Minishover Komatsu SK820-5E0

WEBM009101
Shop Manual
SKID-STEER
LOADER
SK820-5E0
SERIAL NUMBER SK820-5E0 F60003 and up
Shop Manual
SK820-5E0
SKID-STEER LOADER
SK820-5E0
Machine Model Serial number

SK820-5E0 F60003 and up
00 Index and foreword 0 -1
SK820-5E0 00-1
00 Index and foreword Index
Index 0 -2
00 Index and foreword
Index ........................................................................................................................................................... 2
Foreword and general information .............................................................................................................. 6
Safety notice ............................................................................................................................................ 6
How to read the shop manual ................................................................................................................ 11
Explanation of terms for maintenance standard .................................................................................... 13
Handling of hydraulic components ......................................................................................................... 15
Method of disconnecting and connecting push-pull type coupler .......................................................... 17
Handling of electric equipment............................................................................................................... 20
How to read electric wire code ............................................................................................................... 30
Precautions when performing work........................................................................................................ 33
Standard tightening torque table............................................................................................................ 36
List of abbreviation................................................................................................................................. 40
Conversion table .................................................................................................................................... 44
01 Specification
Specification................................................................................................................................................ 4
Dimensions (with bucket)......................................................................................................................... 4
Dimensions (with pallet forks) .................................................................................................................. 6
Specification............................................................................................................................................. 8
Table of weight......................................................................................................................................... 9
Fuel, coolant and lubricants ................................................................................................................... 10
10 Structure, function and maintenance standard

PTO.......................................................................................................................................................... 3
Power train............................................................................................................................................... 5
Transmission............................................................................................................................................ 6
Final drive ................................................................................................................................................ 9
Hydraulic pump ...................................................................................................................................... 16
Control valve (3-spool)........................................................................................................................... 37
CLSS...................................................................................................................................................... 53
Solenoid valves...................................................................................................................................... 60
Accumulator ........................................................................................................................................... 62
R.H. PPC valve ...................................................................................................................................... 63
L.H. PPC valve....................................................................................................................................... 68
Cylinders ................................................................................................................................................ 74
Work equipment..................................................................................................................................... 76
20 Standard value table

Standard value table ................................................................................................................................... 3
Engine...................................................................................................................................................... 3
Machine ................................................................................................................................................... 4
30 Testing and adjusting

Testing and adjusting .................................................................................................................................. 3
Special tools............................................................................................................................................. 3
Checking the engine speed ..................................................................................................................... 4
Adjustment of valve clearance ................................................................................................................. 5
Measurement of the compression pressure............................................................................................. 7
Control and adjustment of the fan belt tension ........................................................................................ 8
Control and adjustment of the injection timing ......................................................................................... 9
00-2 SK820-5E0
Index 00 Index and foreword
Checking engine oil pressure ................................................................................................................ 11

Adjusting the stroke of the accelerator cables ....................................................................................... 12
Regulation of PPC valves’ drive pressure.............................................................................................. 15
Adjustment of the PPC valve clearances............................................................................................... 17
Adjusting the position of the servo-control. ............................................................................................ 18
Testing and adjustment of gearing chain tension .................................................................................. 19
Control and regulation of the pressures in the hydraulic circuits ........................................................... 20
Testing the hydraulic pump.................................................................................................................... 21
Valve calibration .................................................................................................................................... 22
Checking the travel deviation................................................................................................................. 24
SSC device (Slow speed control) calibration ......................................................................................... 25
Control valve .......................................................................................................................................... 26
Control and regulation of the servo-control power supply...................................................................... 28
Elimination of residual pressures - pressurisation of the tank................................................................ 30
Bleeding air from the hydraulic circuits .................................................................................................. 31
50 Disassembly and assembly

How to read the manual........................................................................................................................... 3
Coating materials list ............................................................................................................................... 5
Removal and installation of engine hood ................................................................................................. 6
Tilting and lowering of cab ....................................................................................................................... 7
Removal and installation of battery........................................................................................................ 10
Removal and installation of starting motor............................................................................................. 11
Removal and installation of alternator ................................................................................................... 12
Removal and installation of muffler........................................................................................................ 13
Removal and installation of turbocharger .............................................................................................. 14
Removal and installation of air intake filter ............................................................................................ 15
Removal and installation of valve cover ................................................................................................ 16
Removal and installation of nozzle holder ............................................................................................. 17
Removal and installation of injection pump ........................................................................................... 18
Removal and installation of cylinder head ............................................................................................. 21
Removal and installation of coolant liquid pump.................................................................................... 23
Removal and installation of radiator group ............................................................................................ 24
Removal and installation of fuel tank ..................................................................................................... 26
Removal and installation of cab ............................................................................................................. 28
Removal and installation of engine-pump group ................................................................................... 32
Removal and installation of hydraulic pump assembly .......................................................................... 35
Removal and installation of gear pump ................................................................................................. 37
Removal and installation of engine-pump coupling ............................................................................... 38
Removal and installation of control valve .............................................................................................. 39
Removal and installation of PPC valve .................................................................................................. 40
Removal and installation of hub wheel .................................................................................................. 41
Removal and installation of final drive ................................................................................................... 45
Removal and installation of lift cylinder.................................................................................................. 46
Removal and installation of bucket cylinder........................................................................................... 48
Disassembly and assembly of work equipment cylinders...................................................................... 50
Removal and installation work equipment assembly ............................................................................. 55
Removal and installation of fulcrum lever .............................................................................................. 57
Removal and installation of lift lever ...................................................................................................... 58
Removal and installation of equipment support frame........................................................................... 60
90 Diagrams and drawings

Hydraulic diagrams ..................................................................................................................................... 3
Hydraulic diagram (float).......................................................................................................................... 3
SK820-5E0 00-3
00 Index and foreword Index
Hydraulic diagram (float - road homologation)......................................................................................... 5

Hydraulic diagram (float - road homologation - Slow Speed control)....................................................... 7
Hydraulic diagram (High-flow).................................................................................................................. 9
Hydraulic diagram (High-flow - road homologation)............................................................................... 11
Hydraulic diagram (High-flow - road homologation - Slow Speed control) ............................................ 13
Electrical circuit diagrams ......................................................................................................................... 15
Electrical circuit diagram (1/2)................................................................................................................ 15
00-4 SK820-5E0
Index 00 Index and foreword
SK820-5E0 00-5
00 Index and foreword Foreword and general information
Safety notice
Foreword and general information 0 -12

Safety notice 0 -12
(Rev. 2010/03)
Important safety notice
Appropriate servicing and repair are extremely important to ensure safe operation of the machine.
The shop manuals describe the effective and safe servicing and repair methods recommended by Ko-
matsu. Some of the servicing and repair methods require use of special tools designed by Komatsu
for special purposes.
The symbol mark "k" is indicated for such matters that require special precautions. The work indi-
cated with the warning mark should be performed according to the instructions with special attention
to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure
to keep safe first and take every necessary measure.
1. General precautions
k Inappropriate handling creates an ex- 6) Keep all tools in good condition, learn the
treme danger. Read and understand what correct way to use them, and use the proper
is described in the Operation and Mainte- ones. Before starting work, thoroughly check
nance Manual before operating the ma- the tools, machine, forklift truck, service car,
chine. Read and understand what is etc.
described in this manual before starting 7) If welding repairs are needed, always have a
work. trained and experienced welder perform the
1) Before performing any greasing or repairs, work. When performing welding work, always
read all the safety labels stuck to the wear welding gloves, apron, shielding
machine. For the locations of the safety goggles, cap and other clothes suited for
labels and detailed explanation of precau- welding work.
tions, see the Operation and Maintenance 8) Before starting work, warm up your body
Manual. thoroughly to start work under good condi-
2) Locate a place in the repair workshop to keep tion.
tools and removed parts. Always keep the 9) Avoid continuing work for long hours and
tools and parts in their correct places. Always take rests at proper intervals to keep your
keep the work area clean and make sure that body in good condition and at the provided
there is no dirt, water, or oil on the floor. place.
Smoke only in the areas provided for
smoking. Never smoke while working. Safety points
3) When performing any operation, always 1 Good arrangement
wear safety shoes and helmet. Do not wear 2 Correct work clothes
loose work clothes, or clothes with buttons 3 Following work standard
missing. 4 Making and checking signals
5 Prohibition of operation and handling by unli-
q Always wear the safety glasses when hit-
censed workers
ting parts with a hammer. 6 Safety check before starting work
q Always wear the safety glasses when 7 Wearing protective goggles (for cleaning or grind-
grinding parts with a grinder, etc. ing work)
4) When performing any operation with two or 8 Wearing shielding goggles and protectors (for
more workers, always agree on the operating welding work)
procedure before starting. Always inform 9 Good physical condition and preparation
your fellow workers before starting any step 10 Precautions against work which you are not used
of the operation. Before starting work, hang to or you are used to too much
UNDER REPAIR warning tag in the oper-
ator's compartment. 2. Preparation work
5) Only qualified workers must perform the work 1) Before adding oil or making any repairs, park
and operation which require license or quali- the machine on a hard and level ground, and
fication. apply the parking brake and chock the
wheels or tracks to prevent the machine from
moving.
00-6 SK820-5E0
Foreword and general information 00 Index and foreword
Safety notice
2) Before starting work, lower the work equip- 7) When removing components, be careful not
ment (blade, ripper, bucket, etc.) to the to break or damage the electrical wiring.
ground. If this is not possible, insert the lock Damaged wiring may cause electrical fires.
pin or use blocks to prevent the work equip- 8) When removing piping, stop the fuel or oil
ment from falling. In addition, be sure to lock from spilling out. If any fuel or oil drips onto
all the control levers and hang warning tag on the floor, wipe it off immediately. Fuel or oil
them. on the floor can cause you to slip and can
3) When disassembling or assembling, support even cause fires.
the machine with blocks, jacks, or stands 9) As a general rule, do not use gasoline to
before starting the work. wash parts. Do not use it to clean electrical
4) Remove all mud and oil from the steps or parts, in particular.
other places used to get on and off the 10)Be sure to assemble all parts again in their
machine. Always use the handrails, ladders original places. Replace any damaged parts
or steps when getting on or off the machine. and parts which must not be reused with new
Never jump on or off the machine. If it is parts. When installing hoses and wires, be
impossible to use the handrails, ladders or sure that they will not be damaged by contact
steps, use a stand to provide safe footing. with other parts when the machine is oper-
ated.
3. Precautions during work 11)When installing high pressure hoses and
1) Before disconnecting or removing compo- tubes, make sure that they are not twisted.
nents for the oil, water, or air circuits, first Damaged hoses and tubes are dangerous,
release the pressure completely from the so be extremely careful when installing
circuit. When removing the oil filler cap, a hoses and tubes for high pressure circuits. In
drain plug, or an oil pressure pickup plug, addition, check that connections of them are
loosen it slowly to prevent the oil from correct.
spurting out. 12)When assembling or installing parts, always
2) The coolant and oil in the circuits are hot tighten them to the specified torques. When
when the engine is shut down, so be careful installing protective parts such as guards, or
not to get scalded. Wait for the oil and coolant parts which vibrate violently or rotate at high
to cool before performing any work on the oil speeds, be particularly careful to check that
or water circuits. they are installed correctly.
3) Before starting work, shut down the engine. 13)When aligning two holes, never insert your
When working on or around a rotating part, in fingers or hand. Be careful not to get your
particular, shut down the engine. When fingers caught in a hole.
checking the machine without shutting down 14)When measuring hydraulic pressure, check
the engine (measuring oil pressure, revolving that the measuring tools are correctly
speed, temperature, etc.), take extreme care installed.
not to get caught in rotating parts or moving 15)Take care when removing or installing the
parts. wheels.
4) Before starting work, remove the cables from 16)If the engine is operated for a long time in a
the battery. Always remove the cable from place which is not ventilated well, you may
the negative (–) terminal first. suffer from gas poisoning. Accordingly, open
5) When raising a heavy component (heavier the windows and doors to ventilate well.
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly to
prevent the component from hitting any other
part. Do not work with any part still raised by
the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure by a
spring, always leave two bolts in diagonal
positions. Loosen those bolts gradually and
alternately to release the pressure, and then
remove the cover.
SK820-5E0 00-7
Safety notice
4. Precautions for slinging work and making signals

1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaller must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaller must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye 8) When installing wire ropes to an angular
and check its centre of gravity. load, apply pads to protect the wire ropes. If
5) Use proper sling according to the weight of the load is slippery, apply proper material to
the load and method of slinging. If too thick prevent the wire rope from slipping.
wire ropes are used to sling a light load, the 9) Use the specified eyebolts and fix wire ropes,
load may slip and fall. chains, etc. to them with shackles, etc.
6) Do not sling a load with one wire rope alone. 10)Apply wire ropes to the middle portion of the
If it is slung so, It may rotate and may slip out hook.
of the rope. Install two or more wire ropes q Slinging near the tip of the hook may
symmetrically.
k Slinging with one rope may cause
cause the rope to slip off the hook during
hoisting. The hook has the maximum
turning of the load during hoisting, un- strength at the middle portion.
twisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dan-
gerous accident.
7) Limit the hanging angle to 60 degree, as a
rule.
Do not sling a heavy load (25 kg or more)
with ropes forming a wide hanging angle
from the hook.
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angle. The table below
shows the variation of allowable load in kN
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN
{1000 kg} vertically, at various hanging 11)Do not use twisted or kinked wire ropes.
angles. When the two ropes sling a load verti- 12)When lifting up a load, observe the following.
cally, up to 19.6 kN {2000 kg} of total weight q Wind in the crane slowly until wire ropes
can be suspended. This weight is reduced to are stretched. When settling the wire
9.8 kN {1000 kg} when the two ropes make ropes with the hand, do not grasp them
a hanging angle of 120 degree. If the two but press them from above. If you grasp
ropes sling a 19.6 kN {2000 kg} load at a them, your fingers may be caught.
lifting angle of 150 degree, each of them is q After the wire ropes are stretched, stop
subjected to a force as large as 39.2 kN the crane and check the condition of the
{4000 kg}. slung load, wire ropes, and pads.
00-8 SK820-5E0
Safety notice
qIf the load is unstable or the wire rope or 13)If the hoist stops because of a power failure,
chains are twisted, lower the load and lift turn the power switch OFF. When turning on
it up again. a switch which was turned OFF by the
q Do not lift up the load at an angle. ground fault circuit interrupter, check that the
13)When lowering a load, observe the following. devices related to that switch are not in oper-
q When lifting down a load, stop it tempo- ating condition.
rarily at 30 cm above the floor, and then 14)If you find an obstacle around the hoist, stop
lower it slowly. the operation.
q Check that the load is stable, and then re- 15)After finishing the work, stop the hoist at the
move the sling. specified position and raise the hook to at
q Remove kinks and dirt from the wire least 2 m above the floor. Do not leave the
ropes and chains used for the sling work, sling installed to the hook.
and put them in the specified place.
7. Selecting wire ropes
5. Precautions for using mobile crane 1) Select adequate ropes depending on the
a Read the Operation and Maintenance Manu- weight of parts to be hoisted, referring to the
al of the crane carefully in advance and oper- table below
ate the crane safely. Wire ropes
(Standard "Z" twist ropes without galvanizing)
6. Precautions for using overhead traveling (JIS G3525, No. 6, Type 6X37-A)
crane Nominal diameter Allowable load
k A hoist crane or similar device must be
of rope
mm kN ton
used for lifting a heavy load (25 kg or
10 8.8 0.9
more). The weight of a part that is 25 kg or 12 12.7 1.3
more is indicated with the symbol "4" in 14 17.3 1.7
"Disassembly and assembly". 16 22.6 2.3
1) Before starting work, inspect the wire ropes, 18 28.6 2.9
brake, clutch, controller, rails, over wind stop 20 35.3 3.6
device, ground fault circuit interrupter, crane 25 55.3 5.6
30 79.6 8.1
collision prevention device, and power appli-
40 141.6 14.4
cation warning lamp, and check safety. 50 221.6 22.6
2) Observe the signals for sling work. 60 318.3 32.4
3) Operate the hoist at a safe place.
a The allowable load is one-sixth of the
4) Check the direction indicator plates (east,
breaking strength of the rope to be used
west, south, and north) and the directions of
(Safety coefficient: 6).
the control buttons without fail.
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.
10)Place the control switch in a position where it
will not be an obstacle to work and passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.
SK820-5E0 00-9
Safety notice
8. Precautions for disconnecting and a For tightening torque, see the precau-
connecting hoses and tubes in an air conditions for installation in each section of
tioner circuit "Disassembly and assembly".
1) Disconnection
k Although the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friend-
liness, it is not allowed to be released
into the atmosphere as is. Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refriger-
ant gas to reuse it.
a Ask a qualified person for collection and
charge of the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be frozen.
Whenever recovering or adding refrig-
erant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner circuit
hoses and tubes, take care that dirt, dust,
water, etc. will not enter them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings (1)
are fitted to their joints.
3] Check that O-ring (1) is free from flaw and
deterioration.
4] When connecting the refrigerant piping,
apply compressor oil for refrigerant
(R134a) (DENSO: ND-OIL8, VALEO
THERMAL SYSTEMS: ZXL100PG
(equivalent to PAG46)) to its O-rings.
a Example of O-ring (Fitted to every
joint of hoses and tubes)
00-10 SK820-5E0
How to read the shop manual
How to read the shop manual 0 -17

