Komatsu Skid-Steer Loader SK820-5N Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Skid-Steer Loader SK820-5N, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Skid-Steer Loader SK820-5N workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 619 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM016201 - Skid-Steer Loader SK820-5N Operation & Maintenance Manual.pdf
CEBM016001 - Skid-Steer Loader SK820-5N Shop Manual.pdf
MAIN SECTIONS
CEAM016201 - Skid-Steer Loader SK820-5N Operation & Maintenance Manual....2
COVER....2
INTRODUCTION....3
FOREWORD....4
Operation and Maintenance Manual Storage....4
SAFETY INFORMATION....5
APPROVED AND NON APPROVED USES....7
Approved....7
Non Approved....7
PRODUCT INFORMATION....8
Main Features....8
Break In Period....8
Synthetic Biodegradable Oil Types....8
PRODUCT IDENTIFICATION....9
Machine Serial Number....9
Machine Identification Plate....9
Engine Serial Number And Emission Plate....10
Travel Reduction Gear Serial Number....10
Cab Serial Number....10
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION....11
Model: SK820-5N....11
TABLE OF CONTENTS....12
SAFETY....19
SAFETY LABELS....20
Safety Label Using Both Words And Pictorial Message....20
Hazard Panel....20
Avoidance Panel....20
Safety Label Using Pictograms....20
Hazard Panel....20
Avoidance Panel....20
Safety Label Using Both Words And Pictorial Message....23
Decals Pictograms And Relevant Meanings....34
SAFETY LOCKS....40
Loader Locks....40
GENERAL PRECAUTIONS....42
Safety Rules....42
If Abnormalities Are Found....42
Clothing And Personal Protective Items....43
Fire Extinguisher And First Aid Kit....43
Keep Machine Clean....43
Inside Operator's Compartment....44
Precautions When Using ROPS....44
Unauthorized Modifications....45
Leaving The Operators Seat....45
Getting On And Off The Machine....46
Checking The Rear-view Mirrors....46
Preventing Fires Due To Fuel And Oil....47
Preventing Burns....47
Preventing Injury Due To Asbestos Dust....48
Preventing Injury Caused By The Work Equipment....48
Precautions Concerning The Cab Structure....48
Precautions Concerning The Equipment....49
PRECAUTIONS TAKEN BEFORE STARTING THE ENGINE....49
Safety On The Worksite....49
Fire Prevention....49
Precautions Taken In The Operators Cab....49
Room Ventilation....50
Precautions Taken For Lights....50
Cleaning Windows And Rear-view Mirrors - Checking Windshield Wiper Blades....50
PRECAUTIONS TAKEN WHEN WORKING....51
Starting The Engine....51
Rules Followed When Traveling On Roads....51
Checks For Traveling In Reverse....51
Moving The Machine....52
Working On Slopes....52
Preventing Electrocution....54
Visibility....54
Working On Icy Or Snow-Covered Surfaces....55
Preventing Damage Caused By Work Equipment....55
Working On Loose Ground....55
Parking The Machine....56
TRANSPORTING THE MACHINE ON OTHER VEHICLES....57
Loading And Unloading The Machine....57
The Route....57
BATTERY....58
Safety Precautions For Work On Batteries....58
Starting With Booster Cables....58
PRECAUTIONS FOR EMERGENCY RECOVERY....59
PRECAUTIONS DURING MAINTENANCE....61
Warning Plates....61
Tools....61
Personnel....62
Equipment....62
Working Under The Machine....62
Keeping The Machine Clean....62
Use Of The Engine During Maintenance....63
Periodical Replacement Of Parts That Are Critical For Safety....63
Stop The Engine Before Carrying Out Any Maintenance Operation Or Inspection....63
Rules For Refuelling And Adding Oil....64
