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Komatsu SK820-5 turbo User Manual

Komatsu SK820-5 turbo
244 pages
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Operation & Maintenance
Manual
WEAM005102
SK820-5 turbo
Unsafe use of this machine may cause serious injury
or death. Operators and maintenance personnel
must read this manual before operating or
maintaining this machine.
This manual should be kept inside the cab for
reference and periodically reviewed by all personnel
who will come into contact with the machine.
WARNING
SKID-STEER LOADER
SERIAL NUMBER
SK820-5 turbo 37BTF50112 and up

Table of Contents

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Komatsu SK820-5 turbo Specifications

General IconGeneral
BrandKomatsu
ModelSK820-5 turbo
CategoryFront End Loaders
LanguageEnglish

Summary

Foreword

Information on Safety

Signal Words and Hazard Levels

Defines DANGER, WARNING, CAUTION signal words for hazard levels.

Other Signal Words

Defines IMPORTANT and NOTE signal words for precautions and useful info.

Introduction

Intended Uses

Specifies the intended uses for Komatsu machines.

Improper or Unauthorized Uses

Lists forbidden uses of the machine and related cautions.

Main Characteristics

Lists key features and characteristics of the machine.

Running-In Procedure

Outlines the running-in procedure for new machines.

Product Identification

Machine Serial Number and Identification Plate

Explains where to find serial number and identification plate.

Component Serial Numbers

Locates engine, travel reduction gear, cab, and excavator serial numbers.

Serial Numbers and Dealer Address Record

Provides fields to record serial numbers and dealer info.

Safety, Noise and Vibration Plates

Safety Plate Positions and Maintenance

Explains how to maintain and locate safety plates on the machine.

Pictograms and Their Meanings

Explains meanings of warning and danger pictograms.

Noise Plate Locations & Vibration Data

Details noise plates and operator vibration exposure.

General Precautions

General Safety Rules and PPE

Outlines safety rules, PPE, and clothing advice.

Safety Devices, Guards, and Modifications

Importance of safety devices, guards, and warns against modifications.

Operator Seat and Machine Access Safety

Instructions for safely leaving seat and mounting/dismounting machine.

Fire and Burn Prevention Measures

Precautions to prevent fires and avoid burns from hot components.

Asbestos, Work Equipment, and Safety Gear

Safety for asbestos, work equipment, fire extinguishers, and first aid kit.

Cab Structure and Equipment Installation Precautions

Advises on cab damage and using authorized optional equipment.

Precautions Before Starting the Engine

Work Site, Fire, and Cab Safety Measures

Safety for work area, fire prevention, and operator cab.

Ventilation, Lights, and Wiper Checks

Ventilation, lights, and wiper checks before starting.

Precautions When Working

Starting Engine and Road Travel Rules

Procedures for starting engine and rules for road travel.

Reverse Travel Checks and Moving Safely

Checks before reverse travel and general machine moving.

Slope Operations and Electrocution Prevention

Precautions for working on slopes and preventing electrocution.

Visibility, Snow/Ice, Loose Ground, and Parking

Visibility, working on snow/ice, loose ground, and parking procedures.

Transporting the Machine on Other Vehicles

Loading, Unloading, and Route Planning

Procedures and safety for loading/unloading and route planning.

Battery Safety

Battery Work Precautions and Booster Starting

Safety measures for battery work and booster starting.

Emergency Recovery Precautions

Precautions to be Taken During Maintenance

Warning Plates and Tool Usage Guidelines

Procedures for warning plates and tool usage/storage.

Personnel, Equipment, and Under-Machine Work Safety

Rules for personnel, equipment handling, and working under the machine.

Machine Cleanliness and Engine Use During Maintenance

Importance of cleanliness and engine use rules during maintenance.

Critical Safety Parts and Engine Stop Before Maintenance

Critical parts for safety and stopping engine before maintenance.

Refueling, Coolant, Lamps, and Electrical Safety

Safety for refueling, coolant, lamps, battery, alternator, starter.

Hose, High-Pressure Systems, and Temp/Pressure Safety

Safety for hoses, high-pressure systems, and high temp/pressure maintenance.