(Rev. 2010/03)
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is
required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine vol-
ume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function

This section explains the structure and function of each component. It serves not only to give an under-
standing for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjust-
ing and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for "Testing and adjusting" are
explained in "Standard value table".
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and assem-
bling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard

This section gives maintenance standard values of each component. The maintenance standard sub-sec-
tion explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of re manufacturing and repairing engine and replacing parts.
SK820-5E0 00-11
How to read the shop manual
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
3. Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED
PAGES.
q Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (01), (02), (03)...)
q Revisions
The revised pages are shown in the LIST OF REVISED PAGES.
4. Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol Item Description
k
Special safety precautions which are necessary when performing work are
Safety
described.
Special technical precautions or other precautions for preserving standards which

a Caution
are necessary when performing work are described.
4
Weight of parts of component or parts are indicated. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc. are described.
3
Places that require special attention for tightening torque during assembly are
Tightening torque
indicated.
2 Coat Places to be coated with adhesives, etc. during assembly are indicated.
5 Oil, coolant Places where oil, etc. must be added, and capacity are indicated.
6 Drain Places where oil, etc. must be drained, and quantity to be drained are indicated.
5. Unit
In this shop manual, the units are indicated with International System of units (SI).
For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00-12 SK820-5E0
Explanation of terms for maintenance standard
Explanation of terms for maintenance standard 0 -19

(Rev. 2010/03)
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the ma-
chine maintenance work. The following terms are used to explain the criteria.
1. Standard dimension and tolerance q When some parts are repaired, the value of
q To be accurate, the finished dimension of performance/function is set to the standard
parts is slightly different from one to another. value.
q To specify the finished dimension of a part, a
certain dimension is set for the part and an al-
lowable difference from that dimension is in-
dicated.
q The above dimension set is called the "stand-
ard dimension" and the range of difference
from the standard dimension is called the
"tolerance".
q The tolerance with the symbols of + or – is in-
dicated on the right side of the standard di-
mension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
a The tolerance may be indicated in the text
and a table as [standard dimension (upper
limit of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the dimension of a hole and the di-

mension of the shaft to be inserted into that
hole are indicated by the same standard di-
mension and different tolerances of the hole
and shaft. The tightness of fit is decided by
the tolerance.
q Indication of dimension of rotating shaft and
hole and their related drawing.
3. Standard interference
Example: q When the diameter of a hole of a part shown
Tolerance
Standard dimension in the given standard dimension and toler-
Shaft Hole
-0.030 +0.046 ance table is smaller than that of the shaft to
60 be inserted, the difference between those di-
-0.076 0
ameters is called the "interference".
q The range (between A and B) from the differ-
2. Standard clearance and standard value ence (A) between the minimum dimension of
q The clearance made when new parts are as-
the shaft and the maximum dimension of the
sembled is called the "standard clearance", hole to the difference (B) between the maxi-
which is indicated by the range from the min- mum dimension of the shaft and the mini-
imum clearance to the maximum clearance. mum dimension of the hole is the “standard
q When some parts are repaired, the clearance
interference”.
is generally adjusted to the standard clear- q After repairing or replacing some parts,
ance. measure the dimension of their hole and
q The values indicating performance and func-
shaft and check that the interference is in the
tion of new products or equivalent are called standard range.
the "standard value", which is indicated by a
range or a target value.
SK820-5E0 00-13
Explanation of terms for maintenance standard
4. Repair limit and allowable value or allowable

dimension
q The dimension of a part changes because of
wear and deformation while it is used. The
limit of changed dimension is called the "re-
pair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value with which the
product can be used without causing a prob-
lem is called the "allowable value" or "allowa-
ble dimension".
q If a product deviates from the allowable val-
ue, it must be checked or repaired. However,
since most of the allowable values are esti-
mated from various tests or experiences in
most cases, it must be judged after consider-
ing the operating condition and customer's
requirement.
5. Allowable clearance
q Parts can be used until the clearance be-
tween them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "allowable clearance".
q If the clearance between the parts exceeds
the allowable clearance, they must be re-
placed or repaired.
6. Allowable interference
q The allowable maximum interference be-
tween the hole of a part and the shaft of an-
other part to be assembled is called the
"allowable interference".
q The allowable interference shows the repair
limit of the part of smaller tolerance.
q If the interference between the parts exceeds
the allowable interference, they must be re-
placed or repaired.
00-14 SK820-5E0
Handling of hydraulic components
Handling of hydraulic components 0 -21

(Rev. 2010/03)
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil,
or when disassembling or assembling hydraulic components.
1. Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the perform-
ance should be checked with special test equip-
ment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.
4. Preventing intrusion of foreign materials

during refilling operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has been collected during storage, so this is
an even more effective method.
SK820-5E0 00-15
Handling of hydraulic components
5. Replacing hydraulic oil while its temperature is high

When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
hole in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
performed twice. Primary flushing is performed
by use of flushing oil and secondary flushing is
performed by use of the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 ␮) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.
00-16 SK820-5E0
Method of disconnecting and connecting push-pull type coupler
Method of disconnecting and connecting push-pull type coupler 0 -23

(Rev. 2010/03)
k Before performing the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the remaining pressure in the hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 0 -2 3
1. Disconnection
1) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).
2) With hose joint (2) pushed into adapter (3),
press rubber cap portion (4) against adapter
(3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull it
out. (Fig. 3)
a Since some hydraulic oil flows out, pre-
pare an oil container.
2. Connection
1) Hold hose adapter (1) or hose (5) and insert
it in mating adapter (3), aligning them with
each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose fitting in the adapter
on the other side perfectly, pull it back to
check the connecting condition (Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormal-
ity, however.
SK820-5E0 00-17
Type 2 0 -2 4
1. Disconnection
1) Hold the tightening portion and push body (7)
straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal
portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1) and
2), pull out whole body (7) to disconnect it.
(Fig. 8)
2. Connection
q Hold the tightening portion and push body (7)
straight until sliding prevention ring (6) con-
tacts contact surface (a) of the hexagonal
00-18 SK820-5E0
Type 3 0 -2 5
1. Disconnection
1) Hold the tightening portion and push body (9)
straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal
2) While holding the condition of Step 1), push
cover (10) straight until it contacts contact
surface (b) of the hexagonal portion at the
male end. (Fig. 11)
3) While holding the condition of Steps 1) and
2), pull out whole body (9) to disconnect it.
(Fig. 12)
2. Connection
q Hold the tightening portion and push body (9)
straight until sliding prevention ring (8) con-
tacts contact surface (b) of the hexagonal
SK820-5E0 00-19
Handling of electric equipment
Handling of electric equipment 0 -26

(Rev. 2010/03)
To maintain the performance of the machine over a long period, and to prevent failures or other troubles be-
fore they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics and is aimed at im-
proving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment".
Points to remember when handling electric equipment 0 -26

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harnesses
1) Defective contact of connectors (defective
contact between male and female connec-
tors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and discon-
necting the connector about ten times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are attached to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated and causes a
defective contact or the wire is broken.
00-20 SK820-5E0
3) Disconnections in wiring
If the harness is pulled to disconnect the
connector, or components are lifted with a
crane with the harness still connected, or a
heavy object hits the harness, the crimping of
the connector may separate, or the soldering
may be damaged, or the harness may be
broken.
4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to spray water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it to dry with compressed air and spray it with
electric contact cleaner.
a When wiping the joint portion of the con-
nector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the com-
pressed air completely before cleaning
with compressed air.
SK820-5E0 00-21
3. Removing, installing, and drying connectors

and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is in-
stalled.
q When removing a connector from a

clip, pull the connector in a parallel di-
rection to the clip for removing stop-
pers.
a If the connector is pried up and down
or to the left or right, the housing may
break.
3] Action to take after removing connectors

After removing a connector, cover it with
a vinyl bag to prevent the entry of dust,
dirt, oil, or water to the contact portion.
a If the machine is left disassembled for
a long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
00-22 SK820-5E0
2) Connecting connectors
1] Check the connector visually. a If there is any damage or breakage,
Check that no oil, dirt, or water is stuck to replace the connector.
connector pins (joint portion).
Check that connector pins are free from
deformation, defective contact, corrosion,
or damage.
Check that external surfaces of the
connectors are free from damage or
breakage.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the con-
nector and harness with a dryer, but
be careful not to make them too hot as
this will cause short circuits.
2] Fix the connector securely.
Position the connectors correctly, and
then fit them securely. For connectors
with the lock stopper, push in the
connector until the stopper clicks into
position.
3] Correcting protrusion of the boot and
misalignment of the wiring harness
For connectors fitted with the boot,
correct any extrusion of the boot. In addi-
tion, if the wiring harness is moved in
laying, or the clamp is out of position,
correct it to its right position.
a If the connector cannot be corrected
easily, remove the clamp and adjust
the position.
q If the connector clamp is removed, be
sure to return it to its original position.
Check also that there are no loose
clamps.
SK820-5E0 00-23
3) Deutsch connector (DT 8-pin, 12-pin)

Disconnection (Left of figure) q Disconnection q Connection (Example of
While pressing locks (a) and (b), pull out the incomplete setting of
female connector (2). (a))
Connection (Right of figure)
1] Push in female connector (2) horizontally
until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector (2)
while moving it up and down until the
locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
00-24 SK820-5E0
4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pres-
sure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is the risk that
oil in the air may cause defective con-
tact, remove oil and water in the air
before starting air blow.
2] Dry the inside of the connector with a

dryer.
If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connec-
tor or related parts too hot, as this will
cause deformation or damage to the
connector.
3] Perform a continuity test on the

connector.
After drying, leave the wiring harness
disconnected and perform a continuity
test to check for any short circuits
between pins caused by water.
a After completely drying the connector,
blow it with electric contact cleaner
and reassemble.
SK820-5E0 00-25
4. Handling of connectors used on engine

a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3
1) Slide, lock type (FRAMATOME-3, FRAM- 2) Pull lock type (PACKARD-2)

ATOME-2) q 95/107/114/125/140/170/12V140 Series
q 95/107/114/125/140/170/12V140 Series q Various temperature sensors
q Various pressure sensors and NE Examples)
speed sensor Intake air temperature sensor in
Examples) intake manifold: TIM
Intake air pressure sensor in intake Fuel temperature sensor: TFUEL
manifold: PIM (125/170/12V140 Oil temperature sensor: TOIL
series) Coolant temperature sensor: TWTR,
Oil pressure sensor: POIL etc.
(125/170/12V140 series)
Oil pressure switch (95/107/114 Disconnection
series) Disconnect the connector by pulling lock (B)
Ne speed sensor on flywheel housing: (on the wiring harness side) of connector (2)
NE (95/107/114/125/140/170/12V140 outward.
series)
Ambient pressure sensor: PAMB
(125/170/12V140 series)
Disconnection
1] Slide lock L1 to the right.
2] While pressing lock L2, pull out connector
(1) toward you.
a Even if lock L2 is pressed, connector
(1) cannot be pulled out toward you, if
part (A) does not float. In this case,
float part (A) with a small screwdriver
while pressing lock L2, and then pull
out connector (1) toward you.
Connection
Insert the connector straight until it "clicks".
Connection
00-26 SK820-5E0
3) Push lock type (1) While pressing up lock (C) of the connector
q 95/107/114 series with flat-head screwdriver [1], pull out
Example) Fuel pressure sensor in connector (3) in the direction of the arrow.
common rail (BOSCH-03)
Disconnection
While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 series
Connection
4) Push lock type (2)

q 107/114 series
Example) Intake air pressure/tempera-
ture sensor in intake manifold (SUMI-
q 107 series TOMO-04)
Disconnection
While pressing lock (D), pull out connector
(4) in the direction of the arrow.
a If the lock is located on the underside, use

flat-head screwdriver [1] since you cannot
insert your fingers.
Connection
SK820-5E0 00-27
5) Push lock type (3) Example) Intake air pressure sensor in

q 95/125/140/170/12V140 series intake manifold.
(CANNON-04): PIM, etc.
Disconnection
While pressing lock (E) of the connector, pull
out connector (5) in the direction of the arrow. Disconnection
Example) Fuel pressure sensor in common 1] Turn housing (H1) in the direction of the
rail: PFUEL etc. (AMP-3) arrow.
a When connector is unlocked, housing
(H1) becomes heavy to turn.
2] Pull out housing (H1) in the direction of
the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example) Injection pressure control valve of

fuel supply pump: PCV (SUMITOMO-2)
Connection
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of the
arrow until it "clicks".
Examples) Speed sensor of fuel supply

pump: G (SUMITOMO-3)
a Pull the connector straight up.
Connection
6) Turn-housing type (Round green
connector)
q 140 series
00-28 SK820-5E0
5. Handling controller
1) The controller contains a microcomputer and
electronic control circuits. These control all of
the electronic circuits on the machine, so be
extremely careful when handling the
controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or a
vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in a place that can be heated to a high
temperature even for a short time. (Place it
on a suitable dry stand.)
6) Precautions when performing arc welding
When performing arc welding on the
machine body, disconnect all of the wiring
harness connectors connected to the
controller. Fit an arc welding ground to the
place close to the welding point.
6. Points to remember when troubleshooting

electric circuits
1) Be sure to turn the power OFF before discon-
necting or connecting connectors.
2) Before performing troubleshooting, check all
the related connectors for loose connection.
a Disconnect and connect the related con-
nectors several times to check.
3) Be sure to connect any disconnected
connectors before going on to the next step.
a If the power is turned ON with the connec-
tors still disconnected, unnecessary
warning will be displayed.
4) When performing troubleshooting of circuits
(measuring the voltage, resistance, conti-
nuity, or current), wag the related wiring
harnesses and connectors several times and
check that there is no change in the reading
of the tester.
a If there is any change, there may be de-
fective contact in the circuit.
SK820-5E0 00-29
How to read electric wire code
How to read electric wire code 0 -36

(Rev. 2010/03)
In the electric circuit diagram, the material, thickness, and colour of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Exam- AEX 0.85 L --- Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
ple: of 0.85
Indicates colour of wire by colour code.