Checking The Coolant Level In The Radiator....64
Using Lamps....64
Precautions Concerning The Battery And Alternator....65
Precautions Concerning The Starter....66
Precautions Concerning High-Pressure Hoses....67
Precautions When Working On High-Pressure Hoses....67
Precautions For Maintenance Work Involving High Temperatures And Pressures....67
Cooling Fan And Fan Belt....68
Waste Materials....68
Precautions When Inflating The Tires....68
Precautions When Using Synthetic Biodegradable Oil Type (HEES)....69
OPERATION....71
GENERAL VIEWS....72
Front General View....72
Rear general view....73
Cab Inside General View....74
INSTRUMENTS AND CONTROLS....76
Instruments....76
Warning Lights....78
Switches And Push Buttons....83
Electrical Accessories....88
Machine Controls....91
ISO Pattern Control System....92
Optional Pattern Control System....94
Optional Pattern Control System....98
FUSES AND RELAYS....109
Machine Function Fuses....109
Version With Optionals....110
Main Fuse....110
Relays....111
GUARDS AND DRIVERS SEAT....113
Engine Hood....113
Rear Panel....114
Cab....115
Raising The Cab....116
Standard Seat....118
Cushioned Seat....118
Seat Safety Switch....119
Safety Belt....120
Emergency Exit....120
Technical Documentation Case....121
Fire Extinguisher....121
First Aid Kit....121
Battery Disconnect Switch....122
OPERATING THE MACHINE....123
Checks Before Starting The Engine....123
Visual Checks....123
Daily Checks....123
Operational Checks....124
Starting The Engine....125
Starting With Warm Engine Or In Temperate Climates....125
Starting With Cold Engine Or In Cold Climates....126
Warming The Engine....127
Heating The Hydraulic Oil....127
Travel Circuit Hydraulic Oil Warm-Up....128
How To Move The Machine (ISO Pattern Control System)....129
Steering (Changing Direction)....131
How To Move The Machine (Optional Pattern Control System)....133
Steering (Changing Direction)....135
Moving On Slopes....137
CHANGING THE OPERATING PATTERN....138
How To Change The Operating Pattern....140
Maximum Immersion Depth....141
HAND & FOOT CONTROL SYSTEM....142
Machine Controls....142
Travel And Steering Control Levers....143
Work Equipment Control Pedals (Loader Arm And Bucket)....145
Auxiliary Hydraulic Kit Control....148
How To Move The Machine (Hand & Foot Control System)....151
Steering (Changing Direction)....153
PARKING THE MACHINE....155
Parking On Level Ground....155
STOPPING THE ENGINE....156
TRANSPORTING THE MACHINE ON OTHER VEHICLES....157
Loading And Unloading The Machine....157
Transport....158
HOW TO LIFT THE MACHINE....159
PRECAUTIONS IN THE COLD SEASON....160
Fuel And Lubricants....160
Coolant....160
Battery....161
Other Precautions....161
Precautions At The End Of Work....161
Precautions In The Warm Season....162
USING THE WORK EQUIPMENT....163
Lowering The Equipment In Case Of Machine Failure....163
Organizing The Work Area....164
Loading Material On Heaps And On Level Surfaces....165
Loading Material On Slopes....166
Digging Method....167
Changing The Bucket Or The Equipment With Standard Rapid Coupling....168
Releasing The Bucket....169
Coupling The Bucket....169
Changing The Bucket Or The Equipment With Optional Rapid Coupling....171
Removing The Bucket Or The Equipment....172
Connecting The Bucket....173
Checking The Position Of The Locking Pins....174
Adjusting The Locking Pins....175
LONG PERIODS OF INACTIVITY....176
Before The Period Of Inactivity....176
During The Period Of Inactivity....177
