Komatsu SKID-STEER LOADER SK820-8E0 Shop Manual WENBM00410 PDF

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Komatsu SKID-STEER LOADER SK820-8E0 Shop Manual WENBM00410 – PDF DOWNLOAD

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Komatsu SKID-STEER LOADER SK820-8E0 Shop Manual WENBM00410 – PDF DOWNLOAD

Language : English
Pages :650
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu SKID-STEER LOADER SK820-8E0 Shop Manual WENBM00410 – PDF DOWNLOAD

SERIAL NUMBERS F50002 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for Testing and Adjusting are described in
“Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Other Information
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu SKID-STEER LOADER SK820-8E0 Shop Manual WENBM00410 – PDF DOWNLOAD

SERIAL NUMBERS F50002 and up

00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 9
How to Read the Shop Manual 9
Safety Notice for Operation 11
Precautions to Prevent Fire 18
Procedures If Fire Occurs 20
Precautions When You Dispose of Waste Materials 21
Precautions When You Handle Hydraulic Equipment 22
Precautions When You Disconnect and Connect Pipings 25
Precautions When You Handle Electrical Equipment 32
Precautions When You Handle Fuel System Equipment 34
Precautions When You Handle Intake System Equipment 35
Practical Use of KOMTRAX 36
Disconnect and Connect Push-Pull Type Coupler 37
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 37
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 38
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 39
Precautions for Disconnection and Connection of Connectors 41
How to Disconnect and Connect Deutsch Connector 45
How to Disconnect and Connect Slide Lock Type Connector 46
How to Disconnect and Connect Connector with Lock to Pull 48
How to Disconnect and Connect Connector with Lock to Push 49
How to Disconnect and Connect Connector with Housing to Rotate 51
Standard Tightening Torque Table 52
Conversion Table 59
Abbreviation List 64
01 Specifications 67
Table of Contents 68
Specifications 69
Specification Drawing 69
Specification 74
Weight Table 76
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 77
10 Structure and Function 79
Table of Contents 80
NOx Control System 82
Function of NOx Control System 82
Boot-up System 84
Layout Drawing of Boot-up System 84
System Operating Lamp System 85
System Diagram of System Operating Lamp System 85
Function of Operation Lamp System 85
Quick Release Battery Terminal (-) 87
Function of Quick Release Battery Terminal (-) 87
Engine System 88
Layout Drawing of Engine System 88
Engine Control System 89
System Diagram of Engine Control 89
Function of Engine Control System 90
Component Parts of Engine System 92
PTO 92
Cooling System 93
Layout Drawing of Cooling System 93
Control System 94
Layout Drawing of Control System 94
Machine Monitor System 95
System Diagram of Machine Monitor System 95
KOMTRAX System 96
System Diagram of KOMTRAX System 96
Function of KOMTRAX System 96
Component Parts of Control System 97
Machine Monitor 97
KOMTRAX Terminal106
Machine Controller108
Hydraulic System112
Layout Drawing of Hydraulic System112
CLSS113
Structure of CLSS113
Function of CLSS113
Component Parts of Hydraulic System115
Hydraulic Tank115
Hydraulic Pump116
Control Valve130
Work Equipment System144
Layout Drawing of Work Equipment System144
PPC Lock System145
System Diagram of PPC Lock145
Function of PPC Lock System145
Component Parts of Work Equipment System146
Work Equipment PPC Valve146
Attachment PPC Valve151
Solenoid Valve Group153
Super Flow Solenoid Valve154
Pilot Circuit Accumulator155
Travel System156
Layout Drawing of Travel System156
System Diagram of Travel Control System157
Function of Travel Control System157
Component Parts of Travel System158
Travel PPC Valve158
Final Drive162
Power Train168
Transmission169
Work Equipment171
Structure of Work Equipment171
Function of Work Equipment172
Work Equipment Clearance Adjustment Shim173
Function of Work Equipment Clearance Adjustment Shim173
20 Standard Value Table175
Table of Contents176
Standard Value Table for Engine177
