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KOMATSU SK818-5 SK820-5 turbo SKID-STEER LOADER SHOP MANUAL WEBM005001 – PDF
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KOMATSU SK818-5 SK820-5 turbo SKID-STEER LOADER SHOP MANUAL WEBM005001 – PDF DOWNLOAD
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Description
KOMATSU SK818-5 SK820-5 turbo SKID-STEER LOADER SHOP MANUAL WEBM005001 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU SK818-5 SK820-5 turbo SKID-STEER LOADER SHOP MANUAL WEBM005001 – PDF DOWNLOAD
Language : English
Pages : 272
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU SK818-5 SK820-5 turbo SKID-STEER LOADER SHOP MANUAL WEBM005001 – PDF DOWNLOAD
SHOP MANUAL................................................................................ 1 CONTENTS............................................................................... 4 SAFETY................................................................................. 7 FOREWORD............................................................................... 9 HOW TO READ THE SHOP MANUAL............................................................ 10 HOISTING INSTRUCTIONS.................................................................. 11 STANDARD TIGHTENING TORQUE............................................................. 12 COATING MATERIALS...................................................................... 14 WEIGHT TABLE........................................................................... 16 TABLE OF OIL AND COOLANT QUANTITIES.................................................... 17 CONVERSION TABLE....................................................................... 19 10 STRUCTURE AND FUNCTION.............................................................. 27 P.T.O.............................................................................. 28 POWER TRAIN........................................................................ 29 TRANSMISSION....................................................................... 30 FINAL DRIVE........................................................................ 32 1. HYDRAULIC MOTOR............................................................. 34 2. FLUSHING RELIEF VALVE....................................................... 36 3. REDUCTION GEARING........................................................... 37 HYDRAULIC CIRCUIT SK818-5 - SK820-5 turbo (STANDARD)............................... 39 HYDRAULIC CIRCUIT SK818-5 - SK820-5 turbo (HIGH-FLOW).............................. 40 HYDRAULIC CIRCUIT SK818-5 - SK820-5 turbo (ROAD HOMOLOGATION)...................... 41 HYDRAULIC PUMP..................................................................... 43 CONTROL VALVE (3-SPOOL)............................................................ 60 CONTROL VALVE (4-SPOOL)............................................................ 63 CLSS............................................................................... 67 1. OUTLINE..................................................................... 67 2. PRESSURE COMPENSATION CONTROL............................................... 67 3. OPERATION FOR EACH FUNCTION AND VALVE....................................... 68 3.1 SERIES CIRCUIT......................................................... 69 3.2 SELF LEVELING FUNCTION................................................. 70 3.3 THE FUNCTION TO SWITCH SERIES CIRCUIT TO PARALLEL CIRCUIT.............. 71 3.4 PRESSURE COMPENSATION VALVE............................................ 73 3.5 DIVIDING FUNCTION (1:9) (Only Super-Flow specification for SK815-5).... 74 SOLENOID VALVE..................................................................... 75 ACCUMULATOR........................................................................ 77 PATTERN CHANGE VALVE (OPTIONAL).................................................... 78 OPERATION.......................................................................... 80 PATTERN ISO........................................................................ 80 PATTERN OPTIONAL................................................................... 80 R.H. PPC VALVE (STANDARD).......................................................... 82 R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)......................................... 86 L.H. PPC VALVE (STANDARD).......................................................... 90 L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL)......................................... 94 CYLINDERS.......................................................................... 98 BUCKET RAISE................................................................... 98 BUCKET TILT.................................................................... 98 ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE OMOLOGATION) (1/2)........................127 ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE OMOLOGATION) (2/2)........................128 ELECTRICAL DIAGRAM (REAR LIGHT LINE) (1/2).........................................129 ELECTRICAL DIAGRAM (REAR LIGHT LINE) (2/2).........................................130 ELECTRICAL DIAGRAM (ENGINE LINE) (2/3).............................................100 ELECTRICAL DIAGRAM (ENGINE LINE) (3/3).............................................101 ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3).....................................103 ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (2/3).....................................104 ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (3/3).....................................105 ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3).....................................107 ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (2/3).....................................108 ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (3/3).....................................109 ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5).....................................111 ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (2/5).....................................112 ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (3/5).....................................113 ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (4/5).....................................114 ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (5/5).....................................115 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7).....................................117 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (2/7).....................................118 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (3/7).....................................119 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (4/7).....................................120 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (5/7).....................................121 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (6/7).....................................122 ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7).....................................123 ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (1/2)...........................125 ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (2/2)...........................126 ELECTRICAL DIAGRAM (ENGINE LINE) (1/3)............................................. 99 ELECTRICAL DIAGRAM (STANDARD)...................................................... 99 20 TESTING AND ADJUSTMENTS.............................................................133 NORMAL OR STANDARD TECHNICAL DATA..................................................134 SPECIAL TOOLS......................................................................146 CHECKING THE ENGINE SPEED..........................................................147 ADJUSTMENT OF VALVE CLEARANCE (SK818-5)............................................148 ADJUSTMENT OF VALVE CLEARANCE (SK820-5 turbo)......................................149 MEASUREMENT OF THE COMPRESSION PRESSURE (SK818-5)..................................151 MEASUREMENT OF THE COMPRESSION PRESSURE (SK820-5 turbo)............................152 CONTROL AND ADJUSTMENT OF THE FAN BELT TENSION.....................................153 CONTROL AND ADJUSTMENT OF THE INJECTION TIMING.....................................154 CHECKING ENGINE OIL PRESSURE.......................................................156 ADJUSTING THE STROKE OF THE ACCELERATOR CABLES.....................................157 REGULATION OF PPC VALVES’ DRIVE PRESSURE........................................... 5 ADJUSTMENT OF THE PPC VALVE CLEARANCES............................................. 7 ADJUSTING THE POSITION OF THE SERVO-CONTROL ENGAGEMENT SAFETY SENSOR...............161 TESTING AND ADJUSTMENT OF GEARING CHAIN TENSION....................................162 CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS..................163 TESTING THE HYDRAULIC PUMP.........................................................164 VALVE CALIBRATION..................................................................165 CHECKING THE TRAVEL DEVIATION......................................................167 CONTROL VALVE......................................................................169 CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY...........................170 ELIMINATION OF RESIDUAL PRESSURES - PRESSURISATION OF THE TANK.....................172 BLEEDING AIR FROM THE HYDRAULIC CIRCUITS...........................................173 30 REMOVAL AND INSTALLATION............................................................175 HOW TO READ THE MANUAL.............................................................177 PRECAUTIONS TO BE TAKEN WHILE WORKING..............................................178 REMOVAL THE ENGINE HOOD............................................................179 INSTALLATION THE ENGINE HOOD.......................................................179 TILTING THE CAB....................................................................180 LOWERING THE CAB...................................................................182 REMOVAL OF THE BATTERY.............................................................183 INSTALLATION OF THE BATTERY........................................................183 REMOVAL OF THE STARTING MOTOR......................................................184 INSTALLATION OF THE STARTING MOTOR.................................................184 REMOVAL OF THE ALTERNATOR..........................................................185 INSTALLATION OF THE ALTERNATOR.....................................................185 REMOVAL OF THE MUFFLER (SK818-5)...................................................186 INSTALLATION OF THE MUFFLER........................................................186 REMOVAL OF THE MUFFLER (SK820-5 turbo).............................................187 INSTALLATION OF THE MUFFLER........................................................187 REMOVAL OF TURBOCHARGER (SK820-5 turbo)............................................188 INSTALLATION OF TURBOCHARGER.......................................................189 REMOVAL OF THE AIR INTAKE FILTER...................................................190 INSTALLATION OF AIR INTAKE FILTER..................................................190 REMOVAL OF THE VALVE COVER (SK818-5)...............................................191 INSTALLATION OF THE VALVE COVER....................................................191 REMOVAL OF THE VALVE COVER (SK820-5 turbo).........................................192 INSTALLATION OF THE VALVE COVER....................................................193 REMOVAL OF THE NOZZLE HOLDER (SK818-5).............................................194 INSTALLATION OF THE NOZZLE HOLDER..................................................194 REMOVAL OF THE NOZZLE