Colour codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols
are not indicated on the diagram.)
1. Type, symbol, and material

AV and AVS are different only in thickness and outside diameter of the cover. CAVS has a circular
compressed conductor. It differs from AV and AVS in the outside diameter and thickness of the cover. And
AEX is similar to AV in thickness and outside diameter of the cover but different from AV and AVS in mate-
rial of the cover.
(Table 1)
Tempera-
Type Symbol Material ture range Example of use
for use ( °C)
Annealed copper for electric
Low-voltage Conductor
appliance General wiring
wire for automo- AV
(nominal No. 5 and above)
biles Insulator Soft polyvinyl chloride
Thin low-volt- Annealed copper for electric
Conductor
age wire for appliance General wiring
AVS -30 – +60
automobile (nominal No. 3 and below)
Insulator Soft polyvinyl chloride
(type 1)
Thin low-volt- Annealed copper for electric
Conductor
age wire for appliance For mid- to small-size excavators
CAVS
automobile (nominal No. 1.25 and below)
Insulator Soft polyvinyl chloride
(type 2)
Annealed copper for electric
Heat resistant Conductor General wiring in extremely cold
appliance
low-voltage wire AEX -50 – +110 weather district, wiring at high
Heat-resistant cross linked
for automobiles Insulator ambient temperature place
polyethylene
00-30 SK820-5E0
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diame- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
ter of strand
Conduc- Sectional area
tor 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –

Cover D
AV Standard – – – – – – – 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diame- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
ter of strand
tor 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cover D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of 7/Circular com- 11/Circular com- 16/Circular com-
strands/Diame- – – –
ter of strand pressed pressed pressed
tor – 0.56 – 0.88 – 1.29
(mm2)
d (approx.) – 0.9 – 1.1 – 1.4

Cover D
CAVS Standard – 1.6 – 1.8 – 2.1
"f" of nominal No. denotes "flexible".
SK820-5E0 00-31
3. Color codes table
(Table 3)
Colour Code Colour of wire Colour Code Colour of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a colour code consisting of 2 colours, the first colour is the colour of the background and the
second colour is the colour of the marking.
Example: "GW" means that the background is "Green" and marking is "White".
4. Types of circuits and color codes
(Table 4)
Type of wire AVS, AV, CAVS AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of cir-
Br BrW BrR BrY BrB – – –
cuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
00-32 SK820-5E0
Precautions when performing work
Precautions when performing work 0 -39

(Rev. 2010/03)
When removing, installing, disassembling or assembling a unit, be sure to follow the general precautions giv-
en below.
1. Precautions for removal work

q If the coolant contains antifreeze, dispose of it correctly as chemicals.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Check the match marks showing the installation position, and put match marks in the necessary places
before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Attach the tags to wires and hoses to show their installation position to prevent any mistake when in-
stalling.
q Check the number and thickness of the shims, and keep them in a safe place.
q When slinging component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly and alter-
nately.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Put the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal Plug (nut end) Sleeve nut (elbow end)
number
02 07376 - 70210 02789 - 20210
03 07376 - 70315 02789 - 20315
04 07376 - 70422 02789 - 20422
05 07376 - 70522 02789 - 20522
06 07376 - 70628 02789 - 20628
10 07376 - 71034 07221 - 21034
12 07376 - 71234 07221 - 21234
2) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379 - 00400 07378 - 10400 07371 - 30400
05 07379 - 00500 07378 - 10500 07371 - 30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part No.
number D d L
06 07049 - 00608 6 5 8
08 07049 - 00811 8 6.5 11
10 07049 - 01012 10 8.5 12
12 07049 - 01215 12 10 15
14 07049 - 01418 14 11.5 18
16 07049 - 01620 16 13.5 20
18 07049 - 01822 18 15 22
20 07049 - 02025 20 17 25
22 07049 - 02228 22 18.5 28
24 07049 - 02430 24 20 30
27 07049 - 02734 27 22.5 34
SK820-5E0 00-33
2. Precautions for installation work

q Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
q Install the hoses without twisting or interference and fix them with intermediate clamps, if available.
q Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean and degrease the part, and coat the threaded portion with two to
three drops of adhesive.
q When coating with liquid gasket, clean and degrease the surface, and apply it uniformly after making
sure that the surface is free from dirt or damage.
q Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
q Coat the rotating parts and sliding parts with engine oil.
q When press-fitting parts, coat the surface with molybdenum disulphide lubricant (LM-P).
q After installing the snap rings, check that the snap ring is settled in the ring groove completely.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
them securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten them uniformly and alternately to prevent excessive tightening on
one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, hydraulic
pumps and other hydraulic component removed for repair, be sure to bleed the air as follows:
1] Start and run the engine at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder four to five times, stop-
ping the piston at 100 mm off the end of its stroke.
3] Next, operate the hydraulic cylinder three to four times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions for completing work

1) Refilling of coolant, oil and grease
q If the coolant is drained, close the drain valve, and add coolant to the specified level. Run the engine
to circulate the coolant through the system . Then add the coolant again if necessary.
q If the hydraulic component is removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then add the oil again if necessary.
q If the hydraulic piping or hydraulic equipment are removed, be sure to bleed air from the system
after reassembling the parts, by referring to "Testing and adjusting".
q Supply the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Check of installed condition of cylinder head and manifolds

Check the cylinder head and intake and exhaust manifold mountings for looseness.
If any part is loosened, retighten it.
q For the tightening torques, see the "Disassembly and assembly".
3) Checking engine piping for damage and looseness

Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and
exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leak-
age.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage.
00-34 SK820-5E0
4) Checking muffler, exhaust pipe and their mounts for damage and looseness
1] Visually check the muffler, exhaust pipe and their mounts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounts for looseness.
If any part is loosened, retighten it.
5) Checking muffler function
Check the muffler for unusual sound and sound different from that of a new muffler.
If any unusual sound is heard, repair the muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
SK820-5E0 00-35
Standard tightening torque table
Standard tightening torque table 0 -42

(Rev. 2010/03)
1. Table of tightening torques for bolts and nuts
a Unless otherwise specified, tighten metric nuts and bolts to the torque shown in the following table.
1) The following table applies to the bolts in Fig. A.

Thread diam- Width across
Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10(10) 11.8 – 14.7 1.2 – 1.5
8 13(12) 27 – 34 2.8 – 3.5
10 17(14) 59 – 74 6.0 – 7.5
12 19(17) 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1030 84 – 105
27 41 1180 – 1470 120 – 150
30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2) The following table applies to the bolts in Fig. B.

Tightening torque
eter of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
Fig. A Fig. B
a Values with ( ) are applied to (*) marked bolt (flange bolt) as the width across flats.
00-36 SK820-5E0
2. Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten split flanged bolts to the torque shown in the following table.
Tightening torque
eter of bolt flats
mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten O-ring boss piping joints to the torque shown in the following table.
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
02 14 Varies 35 – 63 {3.5 – 6.5} 44 {4.5}
03, 04 20 84 – 132 {8.5 – 13.5} 103 {10.5}
depending on
05, 06 24 128 – 186 {13.0 – 19.0} 157 {16.0}
type of con-
10, 12 33 363 – 480 {37.0 – 49.0} 422 {43.0}
nector.
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
4. Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten O-ring boss plugs to the torque shown in the following table.
Tightening torque (Nm {kgm})
Nominal No. eter flats
mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
SK820-5E0 00-37
5. Table of tightening torque for hoses (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a Apply the following torque when the threads are coated with engine oil (wetted).
Tightening torque (Nm {kgm}) Taper seal Face seal
Nominal Width Nominal No.
Thread diame-
number of across Thread size –Number of
Range Target ter (mm) (Ref-
hose flats (mm) (mm) threads, type of
erence)
thread
34 – 54 {3.5 – 5.5} 44 {4.5} – 9/16-18UN 14.3
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
22 54 – 93 {5.5 – 9.5} 74 {7.5} – 11/16 – 16UN 17.5
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 13/16 – 16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16 – 12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torque for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Tightening torque (Nm {kgm}) Face seal
Outer diam- Width across Nominal No.
Thread diameter
eter of pipe flats –Number of
Range Target (mm)
(mm) (mm) threads, type of
(Reference)
thread
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16 – 18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16 – 16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16 – 16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UNS 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1 – 3/16 – 12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
00-38 SK820-5E0
7. Table of tightening torque for 102, 107 and 114 engine series (bolts and nuts)
a Unless otherwise specified, tighten the metric bolts and nuts used for the 102, 107 and 114 engine se-
ries to the torque shown in the following table.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 – –
8. Table of tightening torque for 102, 107 and 114 engine series (eye joints)
a Unless otherwise specified, tighten the metric eye joints used for the 102, 107 and 114 engine series
to the torque shown in the following table.
Thread size Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
9. Table of tightening torque for 102, 107 and 114 engine series (taper screws)
a Unless otherwise specified, tighten NPT screws used for the 102, 107 and 114 engine series to the
torque shown in the following table.
Tightening torque
Material In cast iron or steel In aluminium
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
SK820-5E0 00-39
List of abbreviation
List of abbreviation 0 -46

(Rev. 2010/03)
q This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline
of the meaning.
q Abbreviations that are used in general society may not be included.
q Special abbreviations that appear infrequently are marked in the text with an *.
q This list of abbreviations consists of two parts. The first part is a list of abbreviations used in the text of the
manual, and the second part is a list of abbreviations used in circuit diagrams.
List of abbreviations used in the shop manual
Purpose of use (major appli-
Abbrevia-
Full Spelling cable machine (*), or compo- Explanation
tion
nent/system)
With this function, when the tires skid (wheels stop
Travel and brake
A.B.S. Anti-skid Brake System rotating), the brakes are released, and when the
(HD, HM)
wheels start to rotate, the brakes are applied again.
Automatic Idling Setting
A.I.S.S. Engine This function automatically sets the idle speed.
System
Instead of a steering wheel, a lever is used to per-
Advanced Joystick Steer- Steering
A.J.S.S. form the steering operations as well as to shift gear
ing System (WA)
and change direction (forward or reverse).
When the machine is travelling downhill, if the
Automatic Retarder Travel and brake accelerator pedal is released, this function auto-
A.R.A.C.
Accelerator Control (HD, HM) matically applies the retarder with a constant brak-
ing force.
When the machine is travelling downhill, if the
accelerator pedal is released, this function auto-
Automatic Retarder Travel and brake
A.R.S.C. matically applies the retarder to ensure that the
Speed Control (HD, HM)
machine speed does not accelerate above the
speed set by the operator.
When the rear wheels spin on soft ground sur-
Travel and brake
A.S.R. Automatic Spin Regulator faces, this function automatically uses the optimum
(HD, HM)
braking force to drive both wheels.
A device that can be fixed onto a machine in order
ATT. Attachment Work equipment
to enable it to do different jobs.
When the retarder is not being used, this valve
Brake Cooling oil control Brake
B.C.V. bypasses part of the brake cooling oil to reduce the
Valve (HD)
load on the hydraulic pump.
Communication and elec- Communications standard standardized as
C.A.N. Controller Area Network
tronic control ISO11898.
System that can simultaneously actuate multiple
Closed-centre Load
C.L.S.S. Hydraulic actuators regardless of the load (provides better
Sensing System
ease of combined operation than O.L.S.S.).
Uses engine controller to perform electronic control
of supply pump, common rail, and injector. Func-
C.R.I. Common Rail Injection Engine
tions to maintain optimum fuel injection amount
and fuel injection timing.
Electronic control device that uses the signals from
Electronic Control Mod-
E.C.M. Electronic control system the sensors on the machine to indicate to the actu-
ule
ators the optimum actuation. (same as ECU)
Proportional electromagnetic valve that gradually
Electric Control Modula- Transmission
E.C.M.V. increases oil pressure to engage clutch and
tion Valve (D, HD, WA, etc.)
reduces transmission shock.
System that ensures smooth high-speed travel by
Electronically Controlled Travel
E.C.S.S. using hydraulic spring effect of accumulator to
Suspension System (WA)
absorb vibration of machine during travel
Electronic control device that uses the signals from
E.C.U. Electronic Control Unit Electronic control system the sensors on the machine to indicate to the actu-
ators the optimum actuation. (same as ECM)
Functions to recirculate part of exhaust gas to com-
Exhaust Gas Recircula-
E.G.R. Engine bustion chamber in order to reduce combustion
tion
temperature, controls emission of Nox.
00-40 SK820-5E0

Abbrevia-
tion
nent/system)
System that allows data (filter, oil replacement
Equipment Management interval, malfunctions on machine, failure code,
E.M.M.S. Machine monitor
Monitoring System and failure history) from each sensor on the
machine to be checked on monitor.
Control system that moves an actuator in propor-
Electromagnetic Propor-
E.P.C. Hydraulic tion to the amperage of an electric current passing
tional Control
through the solenoid.
F-N-R Forward-Neutral-Reverse Operation Position of the gear shift lever or switch.
System that is used to determine the current loca-
Global Positioning Sys- Communication tion on the Earth of a ship, car, machine, etc. by
G.P.S.
tem (KOMTRAX, VHMS) receiving the radio wave signals transmitted from
the navigation satellites.
Steering function that uses a combination of
Hydrostatic Steering Sys- Steering hydraulic motor and bevel shaft to control differ-
H.S.S.
tem (D) ence in travel speed of right and left tracks to turn
machine without using steering clutch.
Hydraulic transmission system that uses a combi-
Hydro Static Transmis- Transmission
H.S.T. nation of hydraulic pump and hydraulic motor to
sion (D, WA)
shift gear steplessly without using gears.
Valve installed at inlet port of pump to adjust fuel
I.M.A. Inlet Metering Actuator Engine intake amount in order to control fuel discharge
amount of supply pump. Same as IMV.
I.M.V. Inlet Metering Valve Engine intake amount in order to control fuel discharge
amount of supply pump. Described as IMV (IMA).
Image display device made up of a large number of
L.C.D. Liquid Crystal Display Machine monitor
pixels filled with liquid crystal.
Semiconductor element that emits light when the
L.E.D. Light Emitting Diode Electronic parts voltage is applied in forward direction, positive volt-
age to anode and negative voltage to cathode.
Function that senses differential pressure of pump
L.S. Load Sensing Hydraulic
and controls discharge amount according to load.
Service that allows transmission and reception of
Multimedia Messaging
M.M.S. Communication short messages consisting of characters or voice
Service
or images between cell phones.
Device actuated to open electric or hydraulic cir-
N.C. Normally Closed Electric and hydraulic
cuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic cir-
N.O. Normally Open Electric and hydraulic
cuits that are normally open if not actuated.
Open-centre Load Sens- Hydraulic system that can operate multiple actua-
O.L.S.S. Hydraulic
ing System tors at the same time, regardless of the load.
P.C. Pressure Control Hydraulic Controlling the oil pressure.
System in which a controller instantly analyses
Palm Command Control Steering data from each lever, pedal, and dial, and performs
P.C.C.S.
System (D) optimum electronic control of the engine and trans-
mission.
P.C.V. Pump Control Valve Engine intake amount in order to control fuel discharge
amount of supply pump.
Proportional Pressure Control system that moves an actuator in propor-
P.P.C. Hydraulic
Control tion to the oil pressure.
Hydraulic
P.P.M. Piston Pump and Motor Piston pump and motor.
(D, PC, etc.)
P.T.O. Power Take Off Power transmission A device to take off power of the engine.
Power Tilt and power Work equipment Function that performs hydraulic control of the tilt
P.T.P.
Pitch dozer (D) and pitch of the bulldozer blade.
SK820-5E0 00-41