Standard Value Table for Machine179
Machine Posture and Procedures to Measure Performance188
30 Testing and Adjusting191
Table of Contents192
Engine and Cooling System194
Examine Engine Speed194
How to Examine Engine High Idle Speed194
How to Examine Engine Low Idle Speed194
How to Examine Engine at Travel Relief194
How to Examine Engine at Travel and Work Equipment Relief195
Examine Exhaust Gas Color196
How to Examine Exhaust Gas Color with the Handy Smoke Checker196
How to Examine Exhaust Gas Color with Smoke Meter197
Examine and Adjust Valve Clearance198
How to Examine Valve Clearance198
How to Adjust Valve Clearance199
Examine Compression Pressure200
How to Examine Compression Pressure200
Examine Engine Oil Pressure202
How to Examine Engine Oil Pressure202
Bleed Air from Fuel System203
How to Bleed Air from Fuel System203
Examine Fuel Circuit for Leakage204
How to Examine Fuel Circuit for Leakage at Engine Stop204
How to Examine Fuel Circuit for Leakage at Engine Low Idle204
How to Examine Fuel Circuit for Leakage at Engine High Idle204
Handle Cylinder Cut-out Mode Operation205
Examine and Adjust Alternator Belt Tension206
How to Examine Alternator Belt Tension206
How to Adjust Alternator Belt Tension206
Frame208
Examine and Adjust Gear Chain Tension208
How to Examine Gear Chain Tension208
How to Adjust Gear Chain Tension208
Hydraulic System209
Release Remained Pressure in Hydraulic Circuit209
How to Release Remained Pressure from Hydraulic Tank209
How to Release Remained Pressure in PPC Accumulator Circuit209
How to Release Remained Pressure in Hydraulic Cylinder Circuit209
Examine Oil Pressure of Work Equipment210
How to Examine Unload Pressure210
How to Examine Oil Pressure of Work Equipment211
Adjust Oil Pressure of Work Equipment213
How to Adjust Unload Pressure213
How to Adjust Oil Pressure of Work Equipment Relief Pressure213
Examine Oil Pressure of Control Circuit215
How to Examine Oil Pressure of Control Circuit215
Examine and Adjust Oil Pressure of Pump Circuit217
How to Examine Oil Pressure of Travel Pump HST Charge Circuit217
How to Adjust Oil Pressure of Travel Pump HST Charge Circuit217
How to Examine Oil Pressure of Travel Pump AS Valve218
How to Adjust Oil Pressure of Travel Pump AS Valve at Low Idling219
How to Adjust Oil Pressure of Travel Pump AS Valve at High Idling219
Examine Outlet Pressure of Solenoid Valve221
How to Examine Outlet Pressure of Solenoid Valve221
Operating Condition of Solenoid Valve222
Examine PPC Valve Outlet Pressure223
How to Examine Outlet Pressure of PPC Valve223
How to Examine Outlet Pressure of PPC Valve for Travel System225
Examine Parking Brake Release Pressure227
How to Examine Parking Brake Release Pressure227
Examine and Adjust Travel Deviation228
How to Examine Travel Deviation at High Idling228
How to Examine Travel Deviation at Medium Idling228
How to Adjust Travel Deviation229
Adjust Play of Work Equipment and Travel PPC Valves231
How to Adjust Play of Work Equipment and Travel PPC Valves231
Examine Parts Which Cause Hydraulic Drift of Work Equipment232
How to Examine Parts Which Cause Hydraulic Drift of Arm Cylinder and Bucket Cylinder232
How to Examine Parts that Cause Hydraulic Drift of PPC Valve232
Bleed Air from Hydraulic System233
How to Bleed Air from Travel Pump233
How to Bleed Air from Cylinder234
Pressurize Hydraulic Tank235
How to Pressurize Hydraulic Tank235
Electrical System236
How to Set and Operate Machine Monitor236
Operator Mode238
Examine Function by LCD (Liquid Crystal Display)238
Examine Function of Service Meter239
Usage Limitation and Maintenance Password Change Function239
Service Mode239
How to Start Up KOMTRAX Terminal271
Handle Voltage Circuit of Engine Controller276
40 Troubleshooting277
Table of Contents278
Abbreviation List281
Related Information to Troubleshooting287
General Troubleshooting Points287
Sequence of Events in Troubleshooting288
Troubleshooting Points for Aftertreatment System290
Checks Before Troubleshooting298
Inspection Procedure Before Troubleshooting300
Walk-Around Check300
Test in Accordance with Testing Procedure302
Examine Fuel Level, Add Fuel302