Fan Belt, Waste, and Tyre Inflation Safety

Safety for fan belt, waste disposal, and tyre inflation.

HEES Oil Usage Precautions

Specific safety for HEES oil usage.

Safety Locks

Loader Arm Safety Locks

Details the loader arm safety lock mechanism and operation.

Excavator/Asphalt Cutter Locks for Road Travel

Safety lock procedures for excavators/cutters during road travel.

General Views

Machine Views: Front, Rear, and Interior

Labeled diagrams of machine's front, rear, and interior views.

Instruments and Controls

Dashboard Instruments and Warning Lights

Explains dashboard instruments and warning lights.

Switches, Buttons, and Electrical Accessories

Identifies switches, buttons, and electrical accessories.

Machine Controls Overview

Identifies main control levers and pedals.

Machine Controls (Detailed)

Safety Bars and Left Joystick Operation

Operation of safety bars and left joystick controls (ISO pattern).

Right Servo Lever and Optional Controls

Right servo lever, optional pattern controls, and accelerators.

Parking Brake and Equipment Locking Lever

Instructions for parking brake and equipment locking lever.

Hydraulic System Controls and Speed Settings

Operation of hydraulic systems and speed controls.

Hand & Foot Control System Operation

Operation of machine controls using hand & foot system.

Fuses and Relays

Machine Function Fuses

Lists fuses for machine functions and their circuits.

Main Fuse and Relay Identification

Details the main fuse and identifies relay locations and types.

Guards and Driver’s Seat

Engine Hood and Rear Panel Access

Instructions for opening engine hood and rear panel.

Cab Structure and Raising Procedure

Information on cab structure and how to raise it.

Seat Adjustment Options

Explains adjustment options for standard and cushioned seats.

Safety Belt and Emergency Exit

Importance of safety belt and emergency exit procedure.

Documentation, Fire Extinguisher, First Aid Kit

Location of documentation case, fire extinguisher, and first aid kit.

Use of the Machine

Pre-Start Engine Checks

Essential visual, daily, and operational checks before starting.

Starting the Engine Safely

Procedure for starting the engine in various conditions.

Warming Up Engine and Hydraulic Oil

Steps for warming up engine and hydraulic oil.

Moving the Machine (ISO Pattern)

How to move the machine using ISO pattern controls.

Steering and Direction Changes (ISO Pattern)

Explains steering and direction changes in ISO pattern.

Moving the Machine (Optional Pattern)

How to move the machine using optional pattern controls.

Steering and Direction Changes (Optional Pattern)

How to change direction using joysticks in optional pattern.

Moving on Slopes Safely

Precautions for operating the machine on slopes.

Maximum Immersion Depth

Specifies the maximum safe immersion depth for the machine.

Parking the Machine

Parking on Level Ground

Step-by-step instructions for parking on level ground.

Parking on Slopes Safely

Procedures for safely parking the machine on slopes.

Stopping the Engine

Transporting the Machine on Other Vehicles

Loading, Unloading, and Route Planning

Procedures and safety for loading/unloading and route planning.

How to Lift the Machine

Cold Season Precautions

Fuel, Lubricants, and Coolant in Cold Weather

Recommendations for fuel, lubricants, and coolant in cold weather.

Battery and Other Cold Weather Precautions

Battery and general cold weather operational precautions.

End-of-Work Cold Weather Precautions

End-of-work precautions for cold weather.

Warm Season Precautions

Using the Work Equipment

Lowering Equipment During Machine Failure

Procedure for lowering equipment during failure.

Work Area Organization and Loading Methods

Organizing work area and loading material on slopes/surfaces.

Digging Method Techniques

Correct and incorrect digging techniques.

Bucket Changing Procedures

Steps to change bucket using standard and optional rapid couplings.

Locking and Adjusting Pins

Checking and adjusting the position of locking pins.

Long Periods of Inactivity

Pre-Storage, Storage, and Post-Storage Procedures

Precautions before, during, and after long-term storage.

Troubleshooting

Machine Removal and Fuel Depletion Issues

Guidance on removing stuck machine and fuel depletion.