Abbrevia-
tion
nent/system)
International System of Units (abbreviated SI from
the French Le Systeme Internationale d’Unites) is
the modern form of the metric system, and is the
Le Systeme International world’s most widely used system of measurement.
S.I. Unit
d’ Unites There are seven base units: meter (m), kilogram
(kg), second (s), ampere (A), kelvin (K), candela
(cd), and mole (mol). The derived units include
Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of
fact in engineering, it refers to an actuator consists
of a solenoid and an iron core that is moved by the
SOL. Solenoid Electric
magnetic force when the solenoid is energized.
The word solenoid also often refers to a solenoid
valve.
T.W.V. Two Way Valve Hydraulic and electric Solenoid valve that switches over direction of flow.
Communications system that transmits machine
data, such as the present position of the machine,
Monitoring and communica- daily or aggregate hours of operation, fuel con-
Vehicle Health Monitoring
V.H.M.S. tion sumption, radiator coolant temperature, oil or filter
System
(D, HD, PC, WA : Large size) replacement interval, to make it possible to collect
and check this data from a distant place (Devel-
oped for use on large machines used in mines).
*: Code for machine family
D: bulldozer
HD: dump truck
HM: articulate dump truck
PC: hydraulic excavator
WA: wheel loader
00-42 SK820-5E0
List of abbreviations used in the circuit diagrams

Abbreviation Full Spelling
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
SW Switch
T/C Torque Converter
T/M Transmission
SK820-5E0 00-43
Conversion table
Conversion table 0 -50

(Rev. 2010/03)
Method of using the conversion table 0 -50
The conversion table in this section is provided to enable simple conversion of figures. For details of the meth-
od of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimetres to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from milli-
metres to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-44 SK820-5E0
Conversion table
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 52.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
SK820-5E0 00-45
Conversion table
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-46 SK820-5E0
Conversion table
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
SK820-5E0 00-47
Conversion table
Temperature 0 -5 4
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the centre (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the centre column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the centre column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-48 SK820-5E0
Shop Manual
SK820-5E0
SKID-STEER LOADER
SK820-5E0
Machine model Serial number

SK820-5E0 F60003 and up
01 Specification 01-
SK820-5E0 01-1
01 Specification Contents
Contents 01-2
01 Specification
Specification................................................................................................................................................ 4
Dimensions (with bucket)......................................................................................................................... 4
Dimensions (with pallet forks) .................................................................................................................. 6
Specification............................................................................................................................................. 8
Table of weight......................................................................................................................................... 9
Fuel, coolant and lubricants ................................................................................................................... 10
01-2 SK820-5E0
01 Specification
01-4
SK820-5E0 01-3
01 Specification Specification
Dimensions (with bucket)
Specification 01-4
RU
RV
Z
V
T
C
D
Gm
E
X
B
S
R
Q
F
N
A H L
M
RKA43960
01-4 SK820-5E0
Specification 01 Specification
A Front bucket reach (*) 1422 mm
B Dumping height (*) 2186 mm
C Dumping reach (*) 869 mm
D Max. operating height (*) 3946 mm

E Max. tool carrier pin height (*) 3000 mm
F Rollback angle - 30°
G Dumping angle - 45°

Gm Tool carrier pin distance / Load centre of gravity with maximum extension (**) 310 mm
H Pitch - 1060 mm
L Backhoe swing centre distance - 1024 mm
M Length with bucket (*) 3505 mm
No. Ground clearance - 210 mm
P Cab roof height - 2002 mm
Q Departure angle - 26°
R Load centre of gravity height with maximum extension (**) 2048 mm
RU Front turning radius (*) 2150 mm
RV Rear turning radius - 1666 mm
S Load centre of gravity distance / front axle with maximum extension (**) 1122 mm
T Bucket width (*) 1800 mm
U Max. frame width - 1278 mm
V Tread (***) 1384 mm
Z Tyres external width (***) 1658 mm

X Max. dimension front door / front axle - 415 mm
(*): with Komatsu bucket with largest permissible
(**): with standard Komatsu bucket.
(***): with standard tyres 10x16.5.
SK820-5E0 01-5
Dimensions (with pallet forks)
RU
RV
T
Z
V
C2
I C1
I
D
Gf X
S
P
R
Q
N
A H L
RKA43990
01-6 SK820-5E0
A Front reach with pallet forks 1650 mm
C1 Loading distance with maximum extension 694 mm
C2 Loading distance at maximum operating height 617 mm
D Max. operating height 2851 mm

Gf Tool carrier pin distance / Load centre of gravity with maximum extension 673 mm
H Pitch 1060 mm
I Distance of load centre of gravity from the elbow of the tooth 400 mm
L Backhoe swing centre distance 1024 mm
M Length with pallet forks 3734 mm
No. Ground clearance 210 mm

P Cab roof height 2002 mm
Q Departure angle 26°
R Operating height with maximum extension 1599 mm

RU Front turning radius (*) 2271 mm
RV Rear turning radius 1666 mm
S Load centre of gravity distance / front axle with maximum extension 1485 mm
T Pallet forks frame width 1410 mm
U Max. frame width 1278 mm
V Tread (**) 1384 mm
Z External width of tyres (**) 1658 mm
X Max. dimension front door / front axle 415 mm
(*): with pallet fork teeth positioned at maximum width.
(**): with standard tyres 10x16.5.
SK820-5E0 01-7
Specification 5
Item Unit SK820-5E0
Operating mass (*) 3030
Rated Operating Capacity (*) Without rear ballast kg 900
Tipping load (*) 1800
Standard bucket capacity m3 0.38
Standard bucket width mm 1730
Max. admissible weight (for road homologation) kg 4200
Max. front axle load (for road homologation) kg 2800
Max. rear axle load (for road homologation) kg 2600
Komatsu S4D84E-6BMFD
Type
(turbo)
Diesel engine
Max power kW 36.2 (2600 rpm)
Max torque Nm 156.9 (1700 rpm)
Alternator V 12
Alternator capacity A 55
Electrical system Output Negative
Battery Ah (V) 80 (12)
Starter kW 2.3
1nd forwards 10.5
2nd forwards 16
Travel speeds km/h
1nd backwards 10.5
2nd backwards 16
Standard flow l/min Max. 62
Equipment auxiliary hydraulic
High Flow flow (optional) l/min Max. 100
system
Pressure calibration bar Max. 206
Excavator hydraulic system (if installed) bar Max. 170
Fuel tank capacity litres 68
Standard tyres (10x16.5-8 PR - mod. SKS-BIG DOG) ECOMEGA 4.2
bar
Tyres for heavy duty work (10x16.5-14 PR - mod. Supergrip L5) 4.2
Segmented tyres (10x16.5 AIR BOSS) Not approved for roads
bar
Flat-free solid tyres Not approved for roads
Machine sound level at 2030 rev/min at a speed of 12.0 km/h
86.0 dB(a)
(Directive 2009/63/CE att. VI)
Machine sound level when stopped at 2700 rev/min
Lsf = 80.0 dB(A)
(Directive 2009/63/CE att. VI)
(*)Machine with standard bucket, full fuel tank, all liquids at their correct level, the operator seated in the
driver's seat (weight 75 kg) and the most common machine fittings.
01-8 SK820-5E0
Table of weight
Table of weight 01- 8

k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine assembly - Muffler - Exhaust pipe 200
Radiator 22
Hydraulic oil tank (without oil) 21.5
Engine hood 17
Cabin (without seat) 215
Seat:
attachment 10
with suspension 24
Engine-pump group 283–290
Piston pump:
attachment 82
High-Flow 88
Wheel, assy. (standard) 44
Control valve:
3-spool (standard) 19
4-spool (High-Flow) 21.5
Arm 475
Work equipment support 75
Bucket (L=1730 mm) 190
Lifting cylinder (n. 1) 16.8
Dump cylinder (n. 1) 12
SK820-5E0 01-9
Fuel, coolant and lubricants
Ambient temperature
(°C) Fluid recommended
Reservoir Fluid
by Komatsu
Min. Max.
– 20 40 Komatsu EO10W30DH
– 15 50 Komatsu EO15W40DH
Engine oil pan Engine oil
– 30 30 Komatsu EOS0W30
– 25 40 Komatsu EOS5W40
Final transmission case
Engine oil – 15 50 Komatsu EO15W40DH
(ea.)
Engine oil – 30 30 Komatsu EOS0W30

Hydraulic system
Hydraulic oil – 20 50 HO46-HM
Hydraulic system with See Operation &

– 20 40 PANOLIN HLP SYNTH 46
biodegradable oil maintenance manual
Super white grease

– 20 50 G2-T, G2-TE
(note (1))
Grease EP lithium
Articulation greasing – 20 50 G2-LI
based
Lithium/Calcium based
– 10 130 NLGI2
EP grease
Supercoolant AF-NAC
Engine cooling system – 30 50 AF-NAC
(note (2))
ASTM D975 GRADE

– 30 – 10
No.1-D S15/EN590:2009
Fuel tank Diesel oil (note (3))
ASTM D975 GRADE
– 10 45
No.2-D S15/EN590:2009
Windscreen washer Ethyl alcohol based

– 30 50
fluid detergent
* ASTM: America Society of Testing and Material
First filling quantity (litres) Oil change quantity (litres)

Engine oil pan 8 8
Hydraulic system 38 27
Final transmission case 15.5 15.5
Fuel tank 68 –
Cooling system 9 –
Windscreen washer fluid 1 –
01-10 SK820-5E0
NOTICE
Always use diesel oil as fuel.
To ensure good characteristics of fuel consumption and exhaust gases, the engine fitted to this
machine uses an injection device at high pressure.
This device needs that components and lubrication have high precision characteristics, therefore, its
working life may be considerably reduced if you use low viscosity fuel with poor lubricating capacity.
Note 1:
The super white grease (G2-T, G2-TE) has a high performance.
If it is necessary to increase the grease lubricating capacity to prevent pins or bushes from squeaking, use
recommended G2-T or G2-TE.
Note 2:
Supercoolant (AF-NAC)
Note 3:
Use only low- or ultra low-sulphur content fuel.
SK820-5E0 01-11
01-12 SK820-5E0
Shop Manual
SK820-5E0
SKID-STEER LOADER
Shop Manual 10-1
SK820-5E0

SK820-5E0 F60003 and up
10 Structure, function and

maintenance standard 10-1
SK820-5E0 10-1
10 Structure, function and maintenance standard Contents
Contents 01-2
PTO.......................................................................................................................................................... 3
Power train............................................................................................................................................... 5
Transmission............................................................................................................................................ 6
Final drive ................................................................................................................................................ 9
Hydraulic pump ...................................................................................................................................... 16
Control valve (3-spool)........................................................................................................................... 37
CLSS...................................................................................................................................................... 53
Solenoid valves...................................................................................................................................... 60
Accumulator ........................................................................................................................................... 62
R.H. PPC valve ...................................................................................................................................... 63
L.H. PPC valve....................................................................................................................................... 68
Cylinders ................................................................................................................................................ 74
Work equipment..................................................................................................................................... 76
10-2 SK820-5E0
PTO 10 Structure, function and maintenance standard
PTO
80 Nm
85 Nm
195 Nm
Loctite 262
4
RKA43130
1. Joint
2. Spring pin
3. Dumper
4. Flywheel cover
5. Pump case
SK820-5E0 10-3
10-4 SK820-5E0
Power train 10 Structure, function and maintenance standard
Power train
8 8
4
1
3 C BA 7 2
5 6
8 8
RKA44740
1. Engine 5. High-flow solenoid valve

2. Hydraulic pump 6. L.H. final drive
3. Control valve 7. R.H. final drive
4. Solenoid valve 8. Axle
4a. Speed increment
4b. Servocontrol
4c. Parking brake
SK820-5E0 10-5
10 Structure, function and maintenance standard Transmission
Transmission
B B A A C C
1
4
2
3
2 3
118 Nm X
Loctite 270 A-A 29 Nm
RKA44750
1. L.H. final drive

2. Front transmission chain
3. Rear transmission chain
4. Master link
10-6 SK820-5E0
Transmission 10 Structure, function and maintenance standard
2 3 4 5
B-B
7 2 3 294 Nm 4
6
200 Nm
186 Nm
C -C RKA43140
1. Front wheel
2. Axle
3. Sprocket
4. Shaft
5. Front transmission chain
6. Rear wheel
7. Rear transmission chain
SK820-5E0 10-7
10-8 SK820-5E0
Final drive 10 Structure, function and maintenance standard
Final drive
d
e c
b
A A
Z
RKA43150
L.H. final drive R.H. final drive

a. A Port - To hydraulic pump (PB2 port) a. A Port - To hydraulic pump (PA1 port)
b. B Port - To hydraulic pump (PA2 port) b. B Port - To hydraulic pump (PB1 port)
c. PP1 Port - From solenoid valve group ST1 (A c. PP1 Port - From solenoid valve group ST1 (A
Port) (2nd speed) Port) (2nd speed)
d. PP2 Port - From solenoid valve group ST1 (C d. PP2 Port - From solenoid valve group ST1 (C
Port) (parking brake) Port) (parking brake)
e. DR Port - To hydraulic tank e. DR Port - To hydraulic tank
SK820-5E0 10-9
10 Structure, function and maintenance standard Final drive
46 51 Nm 28.4 31.4 Nm
61.8 75.5 Nm 167 196 Nm
28.4 31.4 Nm
B
B
4 5 6 7
28.4 31.4 Nm
2 3
8
1 9
10
11
12
13
14
15
16
17
29 22
28
51.0 64.7 Nm
21 20 19 18
28.4 31.4 Nm
26 27 A-A
25
24
26
23
B-B
RKA43160
10-10 SK820-5E0
1. Shaft
2. Bearing
3. Bearing
4. Body
5. Pin
6. Gears
7. Shoe
8. Brake piston
9. Valve plate
10. Cylinder block
11. Bearing
12. Spring
13. Brake piston
14. Brake spring
15. Bushing
16. Retainer plate
17. Swash plate
18. Plate
19. Shaft
20. Flange
21. Collar
22. Gasket
23. Plug
24. Spring
25. Spool
26. Plug
27. Spool
28. Plug
29. Spring
SK820-5E0 10-11
Description
Description
The final drive motor consists of:
1. 2-speed hydraulic motor
2. Selector valve
3. Reduction gear
Hydraulic motor
Function
The hydraulic motor is of the axial piston type, and converts hydraulic energy supplied by the pump into rotary
motion.
Operation
The hydraulic oil arriving from the selector valve is sent on to the valve plate (1).
When the oil is sent to port A of the valve, it flows into the corresponding port on the cylinder block (2) and
presses against the pistons (3).
This pressure is converted into rotary motion by a swash plate (4) and hence transmitted to the shaft (5). The
shaft and the cylinder block have been integrated into one piece by means of splined toothing.
The return oil is sent to the pump through port B.
Rotation in the opposite direction is achieved by sending the oil to port B instead of to port A.
5 4
3
B
A
RKS01050
Varying the displacement