Examine Water Separator, Drain Water and Sediment302
Replace Fuel Prefilter Element303
Replace Fuel Main Filter Cartridge305
Examine Oil Level in Engine Oil Pan, Add Oil308
Replace Oil in Engine Oil Pan and Engine Oil Filter Cartridge309
Examine Coolant Level, Add Coolant311
Examine Clogging of Air Cleaner311
Examine Oil Level in Hydraulic Tank, Add Oil316
Replace Hydraulic Oil Drain Filter317
Examine Gear Chains Tension318
Examine Oil Level in Final Transmission319
Bleed Air from Fuel System320
Bleed Air from Hydraulic System320
Examine Electric Equipment321
Procedure for Troubleshooting329
Information Shown in Troubleshooting Table332
Connector Contact Identification (For 4D88E-7 Engine)334
T-Branch Box and T-Branch Adapter Table338
Fuse Location Table344
Failure Code Table346
Troubleshooting by Failure Code (Display of Code)355
Failure Code [989L00]355
Failure Code [989M00]356
Failure Code [989N00]357
Failure Code [AQ20R1]358
Failure Code [AS00R2]359
Failure Code [AS00R3]360
Failure Code [AS00R4]361
Failure Code [B@BCNS]362
Failure Code [D19JKZ]363
Failure Code [D811MC]366
Failure Code [D862KA]367
Failure Code [D8ALKA]368
Failure Code [D8ALKB]370
Failure Code [D8AQKR]372
Failure Code [DAF0KT]374
Failure Code [DAF0MB]375
Failure Code [DAF0MC]376
Failure Code [DAF3KK]377
Failure Code [DAFGMC]379
Failure Code [DAFLKA]380
Failure Code [DAFLKB]382
Failure Code [DAFQKR]384
Failure Code [DB2QKR]385
Failure Code [DBH0MC]389
Failure Code [DBH2KK]390
Failure Code [DBHLKA]392
Failure Code [DBHLKB]394
Failure Code [DBHQKR]396
Failure Code [F@HSZG]401
Failure Code [F@HSZL]403
Troubleshooting of Electrical System (E-Mode)405
Engine Does Not Start (Engine Does Not Crank)405
Engine Does Not Start (Fuel Feed Pump System)411
Automatic Preheating System Does Not Operate412
When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing414
Engine Coolant Temperature Monitor Comes On in White While Engine Runs417
Charge Level Monitor Comes On in Red While Engine is in Operation418
Fuel Level Monitor Comes On in Red While Engine Runs419
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation420
Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation421
Fuel Gauge Display Does Not Move from Minimum or Maximum422
Display of Fuel Gauge is Different from Actual Fuel Level424
Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum425
Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature426
Some Areas of Machine Monitor Screen are Not Shown427
Function Switch Does Not Operate428
Alarm Buzzer Does Not Sound429
Alarm Buzzer Cannot be Canceled431
Service Meter is Not Shown, While Starting Switch is in OFF Position432
Service Mode Cannot be Selected433
Alarm Does Not Sound During Travel434
Travel Alarm Does Not Stop When Machine Stops436
Horn Does Not Sound437
Horn Does Not Stop439
Front or Rear Working Lamps Do Not Light Up440
When Front Wiper Switch is Operated, Front Wiper Does Not Operate444
When Rear Wiper Switch is Operated, Rear Wiper Does Not Operate446
When Front Wiper Switch is Operated, Front Window Washer Does Not Operate448
When Rear Wiper Switch is Operated, Rear Window Washer Does Not Operate450
Travel Indicator is Not Shown Correctly with Monitoring Function452
Arm IN is Not Shown Normally in Monitoring Function453
KOMTRAX System Does Not Operate Normally454
Troubleshooting of Engine (S-Mode)455
Information Shown in Troubleshooting Table (S-Mode)455
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position456
S-2 Engine Cranks but No Exhaust Smoke Comes Out457
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)458
S-4 Engine Startability is Unsatisfactory459
S-5 Engine Does Not Pick Up Smoothly461
S-6 Engine Stops During Operation463
S-7 Engine Runs Rough or is Not Stable465
S-8 Engine Lacks Power466
S-9 KDPF Becomes Clogged in a Short Time468
S-10 Engine Oil Consumption is Excessive470
S-11 Oil Becomes Dirty Quickly471
S-12 Fuel Consumption is Excessive472
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant473
S-14 Oil Pressure Drops474
S-15 Fuel Mixes Into Engine Oil476
S-16 Water Mixes Into Engine Oil (Milky)477