After The Period Of Inactivity....177
TROUBLESHOOTING....178
How To Remove The Machine....178
If The Fuel Has Been Completely Depleted....178
If The Battery Is Depleted....179
Starting With Booster Cables....180
Other Troubles....182
Electrical Circuit....182
Hydraulic System....182
Engine....183
Hydrostatic Transmission....184
MAINTENANCE....187
GUIDE TO MAINTENANCE....188
MAINTENANCE NOTES....189
NOTES REGARDING THE ENGINE....189
Engine Oil....189
Coolant....189
Fuel....190
Notes Regarding The Hydraulic System....190
Notes Regarding The Electrical System....190
Notes Regarding Lubrication....191
Parts Subject To Wear That Periodically Need Changing....191
FUEL, COOLANT AND LUBRICANTS....192
Homologated Synthetic Biodegradable Lubricants Type HEES....193
TORQUE FOR SCREWS AND NUTS....194
Standard Torques....194
Specific Torques....194
LUBRICATION....195
Lubrication Diagram....195
PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY....196
Critical Parts For Safety....197
Fuel Supply System....197
Standard Hydraulic System....198
High-flow And Super Flow Hydraulic System....200
MAINTENANCE SCHEDULE....203
Maintenance Schedule Chart....203
MAINTENANCE PROCEDURE....205
When Required....205
Checking, Cleaning Or Changing The Air Cleaner Cartridge....205
Tire Rotation....206
Draining The Fuel Tank....207
Releasing The Parking Brake....208
Checking The Battery Charge Level....209
Checks Before Starting....210
Various Checks....210
Checking The Coolant Level....210
Checking The Fuel Level....211
Checking The Engine Oil Level....212
Checking The Oil Level In The Hydraulic Circuit....213
Checking The Water Separator For Sediments And Water....214
Checking The Wiring System....214
Maintenance After The First 50 Hours Of Operation....215
Maintenance Every 50 Hours Of Operation....215
Checking The Tire Pressure....215
Checking The Coolant Level In The Radiator....215
Maintenance After The First 250 Hours Of Operation....216
Maintenance Every 250 Hours Of Operation....216
Adjusting The Fan Belt Tension....216
Checking The Gearing Chain Tension....217
Cleaning The Outside Of The Radiators....219
Checking The Wheel Nut Driving Torque....219
Checking The Oil Level In The Final Transmissions....220
Lubricating The Joints....221
Changing The Engine Oil....222
Changing The Engine Oil Filter....223
Maintenance After The First 500 Hours Of Operation (Only For Machines Filled With Synthetic Biodegradable Oil Type HEES)....224
Maintenance Every 500 Hours Of Operation....224
Changing The Fuel Filter....224
Changing The Hydraulic Oil Drain Filter....226
Cleaning The Water Separator....227
Draining The Hydraulic Oil Tank (Only For Machines Filled With Synthetic Biodegradable Oil Type HEES)....229
Maintenance Every 1000 Hours Of Operation....230
Changing The Oil In The Final Transmission....230
Changing The Hydraulic System Oil And Cleaning The Suction Filter....231
Checking And Adjusting The Engine Valve Clearance....232
Maintenance Every 2000 Hours Of Operation....233
Changing The Coolant....233
Changing The Suction Filter....234
Checking The Alternator And The Starter....235
SPECIFICATIONS....237
TECHNICAL DATA....238
Standard Machine Overall Dimensions....238
Overall Dimensions With Standard Bucket L 1730 mm (68.1 in) And Tires (10x16.5)....238
Overall Dimensions With Bucket L 1550 mm (61.0 in) And Tires (10x16.5)....239
Overall Dimensions With Bucket L 1800 mm (70.8 in) And Tires (10x16.5)....239
