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KOMATSU SK820-5N SKID STEER LOADER SHOP MANUAL SL NO SK820-5N A40001 & up ENGINE 4D84E-1 – PDF DOWNLOAD
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KOMATSU SK820-5N SKID STEER LOADER SHOP MANUAL
SERIAL NUMBERS: SK820-5N A40001 & up ENGINE 4D84E-1
PUBLICATION NUMBER:CEBM016001
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Description
KOMATSU SK820-5N SKID STEER LOADER SHOP MANUAL SL NO SK820-5N A40001 & up ENGINE 4D84E-1
KOMATSU SK820-5N SKID STEER LOADER SHOP MANUAL SL NO SK820-5N A40001 & UP ENGINE 4D84E-1 – PDF DOWNLOAD:
SCREENSHOOTS OF THE MANUAL:
DESCRIPTION:
KOMATSU SK820-5N SKID STEER LOADER SHOP MANUAL SL NO SK820-5N A40001 & up ENGINE 4D84E-1
- 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.
TABLE OF CONTENTS:
KOMATSU SK820-5N SKID STEER LOADER SHOP MANUAL SL NO SK820-5N A40001 & 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
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