S-17 Coolant Temperature Increases Too High (Overheating)478
S-18 Unusual Noise is Heard479
S-19 Vibration is Excessive481
S-20 Air Cannot be Bled from Fuel Circuit482
50 Disassembly and Assembly483
Table of Contents484
Related Information on Disassembly and Assembly486
How to Read This Manual486
Coating Materials List488
Engine and Cooling System492
Remove and Install Starter Assembly492
How to Remove Starter Assembly492
How to Install Starter Assembly492
Remove and Install Radiator Assembly493
How to Remove Radiator Assembly493
How to Install Radiator Assembly497
Remove and Install Engine and Pump Assembly500
How to Remove Engine and Pump Assembly500
How to Install Engine and Pump Assembly506
Remove and Install Fuel Tank Assembly512
How to Remove Fuel Tank Assembly512
How to Install Fuel Tank Assembly514
Remove and Install Alternator Assembly516
How to Remove Alternator Assembly516
How to Install Alternator Assembly516
Remove and Install Air Cleaner Assembly517
How to Remove Air Cleaner Assembly517
How to Install Air Cleaner Assembly517
Frame519
Remove and Install Engine Hood519
How to Remove Engine Hood519
How to Install Engine Hood520
Remove and Install Heater Assembly521
How to Remove Heater Assembly521
How to Install Heater Assembly523
Raise Arm and Tilt Cab526
How to Raise Arm526
How to Tilt Cab527
Fully Tilt and Rest the Cab Assembly529
How to Tilt of Cab529
How to Rest of Cab533
Remove and Install Cab Assembly538
How to Remove Cab Assembly538
How to Install Cab Assembly542
Remove and Install Wheel Hub Assembly547
How to Remove Wheel Hub Assembly547
How to Install Wheel Hub Assembly549
Remove and Install Travel Motor Assembly551
How to Remove Travel Motor Assembly551
How to Install Travel Motor Assembly553
Hydraulic System556
Remove and Install Pump Assembly556
How to Remove Pump Assembly556
How to Install Pump Assembly558
Remove and Install Gear Pump Assembly560
How to Remove Gear Pump Assembly560
How to Install Gear Pump Assembly561
Remove and Install Pump Coupling562
How to Remove Pump Coupling562
How to Install Pump Coupling563
Remove and Install Control Valve565
How to Remove Control Valve565
How to Install Control Valve566
Remove and Install PPC Valve569
How to Remove PPC Valve569
How to Install PPC Valve570
Work Equipment572
Remove and Install Arm572
How to Remove Arm572
How to Install Arm574
Remove and Install Lift Lever576
How to Remove Lift Lever576
How to Install Lift Lever577
Remove and Install Fulcrum Lever578
How to Remove Fulcrum Lever578
How to Install Fulcrum Lever578
Remove and Install Lift Cylinder579
How to Remove Lift Cylinder579
How to Install Lift Cylinder580
Remove and Install Bucket Cylinder581
How to Remove Bucket Cylinder581
How to Install Bucket Cylinder581
Remove and Install Equipment Support Frame583
How to Remove Equipment Support Frame583
How to Install Equipment Support Frame583
Electrical System585
Remove and Install Battery585
How to Remove Battery585
How to Install Battery585
60 Maintenance Standard587
Table of Contents588
Engine and Cooling System589
Maintenance Standard for PTO589
Hydraulic System590
Maintenance Standard for Control Valve (Standard Flow)590
Maintenance Standard for Control Valve (Super Flow)595
Maintenance Standard for Work Equipment PPC Valve600
Maintenance Standard for Travel PPC Valve603
Maintenance Standard for Attachment PPC Valve606
Power Train608
Maintenance Standard for Transmission608
Work Equipment610
Maintenance Standard for Work Equipment Linkage610
Maintenance Standard for Lift Cylinder613
Maintenance Standard for Tilt Cylinder614
90 Circuit Diagrams615
Table of Contents616
How to Read the Codes for Electric Cable617
Hydraulic Circuit Diagram621
Symbols Used in Hydraulic Circuit Diagram621
Hydraulic Circuit Diagram625
Electrical Circuit Diagram627
Symbols Used in Electric Circuit Diagram627
Electrical Circuit Diagram (1/6)631
Electrical Circuit Diagram (2/6)633
Electrical Circuit Diagram (3/6)635
Electrical Circuit Diagram (4/6)637
Electrical Circuit Diagram (5/6)639
Electrical Circuit Diagram (6/6)641
INDEX643

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24