Machine Overall Dimensions With Optional Equipment....240
Overall Dimensions With Pallet Forks....240
Overall Dimensions With Snow Blade....240
Overall Dimensions With Mixing Bucket....241
Overall Dimensions With Sweeper....241
Overall Dimensions With Grapple Fork....242
Technical Characteristics....243
Total Mass....243
Bucket Capacity....243
Engine....243
Electrical System....243
Speed....243
Tires....243
Solid Tires....243
OPTIONS, ATTACHMENTS....245
AUTHORIZED OPTIONAL EQUIPMENT....246
Precautions Regarding Safety....246
Precautions Regarding The Installation Of Equipment....247
Characteristics Of The Standard Machine Optional Equipment....247
Characteristics Of The Optional Equipment Of The Machine Version With High-flow And Super-flow Hydraulic System....248
CHANGING THE AUTHORIZED EQUIPMENT....249
Connecting The Excavator....249
Connecting The Hydraulic Circuit....250
Connecting The Return Circuit With Direct Drainage Into The Tank....252
Preparing The Machine For The Use Of The Excavator....253
Using The Machine With The Excavator....253
PALLET FORKS....254
CEBM016001 - Skid-Steer Loader SK820-5N Shop Manual....255
COVER....255
FOREWORD....257
CONTENTS....257
SAFETY....262
Safety Notice....262
IMPORTANT SAFETY NOTICE....262
General Precautions....262
Preparations For Work....262
Precautions During Work....262
GENERAL....264
HOW TO READ THE SHOP MANUAL....265
Volumes....265
Distribution And Updating....265
Filing Method....265
Revised Edition Mark....265
Revisions....265
Symbols....265
HOISTING INSTRUCTIONS....266
Hoisting....266
Wire Ropes....266
COATING MATERIALS....267
STANDARD TIGHTENING TORQUE....269
Bolts And Nuts Standard Tightening Torque....269
Hose Nuts Tightening Torque....270
Split Flange Bolts Tightening Torque....270
Tightening Torque For Flared Nuts....270
Tightening Torque For Flared Nuts....271
O-ring Boss Piping Joints Tightening Torque....271
O-ring Boss Plugs Tightening Torque....271
Hoses (Taper Seal Type And Face Seal Type) Tightening Torque....272
SPECIFIC DRIVING TORQUE....272
ELECTRIC WIRE CODE....273
Classification By Thickness....273
Classification By Color And Code....273
CONVERSION TABLES....274
Method Of Using The Conversion Table....274
PUSH-PULL TYPE COUPLER....280
01 GENERAL....282
WEIGHT TABLE....284
FUEL COOLANT AND LUBRICANTS....285
SERVICE NOTES....286
Homologated Synthetic Biodegradable Lubricants Type HEES....287
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....288
P.T.O....289
POWER TRAIN....291
TRANSMISSION....292
FINAL DRIVE....295
HYDAULIC PUMP....303
HST pump LPV40 + 40 (Standard)....303
HST pump LPV40 + 40 (High Flow)....305
Suction Safety Valve....313
Charge Safety Valve....317
Charge Pump....319
ANTI-ENGINE STALL CONTROL VALVE (AS VALVE)....321
SHUTTLE VALVE....324
CONTROL VALVE....325
Standard (3-Spool)....325
Super High-flow (4-Spool)....339
CLSS....347
SOLENOID VALVE....355
Solenoid Valve Group ST1....355
Solenoid Valve ST2....356
ACCUMULATOR....357
PATTERN CHANGE VALVE....358
Pattern ISO....361
Pattern Optional....361
R.H. PPC VALVE (STANDARD)....362
Equipment Control....362
R.H. PPC VALVE (PATTERN CHANGE)....369
Equipment And Travel Control....369
L.H. PPC VALVE (STANDARD)....373
Travel Control....373
L.H. PPC VALVE (PATTERN CHANGE)....379
Work Equipment and Travel Control....379
CYLINDER....385
Lift Arm....385
Bucket....385
WORKING EQUIPMENT....387
20 STANDARD VALUE TABLES....390
STANDARD TECHNICAL DATA....391
Engine....391
Machine....392