The swash plate (4), which has two surfaces A and When an increase in speed is demanded, the oil is
B on the side opposite the sliding side for the shoes sent under pressure to the command piston (10).
(6), is supported by two bearings (7) attached to the The command piston (10) moves to the left (i) until
body of the motor (8). the surface B makes contact with the housing and
The position of the bearings is eccentric with respect the angle of the swash plate becomes  (the
to the axis of the shaft and when running at low displacement of the motor is reduced).
speed the surface A remains in contact with the
body of the motor through the pressure exerted by
the pistons (3) and by the force of a spring (9)
mounted in the cylinder block (2).
The angle of the swash plate is .
10-12 SK820-5E0
Description
8 10 8 10
B B
6
4 3 4 3
7 7
A A
␣ ␤
3 2 9 3 2 9
RKS01040
Parking brake
The hydraulic motor is equipped with a negative brake.
q When the engine is at a standstill, or when the operator applies the brake, the braking piston (1) is
pushed to the left (i) by the force of the springs (2).
The friction disk (3), which has been integrated with the cylinder block by means of semicircular grooves,
is compressed between steel disks (4) and (5), which are integrated with the housing, and is thus
blocked. The drive shaft (6) can therefore no longer turn.
q When the engine is running and the operator disengages the brake, oil is sent under pressure to the
chamber A.
The force exerted by the oil is greater than the force of the springs (2) and the piston (1) is therefore
pushed to the right (o) thus releasing the friction disk (3) and permitting rotation of the cylinder block (7)
(and also of the drive shaft).
A A
1 1
5 3 2 3 2
5
4 4
7 7
6 6 RKS01060
SK820-5E0 10-13
Description
Selector valve
When the oil is sent under pressure to the A port, the oil that activated the motor returns to the pump through
the B port.
The pressurised oil sent to the A port is also introduced into the chamber C. It now pushes the selector valve
(1) to the right (o). This opens communication between the B port and the oil gallery D which is connected
to the overpressure limitation valve (2).
If the pressure present at port B exceeds the calibration value of the overpressure limitation valve (2), this
valve will open and discharge the excess oil into the reduction gears.
The valve also functions in the same way when the pressurised oil is sent to the B port. The only difference
is that the selector valve moves to the left (i), and the oil gallery D communicates with the A port.
2 D 2 D
C C
1 1
A B A B
RKS01070
10-14 SK820-5E0
Description
Reduction gear
Function
This final drive motor is equipped with a one-stage epicycloidal reduction gear that converts the high rotation
speed and low torque of the hydraulic motor into low speed and high torque at the swing pinion.
Operating principle
The rotary movement of the output shaft of the motor is transmitted to the gear (s1) and hence to the bevel
gears (b1) which are integrated with the planetary gear (1).
Since the gear (a1) is fixed with respect to the output shaft of the hydraulic motor, the planetary gear is obliged
to turn, moving with it the output shaft (2) of the reduction gearing (connected to the planetary gear by means
of grooved toothing).
The reduction ratio of the rotation speed is described by the formula:
R= Zs1/(Zs1+Za1)
Zs1= number of sun gear teeth
Za1= number of ring gear teeth
b1
a1
s1 RKS01080
SK820-5E0 10-15
10 Structure, function and maintenance standard Hydraulic pump
Hydraulic pump
147-186.2 Nm
19.6-27.4 Nm
A
58.8-73.5 Nm
Komatsu.Ltd.
A
49-58.8 Nm
19.6-27.4 Nm
19.6-27.4 Nm 147-186.2 Nm
58.8-73.5 Nm RKA44600
10-16 SK820-5E0
Hydraulic pump 10 Structure, function and maintenance standard
AS Valve
AS Valve
1 2 3
34.3-58.8 Nm 34.3-58.8 Nm
44.1-53.9 Nm 58.8-78.4 Nm
A-A
RKA44610
Unit: mm
Criteria
Standard size Repair limit
No. Check item Remedy
Installed Installed
Free length Installed load Free length
length load
1 Spring 38.1 30 51.7 N – 41.4 N
2 Spring 25.9 23 16.8 N – 13.4 N Replace
3 Spring 42.9 34.5 65.2 N – 52.2 N
SK820-5E0 10-17
HST pump LPV45 + 45 (Standard flow)
HST pump LPV45 + 45 (Standard flow)
10 1 8 7 2 8 7 5
6
4 Komatsu.Ltd.
11 3 11
13
8 9 9 8 RKA44620
1. Piston pump Structure

2. Control piston This pump is composed of variable swash plate type
3. Suction safety valve tandem piston pumps (1), control pistons (2),
suction safety valves (3), charge safety valves (4),
4. Charge safety valve
charge pump (5), work equipment gear pump (6),
5. Charge pump
and adjustment screws (7), (8), (9), AS valve (10),
6. Work equipment pump shuttle valves (11), synchronization valve (12) and
7. Adjustment screw (Neutral position) orifice block (13).
8. Adjustment screw (Max. displacement)
9. Adjustment screw (Pump power control)
10. AS Valve
11. Selector valve
12. Synchronization valve
13. Orifice block
10-18 SK820-5E0
HST pump LPV45 + 45 (High flow)
HST pump LPV45 + 45 (High flow)
10 1 8 7 2 8 7 5
6
11 3 11
13
8 9 9 8 RKA44630
1. Piston pump Structure

2. Control piston This pump is composed of variable swash plate type
3. Suction safety valve tandem piston pumps (1), control pistons (2),
4. Charge safety valve suction safety valves (3), charge safety valves (4),
5. Charge pump charge pump (5), work equipment gear pump (6),
6. Work equipment pump and adjustment screws (7), (8), (9), AS valve (10),
7. Adjustment screw (Neutral position) shuttle valves (11), synchronization valve (12) and
8. Adjustment screw (Max. displacement) orifice block (13).
9. Adjustment screw (Pump power control)
10. AS Valve
11. Selector valve
12. Synchronization valve
13. Orifice block
SK820-5E0 10-19
HST Pump LPV45 + 45
HST Pump LPV45 + 45

Function
q The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and
pressurized oil is discharged according to the load.
q It is possible to change the discharge amount by changing the swash plate angle (plus, zero and minus)
4 2 5 6 14
3 15(Standard )
11
15 (High flow)
A 7 12 8 9 10 13
RKA44640
1. Shaft
2. Pump case
3. Cradle bearing
4. Rocker cam
5. Control piston
6. Slider
7. Shoe
8. Piston
9. Cylinder block
10. Valve plate
11. Main bearing
12. Spline
13. Sub bearing
14. Charge pump
15. Work equipment pump
10-20 SK820-5E0
HST Pump LPV45 + 45
Structure
q Cylinder block (9) is supported to shaft (1) by a spline (12), and shaft (1) is supported by the front and
rear bearings (11), (13).
q The tip of piston (8) is a concave ball, and shoe (7) is caulked to it to form one unit. Piston (8) and shoe
(7) form a spherical bearing.
q Rocker cam (4) has flat surface A, and shoe (7) is always pressed against this surface while sliding in a
circular movement. There is a cradle bearing (3) between cradle and rocker cam (4) which is secured to
the case.Rocker cam (4) sways on cradle bearing.
q Piston (8) carries out relative movement in the axial direction inside each cylinder chamber of cylinder
block (9).
q The cylinder block seals the pressurised oil to valve plate (10) and carries out relative rotation.
q This surface is designed so that the oil pressure balance is maintained at a suitable level.
q The oil inside each cylinder chamber of cylinder block (9) is sucked in and discharged through valve
plate (10).
SK820-5E0 10-21
HST Pump LPV45 + 45
Operation
1. Operation of pump
Cylinder block (9) rotates together with shaft (1), and shoe (7) slides on flat surface A.
When this happens, rocker cam (4) moves along cylindrical surface B, so angle a between the centre line of
shaft (1) and centre line X of rocker cam (4) changes, thereby varying the axial direction of pistons in relation
to the cylinder block. Angle “k” is called "swash plate angle".
q Central line X of rocker cam (4) maintains q Central line X of rocker cam (4) maintains
swash plate angle “k” in relation to the axial swash plate angle “k”in relation to the axial
direction of cylinder block (9), and flat surface direction of cylinder block (9), and flat surface
“A” moves as a cam in relation to shoe (7). “A” moves as a cam in relation to shoe (7).
In this way, piston (8) slides on the inside of In this way, piston (8) slides on the inside of
cylinder block (9), so a difference between cylinder block (9), so a difference between
volumes E and F is created inside cylinder volumes E’’ and F’’ is created inside cylinder
block (9). The suction and delivery is carried block (9).
out by this difference F – E . The suction and delivery is carried out by this
In other words, when cylinder block (7) rotates difference E’’–F’’.
and the volume of chamber F becomes In other words, when cylinder block (9) rotates
smaller, the oil is discharged during that stroke. a nd th e v ol um e of c ha mb er E b ec om es
On the other hand, the volume of chamber E smaller, the oil is discharged during that stroke.
becomes larger, and as the volume becomes On the other hand, the volume of chamber F
bigger, the oil is sucked in (Fig. 1). becomes larger, and as the volume becomes
bigger, the oil is sucked in.
If the direction of swash plate angle is changed,
4 7 8 9 E PA PB
the relation between discharge and suction of
ports PA and PBreverses (Fig. 3).
X
k PA
PA PB
7 8 9 E"
4
PB
PA
1 RKS00271
B A F
k PB
X
Fig. 1
q If centre lineX of rocker cam (4) is in line with F" RKS00101
the axial direction of cylinder block (9) (swash

plate angle “k”= 0), the difference between
volumes E' and F' inside cylinder block (9) Fig. 3
becomes 0, so the pump does not carry out any
suction or delivery of oil (Fig. 2).
9 E'
4 PA PB
RKS00220
F'
Fig. 2
10-22 SK820-5E0
HST Pump LPV45 + 45
2. Control of discharge amount

q If swash plate angle “k” becomes larger, the difference between volumes E and F becomes larger and
discharge amount Q increases. Swash plate angle is changed by control piston (5).
q Control piston (5) moves in a reciprocal movement according to the signal pressure from pilot line (PPC
and AS valves). This straight line movement is transmitted through slider (6) to rocker cam (4), which is
supported by the cylindrical surface to cradle, slides in a rotating movement in direction.
q On this pump, maximum swash plate angle is ±15.8.
5
6
4
4
RKS00280
RKS00360
q Screw A restricts to the maximum stroke of control piston (i.e. maximum displacement of each pump).
When screw A is tightened, maximum displacement decreases, and when screw A is loosened,
maximum displacement increase. This screw should be adjusted when the machine doesn’t travel
straight or machine maximum speed is little bit wrong.
q Screw B is the fine adjuster of neutral position of control piston (5). That adjust prevent machine from
creep.
A 5
A
6
RKS03950
SK820-5E0 10-23
HST Pump LPV45 + 45
Function of the control piston (on non-induction of pilot signal)

q There are no pressure, so control piston (5) doesn’t move and main pump is on neutral condition.
PPA=0 5 PPB=0
RKS03960
Function of the control piston (on induction of pilot signal)
5
PPA > PPB
RKS03970
q When pressurised oil which has the pressure PPA>PPB is led from pilot line (PPC or AS valve), control
piston (5) moves to the right (o).
q Control piston (5) moves the balanced position by spring force and pressure PPA.
q If the relation of pressure dimension of PPA, PPB is reversed, control piston moves to the left (i).
q The lowest between AS valve output pressure and PPC output pressure is selected by shuttle valve and
sent to control piston (5). (For details, see (For details, see "Selector valve").
10-24 SK820-5E0
Suction safety valve
3 3A 3B 3C 3D 3E 3F
1
RKA44650
1. Charge pump
3. Suction safety valve
3A. Valve
3B. Rod
3C. Spool
3D. Spring
3E. Spring
3F. Plug
4. Piston pump
5. Travel motor
SK820-5E0 10-25
Function
There are two suction safety valves installed to each HST pump, and they have the following functions:
1) High pressure safety valve The valve restricts the maximum pressure inside the HST circuit in order to
protect the HST circuit.
2) Suction safety valve: The valve ensures the flow of the charge oil to the closed HST circuit and prevents
the charge oil from flowing into the pump high pressure side (delivery side).
Actuation when acting as high pressure relief valve (Valve at piston pump delivery side)
q Port A is connected to the piston pump circuit and port B is connected to the charge circuit. The
pressurized oil fills port C through drill hole of piston (3A). The pressurized oil at high pressure port A fills
port D through groove b between body and valve.
Poppet (3A) is in tight contact with valve seat (3C).
B 3A 3B 3C 3D 3E
a A b C D RKS00050
q If abnormal pressure is generated in the circuit and the oil pressure at ports A and D reaches the
pressure set by spring (3D), poppet (3A) is pushed to (o) direction, and oil at port A is relieved to port B
to reduce the oil pressure at port A.
B 3A
a A b 3D D
RKS00060
10-26 SK820-5E0
Operation when acting as suction safety valve

q When HST pump delivery is 0.
The HST circuit is closed, and the charge oil does not flow into the HST circuit.
Therefore the charge pressurised oil from the charge pump (1) all passes the charge safety valve (2)
and is drained to the pump case.
A - Travel motor
B - Travel pump
PB PA
3
1
RKA44660
SK820-5E0 10-27
q When HST pump discharges from port PA

1) Valve at piston pump delivery side
When the pressure oil is discharged from port PA of the HST pump (4), port PA becomes the high
pressure side.
This pressure oil at port PA flows into port D through the groove b.
When this happen, sleeve (3C) is pushed to left direction (i), because of the difference in area
(A1>A2). Therefore the pressure oil from charge pump is prevented from flowing into HST pump.
3C b D
PA
A2 A1 PB PA
RKS00070
PB PA
RKS00130
2) Valve at piston pump suction side.

Port PB is at low pressure because port PB is suction side. Sleeve (3C) is pushed to right direction
(o) to open body seat portion because of the difference in area (A1>A2).
In this way, the charge pressure oil at port B flows into port PB through this clearance to charge to the
HST circuit.
3C PB
A1 A2 B
RKS00080
10-28 SK820-5E0
Charge safety valve
Charge safety valve
RKS00140
3
1
2A 2B 2G 2C 2D 2E 2F
RKS00040
1. Charge pump
2A. Valve
2B. Spring
2C. Valve
2D. Poppet
2E. Spring
2F. Adjustment screw
2G. Filter
3. Suction safety valve
SK820-5E0 10-29
Charge safety valve
Function
There is the charge safety valve installed to the HST pump.The charge safety valve restricts the maximum
pressure inside the charge circuit in order to protect the charge circuit.
Function
q Port A is connected to the charge circuit.
Port B is connected to the tank drain circuit.
The pressurised oil fills port C through orifice a in valve (2A).
Poppet (2D) is in tight contact with valve seat (2C).
2A C 2C 2D 2E
1
a B RKS00010
q If abnormal pressure is generated in the circuit or the shuttle valve of HST motor is at neutral and the oil
pressure at ports A and C reaches the pressure set by spring (2E), poppet (2D) is pushed to right
direction (o), and oil at C is relieved to port B and pressure of the oil at C reduces.
2A C 2D 2E
RKS00020
B
q When pressure at port C reduces due to the shifting of poppet (2D), pressure at port A exceeds pressure
at port B due to the hole a in valve (2A).
This pressure gap shifts valve (2A) to right direction (o) and lets the pressurised oil at port A move to
port B, thus allowing charge circuit pressure to be adjusted.
2A C
RKS00030
a B
10-30 SK820-5E0
Charge pump
Charge pump
RKS00150
1. Slide plate Specifications

