDARD (3/4) 341
CABIN LINE STANDARD (4/4) 342
CABIN LINE OPTIONAL (1/6) 343
CABIN LINE OPTIONAL (2/6) 344
CABIN LINE OPTIONAL (3/6) 345
CABIN LINE OPTIONAL (4/6) 346
CABIN LINE OPTIONAL (5/6) 347
CABIN LINE OPTIONAL (6/6) 348
TOP-CABIN LIGHT LINE STANDARD (1/2) 349
TOP-CABIN LIGHT LINE STANDARD (2/2) 350
TOP-CABIN LIGHT LINE HOMOLOGATION (1/2) 351
TOP-CABIN LIGHT LINE HOMOLOGATION (2/2) 352
REAR LIGHT LINE (1/2) 353
REAR LIGHT LINE (2/2) 354
STANDARD (1/5) 355
STANDARD (2/5) 356
STANDARD (3/5) 357
STANDARD (4/5) 358
STANDARD (5/5) 359
HYDRAULIC 360
STANDARD 1/3) 360
STANDARD (2/3) 361
STANDARD (3/3) 362
HIGH FLOW (1/3) 363
HIGH FLOW (2/3) 364
HIGH FLOW (3/3) 365

S.V 15/12/24