30 TESTING AND ADJUSTING....398
T-ADAPTER PROCEDURES AND KITS....400
SPECIAL TOOLS....401
ENGINE....402
Engine Speed....402
Valve Clearance....403
Compression Pressure....405
Fan Belt....406
Injection Timing....407
Checking....407
Adjusting....408
Oil Pressure....409
ACCELERATOR CABLES....410
Adjusting The Stroke....410
PPC VALVES....411
Drive Pressure....411
Valve Clearance Adjustment....413
SERVO-CONTROL SAFETY SENSOR....414
Adjusting The Engagement Position....414
GEARING CHAIN....415
Testing And Adjusting Tension....415
HYDRAULIC CIRCUITS....416
Control And Regulation Of Pressures....416
Hydraulic Pump....417
Valve Calibration....418
HST Valve....418
AS Valve....419
Travel Deviation....420
Control Valve....422
Servo-Control Power Supply....424
Elimination Of Residual Pressures....426
Hydraulic Tank Pressurization....426
Bleeding Air From The Hydraulic Circuits....427
Bleeding air from the pump....427
Bleeding air from the cylinders....428
Bleeding air from any optional equipment....428
40 TROUBLESHOOTING....430
POINTS TO REMEMBER WHEN TROUBLESHOOTING....432
SEQUENCE OF EVENTS IN TROUBLESHOOTING....434
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....435
Precautions When Handling Electrical Equipment....435
Handling Control Box....440
Points To Remember When Troubleshooting Electrical Circuits....441
Points To Remember When Handling Hydraulic Equipment....442
CHECKS BEFORE TROUBLESHOOTING....444
Using Troubleshooting Charts....445
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....446
T-ADAPTER TABLE....470
INFORMATION CONTAINED IN TESTING PROCEDURES....473
BASIC AIR CONDITIONING SYSTEM (TYPICAL)....476
Operator Cab Air Conditioning....477
Principles of Refrigeration....477
Air Conditioning....477
The Act of Cooling....477
The Refrigeration Cycle....478
Air Conditioner System Components....478
Compressor (Refrigerant Pump)....478
Service Valves....478
Condenser....479
Receiver-Drier....479
Thermostatic Expansion Valve....479
Evaporator....480
Electrical Circuit....480
Thermostat....481
Compressor Clutch....481
Safety Switches....481
System Servicing....482
R-134A Refrigerant Containers....483
Service Tools And Equipment....483
Recovery/Recycle Station....483
Leak Detector....484
Service Valves....484
Vacuum Pump....484
Manifold Gauge Set....485
Installing Manifold Gauge Set....486
Purging Air from Service Hoses....487
Adding Refrigerant to the System (Without a Charging Station)....488
Stabilizing the AC System....488
Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling Station)....489
Recovering and Recycling the Refrigerant....489
Performing the Recovery Cycle....489
Performing the Recycling Procedure....490
Evacuating and Charging the AC System....490
System Performance Test....491
System Leak Testing....492
Electronic Leak Detector....492
Tracer Dyes....492
Soap and Water....492
System Repair....493
Hoses and Fittings....493
Lines....493
Expansion Valve....493
Receiver-Drier....493
Thermostat....493
Clutch....494
Compressor....494
Checking Compressor Oil Level....494
Evacuating The System....495
Troubleshooting - Air Conditioning System....496
Pre-Diagnosis Checks....496
Preparing for Diagnosis....496
Preliminary Steps....496
System Performance Test....496
Diagnosis of Gauge Readings and System Performance....497
Troubleshooting by Manifold Gauge Set Readings....498
Preventive Maintenance Schedule for A/C System....503
50 DISASSEMBLY AND ASSEMBLY....506