2. Coupling q Type: trochoid pump
3. Shaft q Theoretical delivery: 25 cm³/rev
4. Outer ring
5. Pump case
6. Inner roter
7. Outer roter
SK820-5E0 10-31
Charge pump
Function
q HST charge pump is built-in the HST pump and driven with HST pump at the same time.
q The pressurised oil generated by the charge pump is sent to safety valve in the charge circuit and to AS
valve.
q Charge pump sucks oil from hydraulic tank.
Operation
a 7 6 B
A
2
d A
A A-A
b RKA44670
a - Delivery
b - Suction
c - Delivery side
d - Suction side
q Charge pump is connected to HST pump shaft by coupling (2), so inner roter (6) and outer roter (7)
rotate.
q During bucket (6) and impeller (7) rotation, oil is sucked in as quantity A increases and is discharged as
quantity B decreases.
q During rotation of inner roter (6) and outer roter (7), port A increases in volume as it performs oil suction,
whereas port B decreases in volume as it performs delivery.
10-32 SK820-5E0
Antiengine-stall control valve (AS valve)
2 5
1A 1B 1C 1F 1D 1E
1G 1L 1H
RKS00170
1. AS Valve
1A. Nut
1B. Screw
1C. Spring
1D. Spring
1E. Spring
1F. Valve
1G. Valve
1H. Nut
1L. Screw
2. Charge pump
3. Orifice
5. Engine
SK820-5E0 10-33
Function
q The AS valve is attached on the main piston pump. It reduces pressure for pump swash plate control
from charge circuit.
q The AS valve outputs pressure correspond with engine revolution.
Operation
2 5
B A
1C 1D 1G
E
D
G
C RKS00180
q The oil from the charge pump (2) that rotates with the engine flows through a orifice (3) that is installed in
the main piston pump. And the oil always flows to pump charge circuit.
q Charge pump (2) is fixed capacity pump, so that discharge flow is proportionate to engine rotation
speed. With the oil from the charge pump (2) passed through the orifice, differential pressure is
generated at port A and port B. This differential pressure actuates the differential pressure sensing valve
(1G) and makes hydraulic force F.
q By the hydraulic force F, the differential pressure sensing valve (1G) is moved direction.
That makes a change of spring (1D) load.
In port C, the AS valve output pressure that is balanced with spring (1C) and (1D) load is generated by
reducing from charge pressure of port G.
So the AS valve output pressure corresponds with charge flow (2) that is changed by engine (5)
revolution.
10-34 SK820-5E0
Selector valve
Selector valve
1 3 2 RKS00200
1. Spool
2. Plug
3. Cover
Function
q The shuttle valves are installed in covers of pump swash plate control pistons. They select lower
pressure either travel PPC pressure or AS valve pressure, and output to pump swash plate control
pressure.
D B A C
F2 F1
E RKS00210
Operation
q Port C is connected to port A (Travel PPC pressure inlet port). And hydraulic force F1 by travel PPC
pressure actuates the valve (1).
q And port D is connected to port B (AS pressure inlet port). Hydraulic force F2 by AS valve pressure
actuates the valve (1).
q By the hydraulic force F1 and F2, the shuttle valve selects lower pressure either PPC pressure or AS
valve pressure. It outputs lower pressure of them from port E to control pump swash plate.
SK820-5E0 10-35
Orifice block
Orifice block
3 2 2 3
PB1 PB2
1A
Left travel Right travel
RKA44680
1. Orifice block
1A. Orifice
2. Travel pump
3. Travel motor
Function
q Orifice block (1) is mounted to main pump.
q Its purpose is to compensate for the difference in flow rate between right (a) and left (b) travel circuits in
backward travel.
This way, the amount of oil circulating through the right and left circuits is almost equal and no deviation
occurs during travel.
q The difference in flow rate is compensated in backward travel and the vehicle travels straight.
q On steering, the difference in flow rate rather than flow rate compensation is controlled and then steering can
be performed.
Operation
q When pressure PB1 is greater than pressure PB2, oil flows from left travel circuit to right travel circuit
through orifice (1A).
10-36 SK820-5E0
Control valve (3-spool) 10 Structure, function and maintenance standard
Standard
Control valve (3-spool)

Standard
P1. From gear pump A3. To attachment port

T. To hydraulic tank B1. To lift arm cylinder (bottom side)
TS. To hydraulic tank B2. To bucket cylinder (bottom side)
A1. To lift cylinder (head side) B3. To attachment port
A2. To bucket cylinder (head side)
SK820-5E0 10-37
10 Structure, function and maintenance standard Control valve (3-spool)
Standard
1. Main relief valve

2. Suction valve (bucket bottom side)
3. Plug
4. Plug
5. Series - parallel circuit switching valve
6. Spool (lift)
7. Spool (bucket)
8. Spool (attachment)
Unit: mm
Criteria
Standard size Permitted value
Free height Installed Installed Installed
Free length
(outside Ø) length load load
9 Spool return spring (attachment) 29x17.5 25 180.4 N – 144.4 N
10 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.2 N
Change
11 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N spring if it is
damage or
12 Spool return spring (lift arm) 28.8x17.1 28.5 6.87 N – 5.50 N deformation
Spring of series - parallel circuit
13 38.3x15.2 24 161.8 N – 129.5 N
switching valve
10-38 SK820-5E0
Standard
1. Exhaust valve
2. Pressure compensation valve F (lift)
3. Pressure compensation valve F (bucket)
4. Pressure compensation valve F (attachment)
5. Pressure compensation valve R (attachment)
6. Pressure compensation valve R (bucket)
7. Pressure compensation valve R (lift)
Unit: mm
Criteria
Free length
Spring of pressure compensation
8 15.4x6 8 7.45 N – 6.0 N
valve R
Change
Spring of pressure compensation spring if it is
9 20x8.4 15 4.28 N – 3.4 N
valve F damage or
10 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N deformation
11 Spring of unload valve 23.9x18.2 18 74.0 N – 59.2 N
SK820-5E0 10-39
Standard
1 19 3 21
6.9 9.8 Nm
22
20 4
2
47 58.8 Nm
AC- AC AE- AE
5 6
7 8 9
E- E
10 11
15 16 15
12 13 14 17 18
F- F G- G RKA42790
10-40 SK820-5E0
Standard
1. Flow divider
2. Check valve (circulating circuit)
3. Combination circulating valve
4. Leveling circulating valve
5. Spool (lift)
6. Plug
7. Selector valve
10. Suction valve
11. Spool (bucket)
12. Shuttle valve
15. Plug
Unit: mm
Criteria
Free length
19 Spring of flow divider 30.2x9.4 23 2.9 N – 2.4 N
20 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N Change
spring if it is
Spring of combination circulating damage or
21 37.5x16.6 22.5 177.5 N – 142.0 N
valve deformation
22 Spring of levelling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N
SK820-5E0 10-41
10-42 SK820-5E0
Float
Float
9.8 12.7 Nm
9.8 12.7 Nm
9.8 12.7 Nm
B 29.4 34.3 Nm
C PB3 A
A3
B3
B2 A2 PB2
PA3
G G
F F
PA2
E Z
E
PA1 B1 A1
D D PB1
T P1
TS
B A
C 29.4 34.3 Nm
29.4 34.3 Nm
19.6 27.5 Nm
9.8 12.7 Nm
RKA42810
Z
P1. From gear pump B1. To lift arm cylinder (bottom side)
T. To hydraulic tank B2. To bucket cylinder (bottom side)
TS. To hydraulic tank B3. To attachment port
A1. To lift cylinder (head side)
A3. To attachment port
SK820-5E0 10-43
Float

3. Plug
4. Float valve
6. Spool (lift)
7. Spool (bucket)
Unit: mm
Criteria
Free length
10 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.2 N
11 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N Change
spring if it is
12 Spool return spring (lift arm) 28.8x17.1 28.5 6.87 N – 5.5 N damage or
Spring of series - parallel circuit deformation
13 38.3x15.2 24 161.8 N – 129.5 N
switching valve
14 Spool return spring (float) 14.7x4.4 9.5 4.9 N – 3.9 N
10-44 SK820-5E0
Float
1. Exhaust valve
Unit: mm
Criteria
Free length
8 15.4x6 8 7.45 N – 6.0 N
valve R
Change
Spring of pressure compensation spring if it is
9 20x8.4 15 4.28 N – 3.4 N
valve F damage or
10 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N deformation
11 Spring of unload valve 23.9x18.2 18 74.0 N – 59.2 N
SK820-5E0 10-45
Float
1 23 21
3
6.9 9.8 Nm
22
4
20 AE- AE
47 58.8 Nm
AC- AC
5 6
19
7 8 9
E- E
10 11
15 16 15
12 13 14 17 18
F- F G- G
RKA42840
10-46 SK820-5E0
Float
1. Flow divider
5. Spool (lift)
6. Float valve
7. Selector valve
10. Suction valve
11. Spool (bucket)
12. Shuttle valve
15. Plug
19. Solenid valve
Unit: mm
Criteria
Free length
20 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N
Spring of combination circulating Change
21 37.5x16.6 22.5 177.5 N – 142.0 N spring if it is
valve
damage or
22 Spring of levelling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N deformation
SK820-5E0 10-47
High-Flow
High-Flow
P1. From hydraulic pump (P4 port) B2. To bucket cylinder (bottom side)
P2. From hydraulic pump (E2 port) B3. To attachment port
T. To hydraulic tank
TS. To hydraulic tank
A1. To arm cylinder (head side)
A3. To attachment port
B1. to lift arm cylinder (bottom side)
10-48 SK820-5E0
High-Flow

3. Plug
4. Float valve
5. Spool (High-Flow)
7. Spool (lift)
8. Spool (bucket)
Unit: mm
Criteria
Free length
10 Spool return spring (bucket) 26.3x17.7 18.5 176.5 N – 141.2 N Change
11 Spool return spring (bucket) 21.6x14.8 10 38.7 N – 31.0 N spring if it is
damage or
12 Spool return spring (lift arm) 28.8x17.1 28.5 6.87 N – 5.5 N
deformation
Spring of series - parallel circuit
13 38.3x15.2 24 161.8 N – 129.5 N
switching valve
SK820-5E0 10-49
High-Flow
1. Exhaust valve
8. Check valve (High-flow)
Unit: mm
Criteria
Free length
9 20x8.4 15 4.28 N – 3.4 N
valve F
Change
10 Spring of unload valve 18.7x9.3 16 3.4 N – 2.7 N spring if it is
11 Spring of unload valve 23.9x18.2 18 74.0 N – 59.2 N damage or
deformation
12 15.4x6 8 7.45 N – 6.0 N
valve R
10-50 SK820-5E0
High-Flow
1 11 3 13
6.9 9.8 Nm
14
12 4
47 58.8 Nm
AC- AC AE- AE
5 6 10
7 8 9
E- E RKA43100
1. Flow divider
5. Spool (lift)
6. Float valve
7. Selector valve
10. Solenid valve
Unit: mm
Criteria
Free length
12 Spring of check valve 18.5x3.8 15.5 1.1 N – 0.9 N Change
spring if it is
Spring of combination circulating damage or
13 37.5x16.6 22.5 177.5 N – 142.0 N
valve deformation
14 Spring of levelling circulating valve 37.5x15.4 22.5 66.7 N – 53.4 N
SK820-5E0 10-51
High-Flow
1 2
6 7 6
3 4 5 8 9
F- F G- G
19.6 24.5 Nm
78.4 102.9 Nm
11
19.6 27.5 Nm
65.7 90.2 Nm 10
29.4 39.2 Nm
H- H RKA43120
1. Suction valve
2. Spool (bucket)
3. Shuttle valve
6. Plug
Unit: mm
Criteria
Free length
10 Spring of check valve 13x6.5 7 3.14 N – 2.5 N Change
spring if it is
Spool return spring (High-flow damage or
11 25.7x11.1 22 67.0 N – 53.4 N
joining circuit) deformation
10-52 SK820-5E0
CLSS 10 Structure, function and maintenance standard
CLSS
1. Description 1.
Specifications
CLSS stands for Closed center Load Sensing System, and has the followings characteristics:
a. controlability, not influenced by load;
b. controllable digging force at fine control range;
c. easy simultaneous operation by spool opening proportional flow dividing function.
2. Pressure compensation control 2.
A valve (pressure compensation valve) is installed to the inlet port side of the control valve to balance the load.
When there is compound operation of the actuators, this valve acts to make pressure difference DP constant
for the upstream flow (inlet port) and downstream flow (outlet port) of the notch of each spool.
In this way, the flow of oil from the pump is divided in proportion to area of opening S1 and S2 of each valve.
Load Load
W W
Actuator Actuator
ÐP ÐP
S1 S2
Pressure Pressure
compensation compensation
valve valve
RKS00691
Pump
SK820-5E0 10-53
10 Structure, function and maintenance standard CLSS
3. Operation for each function and valve 3.

Specifications
q The small capacity gear pump keeps high speed movement because lift arm and the bucket circuit are
connected in a series circuit.
q The control valve has built in self leveling function.
q If loading pressure of bucket becomes beyond a certain value, the lift arm and the bucket circuits
automatically change to parallel circuit to keep strong digging force.
q The lift arm, attachment and High-flow section are connected in a parallel circuit and it has pressure
compensationing function each section.
q During individual operations, attachment High-flow keep individual demand flow rate.
However during compound operations, they are divided in the proportion of 1 to 9 and keep High-flow
section flow rate.
Hydraulic circuit diagram and names of valves
P2
Ls
12
A3
Optional equipment
B3
Pa3 Pa3
Port
5
A2
B2 Bucket cylinder
Pa2 11 Pa2
Dump bucket Curl bucket
4
10 A1
Pa1
Lift arm B1
Lift cylinder
8 7 3
11
9
Pa1
1
Lower arm
2
RKA44761
1. Exhaust valve 11. Check valve (circulating circuit)

2. Main relief valve 12. Spool (High - Flow joining)
3. Pressure compensation valve (arm)
4. Pressure compensation valve (bucket)
5. Pressure compensation valve (attachment)
6. Float valve
9. Flow divider
10. Selector valve
10-54 SK820-5E0
3.1 Series circuit 13.

Function
q Return flow rate from the lift arm is recirculated to the bucket.
F
2 a 3
d
4
b
c
P1
Q1 P2
A B C
Q2
1
5
6
E RKA43200
Operation
When the lift arm raise and the bucket dump are operated at the same time:
q The lift arm spool (1) strokes fully and the bucket spool (2) stokes by half.
q When this happens, notch a doesn’t open, so all flow rate from pump supplies to the lift arm raise.
q The lift arm and the bucket PPC pressure are sent by passage E and F. Then the leveling circulating
valve (3) and the combination circulating valve (4) stroke fully.
q Return flow rate from the lift arm cylinder passes through passage A. Then it is divided to passage B and
C, by the leveling circulating valve (4) and the combination circulating valve (3).
q When this happens, the flow divider (5) is operated as P1 = P2, so flow rate (Q1, Q2) is divided to
passage B and C in proportion to the area of opening of notch (b) and (c) as below expression.
Q1: Q2 = (notch b + notch d): notch c
Q1 = flow rate flows to B
Q2 = flow rate flows to C
q Q1 passes through the check valve (6) and then supplies to the bucket cylinder.
SK820-5E0 10-55
3.2 Self leveling function 14.

Function
When the only lever of the lift arm raise is operated, the lift arm raise and the bucket dump are worked.
When this happens, the work equipment can raise with constant bucket bottom angle. (Only the lift arm raise).
F
2 a 3
d
4
b
c
P1
Q1 P2
A B C
Q2
1
5
6
E RKA43200
Operation
When the lift arm raise is operated individually.
q The lift arm spool (1) strokes fully and the bucket spool strokes by half.
q When this happens, notch (a) doesn’t open, so all flow rate from pump supplies to the lift arm raise.
q The lift arm raise PPC pressure is sent by passage E. Then the leveling circulating valve (4) strokes
fully.
C, by the valve (3).
Q1: Q2 = (notch b + notch d): notchc
q Q1 passes through the check valve (6) and then supplies to the bucket cylinder.
10-56 SK820-5E0
3.3 The function to switch series circuit to parallel circuit 15.

Function
q (1) Low bucket load: series circuit.
q (2) High bucket load: parallel circuit.
q Depend on bucket load, a circuit can change automatically as above.
Then the machine gets high speed and strong digging power.
F
2 a 3
d
H 4
b
A c
P1
Q1 P2
B C
Q2
1
P3
5
6
E e
f G
7 RKA43210
SK820-5E0 10-57
Operation
When the lift arm raise and the bucket digging are operated at the same time:
q The lift arm spool (1) and the bucket spool (2) stroke fully.
q When this happens, the bucket digging PPC pressure is sent by passage H.
Then the combination circulating valve (3) strokes fully to the right and also the lift arm raise PPC
pressure is sent by passage E. Then the leveling circulating valve (4) strokes fully to the left.
C, by the leveling circulating valve (4) and the combination circulating valve (3).
Q1: Q2 = (notch b + notch d): notchc
q If the bucket load becomes beyond a certain valve by influences of digging, the series-parallel switching
valve (7) strokes to the right.
Then it passes thorough passage G by opening notch (e).
And then the spring chamber of flow divider (5) is connected to tank.
q As a result, flow divider (5) strokes fully to the right, and P2 = T.
Return flow rate from the lift arm is connected with tank totally, and Q1 = 0 l/min
q When this happens, notch (f) of the lift arm spool and notch (a) of the bucket spool open, so the lift arm
and the bucket become parallel circuit (CLSS).
And flow rate of the lift arm raise and the bucket digging flow rate are divided as below expression.
Q3: Q4 = notch f: notch a
10-58 SK820-5E0
3.4 Pressure compensation valve 16.

