Komatsu SK818-5 SK820-5 Skid Steer Loader OEM Workshop Service Repair Manual #2
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This is the COMPLETE Official Service Repair Manual for the Komatsu Skid Steer Loader.
This manual contains deep information about maintaining, assembly, disassembly and servicing your Komatsu .
This PDF file is Bookmarked and SEARCHABLE to make what you need easy to find.
This Manual contains information and data to this model.
has specs, diagrams, and actual real photo illustrations, and schemes, which give you complete step by step operations on repair,
servicing, technical maintenance & troubleshooting procedures for your machine.
this manual offers full information you need for repair your machine.
the information in this manual will enable you to find trouble and to understand how to repair and maintain your machine without going into service.
all pages are printable, so run off what you need and take it with you into the garage or workshop.
Model & Serial Number Coverd:
SK818-5 → 37BF50111 and up
SK820-5 turbo → 37BTF50112 and up
SK820-5 turbo → 37BTF50112 and up
Table of Contents:
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10 STRUCTURE AND FUNCTION……………………………………………………………………………. 10-1
P.T.O. ………………………………………………………………………. 2
POWER TRAIN…………………………………………………………. 3
TRANSMISSION……………………………………………………….. 4
FINAL DRIVE ……………………………………………………………. 6
HYDRAULIC CIRCUIT SK818-5 ………………………………… 13
HYDRAULIC CIRCUIT SK820-5 turbo………………………… 14
HST PUMP LPV40 + 40 (STANDARD)……………………….. 15
HST PUMP LPV40 + 40 (HIGHFLOW) ……………………….. 16
SUCTION SAFETY VALVE……………………………………….. 21
CHARGE SAFETY VALVE………………………………………… 25
CHARGE PUMP………………………………………………………. 27
ANTI ENGINE-STALL CONTROL VALVE (AS VALVE) … 29
SHUTTLE VALVE…………………………………………………….. 31
CONTROL VALVE (3-SPOOL) ………………………………….. 32
CONTROL VALVE (4-SPOOL) ………………………………….. 35
SOLENOID VALVE ………………………………………………….. 47
SOLENOID VALVE ST2……………………………………………. 48
ACCUMULATOR ……………………………………………………… 49
PATTERN CHANGE VALVE ……………………………………… 50
R.H. PPC VALVE (STANDARD)…………………………………. 54
R.H. PPC VALVE (PATTERN CHANGE) …………………….. 58
L.H. PPC VALVE (STANDARD) …………………………………. 62
L.H. PPC VALVE (PATTERN CHANGE)……………………… 66
CYLINDERS ……………………………………………………………. 70
ELECTRICAL DIAGRAM (ENGINE LINE)……………………. 71
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) ….. 75
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL)……. 79
ELECTRICAL DIAGRAM (CABIN LINE STANDARD)…… 83
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) ……. 89
ELECTRICAL DIAGRAM
(TOP-CABIN LIGHT LINE STANDARD)………………………. 97
20 TESTING AND ADJUSTING………………………………………………………………………………… 20-1
NORMAL OR STANDARD TECHNICAL DATA……………… 2
SPECIAL TOOLS …………………………………………………….. 14
CHECKING THE ENGINE SPEED …………………………….. 15
ADJUSTMENT OF VALVE CLEARANCE……………………. 16
MEASUREMENT OF THE COMPRESSION PRESSURE 17
CONTROL AND ADJUSTMENT OF THE FAN BELT
TENSION………………………………………………………………… 18
CONTROL AND ADJUSTMENT OF THE INJECTION
TIMING…………………………………………………………………… 19
CHECKING ENGINE OIL PRESSURE ……………………….. 21
ADJUSTING THE STROKE OF THE ACCELERATOR
CABLES …………………………………………………………………. 22
REGULATION OF PPC VALVES’ DRIVE PRESSURE …. 23
ADJUSTMENT OF THE PPC VALVE CLEARANCES…… 25
ADJUSTING THE POSITION OF THE SERVO-CONTROL
ENGAGEMENT SAFETY SENSOR……………………………. 26
TESTING AND ADJUSTMENT OF GEARING
CHAIN TENSION……………………………………………………… 27
CONTROL AND REGULATION OF THE
PRESSURES IN THE HYDRAULIC CIRCUITS ……………. 28
TESTING THE HYDRAULIC PUMP……………………………. 29