HOLDER (SK820-5 turbo).......................................195 INSTALLATION OF THE NOZZLE HOLDER..................................................195 REMOVAL OF INJECTION PUMP..........................................................196 INSTALLATION OF INJECTION PUMP.....................................................199 REMOVAL OF THE CYLINDER HEAD (SK818-5).............................................200 INSTALLATION OF THE CYLINDER HEAD (SK818-5)........................................202 REMOVAL OF THE CYLINDER HEAD (SK820-5 turbo).......................................203 INSTALLATION OF THE CYLINDER HEAD (SK820-5 turbo)..................................205 REMOVAL OF THE COOLANT LIQUID PUMP.................................................206 INSTALLATION OF THE COOLANT LIQUID PUMP............................................206 REMOVAL OF THE RADIATOR GROUP......................................................207 INSTALLATION OF THE RADIATOR GROUP.................................................208 REMOVAL OF THE FUEL TANK...........................................................209 INSTALLATION OF THE FUEL TANK......................................................210 REMOVAL OF THE CAB.................................................................211 INSTALLATION OF THE CAB............................................................213 REMOVAL OF THE ENGINE-PUMP GROUP...................................................214 INSTALLATION OF THE ENGINE-PUMP GROUP..............................................217 REMOVAL OF THE COMPLETE HYDRAULIC PUMP.............................................218 INSTALLATION OF THE HYDRAULIC PUMP.................................................220 REMOVAL OF THE GEAR PUMP...........................................................221 INSTALLATION OF THE GEAR PUMP......................................................221 REMOVAL OF ENGINE-PUMP COUPLING....................................................222 INSTALLATION OF THE ENGINE-PUMP COUPLING...........................................222 REMOVAL OF THE CONTROL VALVE.......................................................223 INSTALLATION OF THE CONTROL VALVE..................................................223 REMOVAL OF PPC VALVES..............................................................224 INSTALLATION OF THE PPC VALVES.....................................................224 REMOVAL OF THE HEATING FAN.........................................................225 INSTALLATION OF THE HEATING FAN....................................................226 REMOVAL OF THE HUB WHEEL...........................................................227 INSTALLATION OF THE WHEEL HUB......................................................228 DISMANTLING THE HUB WHEEL..........................................................153 ASSEMBLY OF THE HUB WHEEL..........................................................230 REMOVAL OF THE FINAL DRIVE.........................................................231 INSTALLATION OF THE FINAL DRIVE....................................................232 REMOVAL OF THE RAISING CYLINDER....................................................233 INSTALLATION OF THE RAISING CYLINDER...............................................234 REMOVAL OF THE BUCKET CYLINDER.....................................................235 INSTALLATION OF THE BUCKET CYLINDER................................................236 DISASSEMBLY OF THE WORK EQUIPMENT CYLINDERS........................................169 ASSEMBLY OF THE WORK EQUIPMENT CYLINDERS...........................................239 REMOVAL OF THE COMPLETE WORKING EQUIPMENT..........................................243 INSTALLATION OF THE COMPLETE WORKING EQUIPMENT.....................................245 REMOVAL OF THE FULCRUM LEVER.......................................................246 INSTALLATION OF THE FULCRUM LEVER..................................................246 REMOVAL OF THE LIFT LEVER..........................................................247 INSTALLATION OF THE LIFT LEVER.....................................................248 REMOVAL OF THE WORKING EQUIPMENT SUPPORT FRAME.....................................249 INSTALLATION OF THE WORKING EQUIPMENT SUPPORT FRAME................................249 40 STANDARD MAINTENANCE................................................................251 STANDARD MAINTENANCE...............................................................251 P.T.O..............................................................................252 TRANSMISSION.......................................................................253 FINAL DRIVE........................................................................254 HYDRAULIC PUMP.....................................................................255 AS VALVE...........................................................................256 CONTROL VALVE (SUPER HIGH-FLOW VERSION)............................................257 CONTROL VALVE (STANDARD)...........................................................258 R.H. PPC VALVE.....................................................................263 L.H. PPC VALVE (STANDARD)..........................................................264 L.H. PPC VALVE PATTERN CHANGE (OPTIONAL)...........................................265 PATTERN CHANGE VALVE (OPTIONAL)....................................................266 CYLINDERS..........................................................................267 WORKING EQUIPMENT..................................................................268
DESCRIPTION:
KOMATSU SK818-5 SK820-5 turbo SKID-STEER LOADER SHOP MANUAL WEBM005001 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This sections 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 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.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 18/12/24