Battery Depletion and Booster Starting

Battery depletion troubleshooting and booster starting.

Electrical, Hydraulic, Engine, and Transmission Issues

Troubleshooting for electrical, hydraulic, engine, and transmission problems.

Guide to Maintenance

Maintenance Notes

Engine, Hydraulic, Electrical, and Lubrication Notes

Notes on engine, hydraulic, electrical, and lubrication maintenance.

Periodic Wear Part Replacement Schedule

Lists parts that require periodic replacement.

Fuel, Coolant and Lubricants

Homologated HEES Lubricant Recommendations

Lists approved HEES biodegradable lubricants.

Driving Torques for Screws and Nuts

Standard and Specific Driving Torques Tables

Tables for standard and specific driving torques for fasteners.

Lubrication

Lubrication Diagram

Diagram showing lubrication points and intervals.

Periodical Change of Components Connected with Safety

Critical Safety Parts Identification and Intervals

Lists critical safety parts for fuel, hydraulic, and operator safety.

Maintenance Plan

When Required Maintenance Tasks

Maintenance tasks required as needed.

Pre-Starting Checks

Daily and pre-operation checks.

Maintenance Schedule by Hours

Maintenance tasks based on operating hours.

Maintenance Procedure

When Required Procedures

Steps for air cleaner, tyre rotation, fuel tank drain, brake release, battery check.

Pre-Starting Checks

Checks for coolant, fuel, engine oil, hydraulic oil, water separator, and wiring.

50 Hours Maintenance Tasks

Tyre pressure and radiator coolant level checks.

250 Hours Maintenance Tasks

Adjusting fan belt tension and checking chain tension.

Wheel Nut Torque and Final Transmission Oil Checks

Checking wheel nut torque and final transmission oil level.

Joint Lubrication and Engine Oil Change

Lubricating joints and changing engine oil.

Engine Oil Filter and Fuel Filter Change

Procedures for changing engine oil filter and fuel filter.

Hydraulic Oil Filter Change and Water Separator Cleaning

Procedures for hydraulic oil filter change and water separator cleaning.

Hydraulic Oil Tank Draining

Procedure for draining the hydraulic oil tank.

Final Transmission Oil Change

Steps to change oil in the final transmission.

Hydraulic System Oil Change & Suction Filter Cleaning

Procedure for changing hydraulic oil and cleaning suction filter.

Engine Valve Clearance and Coolant Change

Engine valve clearance check and coolant change procedure.

Suction Filter Change and Alternator/Starter Check

Steps for suction filter change and alternator/starter inspection.

Technical Data

Standard Machine Overall Dimensions

Overall dimensions of the machine with standard bucket.

Overall Dimensions with Optional Equipment

Overall dimensions with optional equipment like excavator and asphalt cutter.

Machine Technical Characteristics Summary

Lists total mass, bucket capacity, engine, electrical, speed, tyres.

Authorized Optional Equipment

Safety Precautions for Optional Equipment Installation

Safety precautions for installing optional equipment.

Equipment Installation Precautions

Warnings about using lengthened or oversized equipment.

Optional Equipment Specifications

Specs for standard and high/super flow optional equipment.

Changing the Authorized Equipment

Connecting Excavator and Hydraulic Circuit

Steps for connecting the excavator and its hydraulic circuit.

Return Circuit Connection Procedure

Connecting return circuit for direct tank drainage.

Preparing and Using the Excavator

Steps to prepare and use the excavator safely.

Pallet Forks

Changing the Operating Pattern

How to Change Operating Pattern

Steps to change the machine's operating pattern.

Hand & Foot Control System

Machine Controls Overview

Overview of machine controls in hand & foot system.

Travel and Steering Controls

Operation of travel and steering control levers.

Work Equipment Pedals Operation

Operation of loader arm and bucket control pedals.

Auxiliary Hydraulic Kit Control Operation

How to operate the auxiliary hydraulic kit control lever.

Moving the Machine (Hand & Foot System)

How to move the machine using hand & foot controls.

Steering and Direction Changes (Hand & Foot)

How to change direction using joysticks in hand/foot system.

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