VALVE CALIBRATION ……………………………………………… 30
CHECKING THE TRAVEL DEVIATION ………………………. 32
CONTROL VALVE……………………………………………………. 34
CONTROL AND REGULATION OF THE
SERVO-CONTROL POWER SUPPLY………………………… 35
ELIMINATION OF RESIDUAL PRESSURES –
PRESSURISATION OF THE TANK ……………………………. 37
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS …… 38
30 DISASSEMBLY AND ASSEMBLY………………………………………………………………………. 30-1
HOW TO READ THE MANUAL…………………………… 3
PRECAUTIONS TO BE TAKEN WHILE WORKING. 4
ENGINE HOOD
Removal and installation ……………………………………. 5
CAB
Tilting ………………………………………………………………. 6
Lowering ………………………………………………………….. 8
BATTERY
Removal and installation ……………………………………. 9
STARTING MOTOR
Removal and installation ………………………………….. 10
ALTERNATOR
Removal and installation ………………………………….. 11
MUFFLER (SK818-5)
Removal and installation ………………………………….. 12
MUFFLER (SK820-5 turbo)
Removal and installation ………………………………….. 13
TURBOCHARGER (SK820-5 turbo)
Removal ………………………………………………………… 14
Installation ……………………………………………………… 15
AIR INTAKE FILTER
Removal and installation ………………………………….. 16
NOZZLE HOLDER
Removal and installation ………………………………….. 17
INJECTION PUMP
Removal ………………………………………………………… 18
Installation ……………………………………………………… 20
CYLINDER HEAD (SK818-5)
Removal ………………………………………………………… 21
Installation ……………………………………………………… 22
CYLINDER HEAD (SK820-5 turbo)
Removal ………………………………………………………… 23
Installation ……………………………………………………… 24
COOLANT LIQUID PUMP
Removal and installation ………………………………….. 25
RADIATOR GROUP
Removal ………………………………………………………… 26
Installation ……………………………………………………… 27
FUEL TANK (SK818-5)
Removal and installation ………………………………….. 28
FUEL TANK (SK820-5 turbo)
Removal ………………………………………………………….29
Installation ……………………………………………………….30
CAB
Removal ………………………………………………………….31
Installation ……………………………………………………….33
ENGINE-PUMP GROUP
Removal ………………………………………………………….34
Installation ……………………………………………………….37
COMPLETE HYDRAULIC PUMP
Removal ………………………………………………………….38
Installation ……………………………………………………….40
GEAR PUMP
Removal and installation ……………………………………41
ENGINE-PUMP COUPLING
Removal and installation ……………………………………42
CONTROL VALVE
Removal and installation ……………………………………43
PPC VALVES
Removal and installation ……………………………………44
HEATING FAN
Removal ………………………………………………………….45
Installation ……………………………………………………….46
HUB WHEEL
Removal ………………………………………………………….47
Installation ……………………………………………………….48
Dismatling………………………………………………………..49
Assembly…………………………………………………………50
FINAL DRIVE
Removal ………………………………………………………….51
RAISING CYLINDER
Removal ………………………………………………………….53
Installation ……………………………………………………….54
BUCKET CYLINDER
Removal ………………………………………………………….55
Installation ……………………………………………………….56
WORK EQUIPMENT CYLINDERS
Disassembly …………………………………………………….57
Assembly…………………………………………………………59
40 MAINTENANCE STANDARD………………………………………………………………………………. 40-1
P.T.O. ………………………………………………………………………. 2
TRANSMISSION……………………………………………………….. 3
FINAL DRIVE ……………………………………………………………. 4
HYDRAULIC PUMP …………………………………………………… 5
AS VALVE ………………………………………………………………… 6
CONTROL VALVE (SUPER HIGH-FLOW VERSION)…….. 7
CONTROL VALVE (STANDARD) ………………………………… 8
R.H. PPC VALVE……………………………………………………… 13
L.H. PPC VALVE (STANDARD) …………………………………. 14
L.H. PPC VALVE PATTERN CHANGE ……………………….. 15
PATTERN CHANGE VALVE ……………………………………… 16
CYLINDERS ……………………………………………………………. 17
WORKING EQUIPMENT…………………………………………… 18
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Product Details:
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Gary bell –
Great manual, just what I needed