Function
During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries
to increase, compensation is received.
(When this happens, the other actuator being used for compund operation (right side) is at a higher load than
the actuator on this side (left side)).
W W
A A
a a
PLS1 PPA PA
PPA
1
PA
2
PLS
PP
RKS00740
Operation
q If the load pressure of the other actuator (right side) becomes higher during compound operations, the
oil flow in actuator circuit A on this side (left side) tries to increase.
q If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing
valve (1) and flow control valve (2) are pushed to the left in the direction (i) of the arrow.
q Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA.
This pressure loss is generated between PP and PPA.
q Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure
between PA and PLS acting on both ends of reducing valve (2) and the pressure loss between PP and
PPA on both sides of flow control valve (2) are the same.
q In this way, the pressure difference between upstream pressure PPA and downstream pressure PA of
both spools used during compound operations is the same, so the pump flow is divided in proportion to
the area of opening of notch a of each spool.
SK820-5E0 10-59
10 Structure, function and maintenance standard Solenoid valves
Solenoid valve group ST1
Solenoid valves
Solenoid valve group ST1
(Servocontrol - parking brake - 2nd speed)
1 2 3
Z
T
A B C
Z RKA43180
Function
1. 2nd speed A Port - To travel motors (PP1 port)
2. Servocontrol B Port - To PPC valve
3. Parking brake C Port - To travel motors (PP2 port)
P Port - To hydraulic pump (E1 port)
T port - To hydraulic tank
S Port - To accumulator
10-60 SK820-5E0
Solenoid valves 10 Structure, function and maintenance standard
Solenoid valve ST2
Solenoid valve ST2

High-flow control
P2 P2
RKS01140

P1 Port - From control valve (PA3 port)
P2 Port - To control valve (PB3 port)
S Port - From control valve (Pi2 port)
SK820-5E0 10-61
10 Structure, function and maintenance standard Accumulator
Accumulator
B
RKS01650
Technical data Function

q Servocontrol feed unit q An elastic rubber bag (1) containing nitrogen is
q Nominal volume: 0.35 l fitted inside the accumulator to maintain oil
q Pre-loading: 8 bar pressure in the circuit to which the accumulator
q Working pressure: 25-27 bar is connected.
Operation
q When the engine is running the chamber A of
the rubber bag (1) (containing nitrogen) is
compressed by oil under pressure coming from
line B.
q If the oil under in line B falls below the
maximum calibration pressure (even after
intensive use), the rubber bag (1) will expand
due to pressure from the nitrogen it.
10-62 SK820-5E0
R.H. PPC valve 10 Structure, function and maintenance standard
Equipment control
R.H. PPC valve

Equipment control
P2 P4
P3 P1
E E
D D
B T P
A C
C A
RKS00800
P1 port - To control valve (PA1 port)

P2 Port - To control valve (PB1 port)
P3 port - To control valve (PA2 port)
P4 port - To control valve (PB2 port)
P port - From solenoid valve group ST1 (B port)
Functions
P1 Lower arm
P2 Raise arm
P3 Curl bucket
P4 Dump bucket
SK820-5E0 10-63
10 Structure, function and maintenance standard R.H. PPC valve
Equipment control
10-64 SK820-5E0
Equipment control
1. Spool
2. Piston
3. Disc
4. Nut
5. Joint
6. Cover
7. Stopper
8. Body
Unit: mm
Criteria
Free heigh Installed Installed Installed
Free length
9 Metering spring (for P3 and P4) 42.4x15.5 34 9.8 N – 9.2 N
Change
10 Centering spring (for P3 and P4) 32.7x8.2 25.6 40.8 N – 39.4 N spring if it is
11 Metering spring (for P1 and P2) 36.6x15.5 34 17.6 N – 16.5 N damage or
deformation
12 Centering spring (for P1 and P2) 26.2x8.2 25.3 5.3 N – 4.3 N
SK820-5E0 10-65
10 Structure, function and maintenance standard R.H. PPC valve
Equipment control
PPC valve function

1. Neutral 1. 2. During fine control (NEUTRAL o fine control)2.
Ports P1 and P2 of the valve are connected to When piston (4) starts to be pushed by disc (5),
drain chamber D through fine control hole f in retainer (9) is pushed; spool (1) is also pushed by
spool (1). metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the control pump
passes through fine control hole f and goes to
port P1.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f is
shut off from pump pressure chamber PP.
D
At almost the same time, it is connected to drain
f T chamber D to release the pressure at port P1.
P When this happens, spool (1) moves up or down
so that the force of metering spring (2) is
balanced with the pressure at port P1. The
1 relationship in the position of spool (1) and body
(10) (fine control hole f is at a point midway
P1 P2 between drain hole D and pump pressure
RKS00820 chamber PP) does not change even if the
pressure at port P1 becomes max.
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P1 also rises
in proportion to the travel of the control lever.
5
4
9
3
D
2
T
f
P
1 PP
P1 P2 10
RKS00830
10-66 SK820-5E0
Equipment control
3. During fine control (when the lever is

returned) (fine control o neutral) 3.
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is
connected to drain chamber D and the pressure
oil at port P1 is released.
If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D.
At almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
5
4
9
3
D
2
T
f
P f
1 PP
P1 P2
RKS00840
SK820-5E0 10-67
10 Structure, function and maintenance standard L.H. PPC valve
Travel control
L.H. PPC valve

Travel control
P2 P4
P3 P1
T P
E E
F F
D D
A C
RKS00860
C A
10-68 SK820-5E0
L.H. PPC valve 10 Structure, function and maintenance standard
Travel control
P1 port - To hydraulic pump (DA2 port)

P2 port - To hydraulic pump (DB1 port)
P3 port - To hydraulic pump (DA1 port)
P4 port - To hydraulic pump (DB2 port)
P port - From solenoid valve group ST1 (B port)
Functions
P1 L.H. travel forward
P2 R.H. travel reverse
P3 R.H. travel forward
P4 L.H. travel reverse
a When acting control lever, two ports are pressurized contemporarily (i.e.: travel forward pressurize P1
and P3 ports).
SK820-5E0 10-69
Travel control
10-70 SK820-5E0
Travel control
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Disc
6. Nut
7. Joint
8. Cover
9. Stopper
10. Body
11. Plug
12. Ball
13. Seat
14. Body
Unit: mm
Criteria
Free heigh Installed Installed Installed
Free length
13 Metering spring (for P3 and P4) 32.7x8.2 25.3 5.3 N – 52.4 N
Change
Centering spring (for Pout3 and
14 35.5x15.5 34 9.8 N – 9.2 N spring if it is
Pout4)
damage or
Centering spring (for Pout1 and deformation
15 26.2x15.5 34 17.6 N – 16.5 N
Pout2)
SK820-5E0 10-71
Travel control
PPC valve function

1. Neutral 1.
Ports P1 and P2 of the valve are connected to 2. During fine control (NEUTRAL o fine control)2.
drain chamber D through fine control hole f in When piston (4) starts to be pushed by disc (5),
spool (1). retainer (9) is pushed; spool (1) is also pushed by
metering spring (2), and moves down.
When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the control pump
passes through fine control hole f and goes from
port P1.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f is
D
shut off from pump pressure chamber PP.
f T At almost the same time, it is connected to drain
P chamber D to release the pressure at port P1.
When this happens, spool (1) moves up or down
so that the force of metering spring (2) is
1 balanced with the pressure at port P1. The
relationship in the position of spool (1) and body
(10) (fine control hole f is at a point midway
between drain hole D and pump pressure
P1 (P3) P2 (P4)
chamber PP) does not change even if the
RKS00890
pressure at port P1 becomaes max.
Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the
control lever, so the pressure at port P1 also rises
in proportion to the travel of the control lever.
5
4
3
2 D
f T
P
1 PP
10
P1 P2
RKS00900
A B
Distributore
10-72 SK820-5E0
Travel control
3. During fine control (when the lever is

returned) (fine control o neutral) 3.
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port P1.
When this happens, fine control hole f is
connected to drain chamber D and the pressure
oil at port P1 is released.
If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D.
At almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to
a pressure that corresponds to the lever position.
5
4
3
2
D
f T
P
f
1 PP
P1 P2 RKS00880
SK820-5E0 10-73
10 Structure, function and maintenance standard Cylinders
Lifting
Cylinders
Lifting
412 ± 41 Nm 7
2 3 4 5 6 9 430 ± 43 Nm 8
1
13 12 11 10 7
15 16
RKA44770
Specifications
q Ø Rod: 35 mm
q Ø Piston: 55 mm
q Piston stroke: 781±1 mm
q Max. cylinder length: 1822 mm
q Min. cylinder length: 1041±1 mm
q Key size: 32 mm
1. Bushing (piston rod side) 8. Bushing (bottom side)

2. Dust 9. Nut
3. Gasket 10. Piston
4. Gasket 11. Cylinder
5. Rod 12. Gasket
6. Gasket 13. Head
7. Ring
Unit: mm
Criteria
No. Check item Standard Tolerance Minimum Clearance Remedy

size Shaft Hole clearance limit
Tolerance between piston rod and -- 0.025 + 0.039 0.025– Replace

14 35 0.426
cylinder head -- 0.087 +0 0.126 head
Tolerance between bushing and –0.01 + 0.072 0.082–

15 35 1.0
piston rod mounting pin –0.05 + 0.134 0.184 Replace
Tolerance between bushing and –0.01 + 0.072 0.082– bushing
16 35 1.0
cylinder mounting pin –0.05 + 0.134 0.184
10-74 SK820-5E0
Cylinders 10 Structure, function and maintenance standard
Tilt
Tilt
2 420 ± 42 Nm 3 4 14 5 6 7 9 430 ± 43 Nm 8
1
13 12 11 10
15 16
RKA43250
Specifications
q Ø Rod: 30 mm
q Ø Piston: 60 mm
q Piston stroke: 357 mm
q Max. cylinder length: 970 mm
q Min. cylinder length: 613 mm
q Key size: 32 mm
1. Bushing (piston rod side) 8. Bushing (bottom side)

2. Dust 9. Nut
3. Gasket 10. Piston
4. Gasket 11. Cylinder
5. Rod 12. Gasket
6. Gasket 13. Head
7. Ring
Unit: mm
Criteria
No. Check item Standard Tolerance Minimum Clearance Remedy

size Shaft Hole clearance limit
Tolerance between piston rod and -- 0.020 + 0.033 0.020– Replace

14 30 0.405
cylinder head -- 0.072 +0 0.105 head
Tolerance between bushing and –0.090 + 0.099 0.130–

15 35 1.0
piston rod mounting pin –0.130 + 0.040 0.229 Replace
Tolerance between bushing and –0.090 + 0.099 0.130– bushing
16 35 1.0
cylinder mounting pin –0.130 + 0.040 0.229
SK820-5E0 10-75
10 Structure, function and maintenance standard Work equipment
Work equipment
D
F F
E
A G
A
B
E G
B
H
C
H
A-A
B-B
2
3
D-D
C-C
RKA44780
10-76 SK820-5E0
Work equipment 10 Structure, function and maintenance standard
4 8
F-F
E-E
5 9
G- G
RKA44790
H- H
Unit: mm
Criteria
No. Check item Standar Tolerance Minimum Clearan Remedy

d size Shaft Hole clearance ce limit
Clearance between bushing and mounting –0.01 + 0.072 0.082–

1 35 1.0
pin of lift lever –0.05 + 0.134 0.184

2 35 1.0
pin of arm and support frame –0.05 + 0.134 0.184

3 40 1.0
pin of fulcrum lever –0.064 + 0.135 0.199

4 35 1.0
pin of lift lever –0.05 + 0.134 0.184
Clearance between bushing and mounting –0.025 + 0.105 0.130– Replace

5 40 1.0
pin of fulcrum lever –0.064 + 0.135 0.199 bushing

6 35 1.0
pin bucket cylinder (bottom side) –0.05 + 0.134 0.184

7 35 1.0
pin bucket cylinder (head side) –0.05 + 0.134 0.184

8 35 1.0
pin lift cylinder (head side) –0.05 + 0.134 0.184
9 35 1.0
pin lift cylinder (bottom side) –0.05 + 0.134 0.184
SK820-5E0 10-77
10 Structure, function and maintenance standard Work equipment
10-78 SK820-5E0
Shop Manual
SK820-5E0
SKID-STEER LOADER
Shop Manual 10-1
SK820-5E0

SK820-5E0 F60003 and up
20 Standard value table 10-1
SK820-5E0 20-1
20 Standard value table Contents
Contents 20-2
20 Standard value table
Standard value table ................................................................................................................................... 3
Engine...................................................................................................................................................... 3
Machine ................................................................................................................................................... 4
20-2 SK820-5E0
Standard value table 20 Standard value table
Engine
Standard value table

Engine
Machine model SK820-5E0
Engine S4D84E-6BMFD
Check item Test conditions Unit Standard value Permissible value
High idling 2770 2740–2810
Engine speed rpm
Low idling 1100 1050–1150
Sudden acceleration Bosch
Exhaust gas colour 4.5 4.5
At high idling speed index
Intake valve (20°C) mm 0.20 0.15–0.25
Valve clearance
Exhaust valve (20°C) mm 0.20 0.15–0.25
Compression
Oil temperature 40–60 °C kg/cm² 30±1 25±1
pressure (oil
(Engine speed) (rpm) (250) (250)
SAE30)
Blow - by pressure Water temperature in operating range
mm H2O – –
(SAE30 oil) At high idling speed
(Oil temperature 80°C)
Engine oil pressure At high idling speed kg/cm² 3.7–5.2 –
At low idling speed kg/cm² >0.6 –
Engine oil
Entire speed range °C Max. 120 Max. 120
temperature
Fuel injection timing B.T.D.C. degrees 20° 20°
Deflection when pressed with finger force of
Fan belt tension mm 10 10–15
approx. 10 kg
SK820-5E0 20-3
20 Standard value table Standard value table
Machine
Machine
q Stroke of levers and pedals

Neutral o
Travel forward • Engine stopped. 65 58.5–71.5
Forward
• At centre of lever knob
Neutral o
Travel reverse • Reading at end of 65 58.5–71.5
Reverse
travel
R.H. travel • Equipment on the Neutral o Right 65 58.5–71.5
L.H. travel ground Neutral o Left 65 58.5–71.5
Lifting arm Neutral o Lift 65 58.5–71.5
80 mm mm
Lower arm Neutral o Lower 65 58.5–71.5
Dump bucket Neutral o Dump 65 58.5–71.5
Curled bucket Neutral o Curl 65 58.5–71.5
Neutral o Right
Attachment pedal 20 15–25
Neutral o Left
Travel speed lever Min. o Max. 105 100–110
Accelerator pedal Min. o Max. 40 30–50
20-4 SK820-5E0
Machine
q Operating force for control of levers and pedals

Travel forward 2.0 1.8–2.2
Travel reverse 2.0 1.8–2.2
R.H. travel 2.0 1.8–2.2
L.H. travel 2.0 1.8–2.2
Lifting arm • Engine speed: min. 1.8 1.5–2.1
• Oil temperature: 45-55 °C
Lower arm 1.8 1.5–2.1
• Instrument coupling at centre of control kg
Dump bucket lever knob 1.8 1.5–2.1
Curled bucket • Instrument coupling on outside edge of 1.8 1.5–2.1
control pedal
Attachment pedal
5.0 4.0–6.0
(right)
Attachment pedal
5.0 4.0–6.0
(left)
Travel speed lever 7.5 5.0–10
SK820-5E0 20-5
Machine
q Hydraulic pressure

• Engine speed: 1800±50 rpm

Control valve 197 190–206
• Oil temperature: 45–55 °C
• Engine speed: max.