METHOD OF USING MANUAL....510
PRECAUTIONS DURING OPERATION....511
Precautions When Carrying Out Removal Work....511
Precautions When Carrying Out Installation Work....512
Precautions When Completing The Operations....513
Other Precautions....513
CONNECTOR REPAIR PROCEDURES....514
Stripping Insulation....514
Wire Inspection....514
Contact Terminal Removal (HD30 Type)....515
Crimping Contact Terminal (HD30 Type)....516
Insertion Of Contact Terminal (HD30 Type)....517
Contact Terminal Removal (DT Type)....518
Crimping Contact Terminal (DT Type)....519
Insertion Of Contact Terminal (DT Type)....520
ENGINE HOOD....522
Removal....522
Installation....522
CAB....523
Tilting....523
Lowering....525
Removal....526
Installation....528
BATTERY....529
Removal....529
Installation....529
STARTER MOTOR....530
Removal....530
Installation....530
ALTERNATOR....531
Removal....531
Installation....531
MUFFLER....532
Removal....532
Installation....532
TURBOCHARGER....533
Removal....533
Installation....534
AIR INTAKE FILTER....535
Removal....535
Installation....535
VALVE COVER....536
Removal....536
Installation....537
NOZZLE HOLDER....538
Removal....538
Installation....538
INJECTION PUMP....539
Removal....539
Installation....541
CYLINDER HEAD....542
Removal....542
Installation....544
COOLANT LIQUID PUMP....545
Removal....545
Installation....545
RADIATOR GROUP....546
Removal....546
Installation....547
FUEL TANK....548
Removal....548
Installation....549
ENGINE PUMP GROUP....550
Removal....550
Installation....553
HYDRAULIC PUMP....554
Removal....554
Installation....556
GEAR PUMP....557
Removal....557
Installation....557
ENGINE-PUMP COUPLING....558
Removal....558
Installation....558
CONTROL VALVE....559
Removal....559
Installation....559
PPC VALVES....560
Removal....560
Installation....560
HEATING FAN....561
Removal....561
Installation....562
WHEEL HUB....563
Removal....563
Installation....564
Disassembly....565
Assembly....566
FINAL DRIVE....567
Removal....567
Installation....568
CYLINDER....569
Raising....569
Removal....569
Installation....570
Bucket....571
Removal....571
Installation....572
Work Equipment....573
Disassembly....573
Assembly....575
WORKING EQUIPMENT....579
Removal....579
Installation....581
FULCRUM LEVER....582
Removal....582
Installation....582
LIFT LEVER....583
Removal....583
Installation....584
WORKING EQUIPMENT COUPLER....585
Removal....585
Installation....585
90 DIAGRAMS AND SCHEMATICS....586
ELECTRICAL DIAGRAM....587
ENGINE LINE (1/2)....587
ENGINE LINE (2/2)....588
FRAME LINE STANDARD (1/2)....589
FRAME LINE STANDARD (2/2)....590
FRAME LINE OPTIONAL (1/2)....591
FRAME LINE OPTIONAL (2/2)....592
CABIN LINE STANDARD (1/4)....593
CABIN LINE STANDARD (2/4)....594
CABIN LINE STANDARD (3/4)....595
CABIN LINE STANDARD (4/4)....596
CABIN LINE OPTIONAL (1/6)....597
CABIN LINE OPTIONAL (2/6)....598
CABIN LINE OPTIONAL (3/6)....599
CABIN LINE OPTIONAL (4/6)....600
CABIN LINE OPTIONAL (5/6)....601
CABIN LINE OPTIONAL (6/6)....602
TOP-CABIN LIGHT LINE STANDARD (1/2)....603
TOP-CABIN LIGHT LINE STANDARD (2/2)....604
TOP-CABIN LIGHT LINE HOMOLOGATION (1/2)....605
TOP-CABIN LIGHT LINE HOMOLOGATION (2/2)....606
REAR LIGHT LINE (1/2)....607
REAR LIGHT LINE (2/2)....608
STANDARD (1/5)....609
STANDARD (2/5)....610
STANDARD (3/5)....611
STANDARD (4/5)....612
STANDARD (5/5)....613
HYDRAULIC....614
STANDARD 1/3)....614
STANDARD (2/3)....615
STANDARD (3/3)....616
HIGH FLOW (1/3)....617
HIGH FLOW (2/3)....618
HIGH FLOW (3/3)....619