Travel motors • Oil temperature: 45–55 °C
309 274–316
(forward) • Parking brake: applied
• 2nd speed

Travel motors • Oil temperature: 45–55 °C
309 250–316
(reverse) • Parking brake: applied
• 2nd speed
• Engine speed: 2550±10 rpm

Servocontrol 26.5 25–29
• Oil temperature: 45–55 °C
bar
• Machine raised from Low idling 9.5 9–10

the ground
AS Valve • Oil temperature: 45–55
°C
• Travel lever: forward 2400±10 rpm 11.6 11.1–12.1

Unloading valve • Oil temperature: 45–55 °C 9.5 8.5–10.5
• Travel levers: at neutral

Charge safety valve • Oil temperature: 45–55 °C 27.5 19.6–29.4
• Travel levers: at neutral
20-6 SK820-5E0
Machine
q Pilot system and secondary circuit pressures

Pilot system travel
5.5 4.0–7.0
forward (start-up)*
Pilot system travel
14.5 14–15
(maximum)
Pilot system travel
5.5 4.0–7.0
reverse (start-up)*
Pilot system travel
• Engine speed: 2550±10 rpm 14.5 14–15
reverse (maximum)
bar
Pilot system travel • Machine raised from the ground
to right or left * Pressure when wheels start rotating 5.5 4.0–7.0
(start-up)*
Pilot system travel
to right or left 14.5 14–15
(maximum)
Pilot system with
parking brake min. 22 min. 22
disengaged
q Engine speed (with load)


With travel pump • 2nd speed 2600 min. 2500
• Travel lever: at full stroke
• Parking brake: applied
• Engine speed: max. rpm

With travel and • Oil temperature: 45-55 °C
equipment pumps to • 2nd speed
2400 min. 2300
the maximum • Travel lever: at full stroke
pressure • Parking brake: applied
• Raise: at end of stroke
SK820-5E0 20-7
Machine
q Hydraulic drift of work equipment

Measuring posture
Total work
equipment
(Downward Max. 130 Max. 130
movement of tips of
the rake blade)
RKS02050
Raising cylinder • In this position, measure extension or

retraction of each cylinder, and any mm Max. 12 Max. 12
(Retraction)
leakages occurring.
• Horizontal and level ground
• Engine: switched off
• Release all residual pressure as soon as
you stop the engine.
Bucket cylinder • Take all readings immediately after
stopping the engine and releasing all Max. 8 Max. 8
(Extension)
residual pressure.
• Measure the variation 15 minutes after
engine stop.
20-8 SK820-5E0
Machine
q Work equipment speed

Measuring posture
Raise
4.1 3.7–4.5
Arm
Lower
RKS02060
2.6 2.3–2.9
• Average value in 3 tests.
Measuring posture
Arm
sec.
Lower
(lowering with
54 48–60
emergency safety
device)
RKS02060
• Engine: switched off

Measuring posture
Curl
2.0 1.8–2.2
Bucket
RKS02020
Dump
2.2 2.0–2.4
• Average value in 3 tests.
SK820-5E0 20-9
Machine
q Travel
Measuring posture
Normal
72 68–76
Wheel speed
rotation (without rpm
load)
With increment
RKS02040
• Engine speed: max. 114 108–120

• Machine raised from the ground
Measuring posture
Normal
8.5 8.1–8.9
RKS02030
Travel speed sec.
With increment

• Wheel pressure: min. 2.8 bar
• Travel 25 meters and then check 5.6 5.3–5.9
the time needed for cover 25
meters.
• Check all the direction
Measuring posture
RKS02030
Travel deviation mm Max. 62.5 Max. 62.5
• Wheel pressure: min. 2.8 bar
• Travel 10 metres on flat ground and
measure the deviation.
• Check all the direction
a The surface must be firm and horizontal.
20-10 SK820-5E0
Shop Manual
SK820-5E0
SKID-STEER LOADER
SK820-5E0

SK820-5E0 F60003 and up
30 Testing and adjusting 10-1
SK820-5E0 30-1
30 Testing and adjusting Contents
Contents 30-2
30 Testing and adjusting
Testing and adjusting .................................................................................................................................. 3
Special tools............................................................................................................................................. 3
Checking the engine speed ..................................................................................................................... 4
Adjustment of valve clearance ................................................................................................................. 5
Measurement of the compression pressure............................................................................................. 7
Control and adjustment of the fan belt tension ........................................................................................ 8
Control and adjustment of the injection timing ......................................................................................... 9
Checking engine oil pressure................................................................................................................. 11
Adjusting the stroke of the accelerator cables ....................................................................................... 12
Regulation of PPC valves’ drive pressure.............................................................................................. 15
Adjustment of the PPC valve clearances ............................................................................................... 17
Adjusting the position of the servo-control. ............................................................................................ 18
Testing and adjustment of gearing chain tension .................................................................................. 19
Control and regulation of the pressures in the hydraulic circuits ........................................................... 20
Testing the hydraulic pump.................................................................................................................... 21
Valve calibration..................................................................................................................................... 22
Checking the travel deviation................................................................................................................. 24
SSC device (Slow speed control) calibration ......................................................................................... 25
Control valve .......................................................................................................................................... 26
Control and regulation of the servo-control power supply...................................................................... 28
Elimination of residual pressures - pressurisation of the tank................................................................ 30
Bleeding air from the hydraulic circuits .................................................................................................. 31
30-2 SK820-5E0
Testing and adjusting 30 Testing and adjusting
Special tools
Testing and adjusting

Special tools
Measurement check points Symbol Code Name Q.ty Remarks
Commercially
1 Multi-scale tachometer 1 20-4000 rpm
available
Engine speed A
Commercially
2 Stroboscopic tachometer 1 6-30000 rpm
available
Commercially
Valve clearance B 1 Feeler gauge 1 –
available
1 Compression gauge 1 Kit Yanmar

Compression pressure C
2 Adapter 1 TOL-97190080
Commercially
1 Pressure adapter 1 Thread 1/8”
available
Engine oil pressure D
Commercially
2 Compression gauge 1 Scale 10 bar
available
Commercially
available
Commercially 1 Scale 400 bar

2 Compression gauge
available 1 Scale 600 bar
Hydraulic pressure E Commercially

available
Commercially Sensocontrol kit

4 (Differential pressure) 1 0-1000 bar
available
Commercially
5 Pressure adapter 1 Thread M10
available
SK820-5E0 30-3
30 Testing and adjusting Testing and adjusting
Checking the engine speed
Checking the engine speed Stroboscopic tachometer [A2]
k When checking the engine rpm , always be

1. Take out the screws and remove the rear cover
(2).
very careful not to touch parts that reach high
temperatures and not to get entangled in
rotating elements.
a Check the engine speed after the following
conditions have been reached:
q Temperature of engine cooling water:
68-80 °C. 2
q Hydraulic oil temperature: 45–55 °C
Multi-scale tachometer [A1]

1. Loosen and remove the clamp (1).
RKAC5430
2. Apply a reflective mark (4) on the edge of the

engine pulley (3).
1
3
A2
4
RKAC5410
2. Install the sensor on the straight portion of pipe

for the nozzle of cylinder No. 3 and connect the
multi-scale tachometer [A1].
RKAC5440
A1 Checking
1. Start the engine and check:
q Low idling without load (accelerator lever in
“minimum” position): 1100±50 rpm
q High idling without load (accelerator lever
in “maximum” position): 2740-2810 rpm
a If the minimum and maximum speeds do
not fall within permissible limits when the
engine is without load, check the position
locks of the accelerator lever, and the
RKAC5420
sheathing of the accelerator well, before
carrying out any tests under load (see
"Adjusting the stroke of the accelerator
cables").
q Max. speed with parking brake inserted,
2nd speed inserted and travel lever at full
stroke (forward): 2500-2600 rpm
q Max. speed with parking brake inserted,
2nd speed inserted, travel lever at full
stroke (forward) and raising arm at the end
of stroke: 2300-2400 rpm
30-4 SK820-5E0
Adjustment of valve clearance
Adjustment of valve clearance 6. Check that the valve cap (6) is lying flat on the
valve stem and that there is no lop-sided wear.
Zero setting a If the valve caps (6) are damaged, replace
them with new ones.
1. Remove the air filter. (See "50 Disassembly a Make sure that the valve caps fit perfectly
and assembly" - "Removal and installation of and are lying flat on the valve stem.
air intake filter").
2. Remove the valve cover. (See "50 Disassembly
and assembly" - "Removal and installation of 2 1
valve cover"). 3
3. Remove the feedback fuel pipe. (See "50
0mm 0mm
Disassembly and assembly" - "Removal and
installation of nozzle holder").
4. Loosen the nut (1) and the block (3) adjustment
screw (2).
YES NO
6 RKS03731
2 7. Tighten the adjustment screw (2) until it is

seated on the outer valve. Lock the position
with the nut (1).
3
1
RKSA1270
5. Operate on rocker (5) adjustment screw (4) for

seat the block on inner valve.
RKSA1280
SK820-5E0 30-5
Adjustment of valve clearance
Adjustment 5. Adjust the clearance between valve and

rockers to the following values (with cold
1. Turn the drive shaft in the normal direction of
engine):
rotation until the line (1) marked as no. 1 on the
flywheel is in alignment with the reference q Suction valves: 0.20 mm
notch (2) on the flywheel housing. q Exhaust valves: 0.20 mm
If the cylinder is in a compression stroke, the 6. After adjusting the No. 1 cylinder, rotate the
valves do not move when the drive shaft is drive shaft 180° each time and adjust the valve
rotated slightly. clearance of the other cylinders according to
If the valves do move, rotate the drive shaft by the ignition sequence.
one turn and realign the reference marks (1) a Ignition sequence: 1 - 3 - 4 - 2.
and (2).
5
1
2
6
RKS02290
RKSA3570
2. Loosen the lock nut (3) and unscrew the

adjustment screw (4) by approximately 1 turn.
3. Insert the feeler gauge [B1] between the rocker
(6) and the valve cap (5). Rotate the adjusting
screw (4) until it rubs against the feeler gauge
[B1].
4. Lock the position with the nut (3).
a After locking the nut (3), check the valve
clearance again.
5
3 4
6
B1
RKSA1300
30-6 SK820-5E0
Measurement of the compression pressure
Measurement of the compression 4. Turn the engine over a few times, using the
pressure starting motor.
k While measuring the compression, take care

5. Remove the nozzle and mount adapter [C2].
6. Mount the adapter and connect the test
not to get entangled in the cooling fan, the pressure gauge [C1].
alternator belt, or in other rotating parts. Check a Check that the seal is mounted in the
all cylinders. adapter, and that it is undamaged.
Test conditions:
q Engine: at working temperature C1
q Hydraulic oil temperature: 45-55°C.
q Battery: fully charged
q Valve clearance: adjusted (see "Adjustment of
valve clearance").
C2
1. Remove the air filter. (See "50 Disassembly
and assembly" - "Removal and installation of
air intake filter").
2. Remove the valve cover. (See "50 Disassembly
and assembly" - "Removal and installation of
valve cover"). RKAC5740
3. Disconnect the connector (1) of the

7. Turn the engine using the starting motor and
engine-stopping solenoid and close the fuel
read the compression value.
cock (2).
a Read the compression value when the
pressure gauge has stabilised.
a While reading the compression, also
check the engine rpm using the
tachometer [A1] or [A2]; if the speed does
1 2 not correspond with the control value,
check it against the diagram.
q Standard compression value:
30±1 kg/cm² - 250 rpm
q Minim compression value:
25±1 kg/cm² - 250 rpm
q Maximum difference between the
cylinders:
RKSA2960 2-3 kg/cm².
8. After the reading, re-assemble the nozzle, the
valve cover, the air intake filter and the
connector (1).
3 Nut that secures the nozzle: 7.84±0.98
Nm
3 High-pressure coupling: 31.85±2.45 Nm
Compression pressure
(kg/cm2)
40
35
30
25
20
200 250 300 350 400

Engine speed (rpm)
RKS03941
SK820-5E0 30-7
Control and adjustment of the fan belt tension
Control and adjustment of the fan Adjusting the belt tension

belt tension 1. Loosen the screws (4) that secure the
alternator (2).
Checking the tension 2. Rotate the alternator (2) to give the belt (1) the
1. Depress the belt (1) at the centre of the section correct tension and tighten the screw (4).
between the alternator (2) and the pulley (3)
that drives the water pump; check the flexion.
At a pressure of 10 kg (98 N) the flexion should
2
be 10–15 mm; if this value is not found, adjust 4
the belt tension.
a With a new belt the flexion should be 5–8
mm.
1015 mm
3 1
RKSA2971
2 3. Check the belt (1) tension.

a If the belt has been replaced with a new
one, check the tension again after about
1 20 hours of operation.
3 Screw: 25-32 Nm
RKS03741
30-8 SK820-5E0
Control and adjustment of the injection timing
Control and adjustment of the 3. Take off the clamp (3) and disconnect all the
injection timing fuel delivery tubes (4) from the injection pump
(5).
a Check the injection timing of the No.1 cylinder 4. Rotate the flywheel slowly in a
by means of the No.1 union of the injection counter-clockwise direction (seen from the
pump. flywheel side), checking carefully the level of
a The cylinders are numbered 1-2-3-4 counting the fuel in the No. 1 union of the injection
from the flywheel side. pump. Stop the rotation when the fuel level
a The spark advance notches of 0°-10°-15°-20°; starts to rise.
are also marked on the flywheel. In order to
read the intermediate values, sub-divide the
sections between the two marks into equal
lengths. 4
1. Remove the cap (1) of the flywheel casing. 3
1 5
RKSA2990
5. Check the position of the notches at 15° and

20° that appear in the hole in the casing and, in
function of the position, establish the true fuel
injection timing.
a In order to read the intermediate values,
RKSA2980
sub-divide the sections between 15° and
2. Pass a screwdriver between the teeth and 20°.
rotate the flywheel in a counter-clockwise a Standard fuel injection timing: 20°.
direction (as seen from the flywheel side) until
the 1/4 notch of the flywheel is aligned with the
notch (2) marked inside the hole in the casing.
a In this position, the piston of the No. 1
cylinder is at the top dead centre
(B.T.D.C.). Check that the cylinder is in a
compression stroke, i.e. that both valves
are closed.
a Once the B.T.D.C. has been ascertained,
rotate the drive shaft in a clockwise
direction (seen from the flywheel side) for Mark
about 25 teeth. 2
RKSA3001
RKSA1020
RKSA1010
SK820-5E0 30-9
Control and adjustment of the injection timing
6. After you have loosened the check nuts for the

pump (6) and the screws (7), rotate the
injection pump (5) outwards or towards the
engine.
q To BRING FORWARD the injection, rotate
the pump (5) towards the outside.
q To DELAY the injection rotate the pump (5)
towards the cylinder block.
6
RKSA3010
a Check the extent of the movement on the scale

(8).
RKSA3020
7. Lock nuts (6) and screws (7).

8. Connect the fuel delivery tubes (4) to the pump
and replace the clamp (3), after adjustment.
3 Delivery tube couplings:
19.6-24.5 Nm
9. Bleed any air from the fuel circuit.
30-10 SK820-5E0
Checking engine oil pressure
Checking engine oil pressure

k When measuring the engine oil pressure, take
great care not to touch high-temperature parts,
or to become entangled in rotating elements.
a Check pressure with the engine at working
temperature.
a Low and high idling within permissible limits.
1. Start the engine and wait for it to reach working

temperature.
q Working temperature:
Coolant liquid: 90°C
Engine oil temperature: 80°C
2. Stop the engine, disconnect the connector and
remove the oil pressure sensor (1).
RKAC5450
3. Mount the adapter [D1] and connect the

pressure gauge [D2].
4. Start the engine and check the oil pressure at
low idling (accelerator lever in low idling
position) and at high idling (accelerator lever in
high idling position).
a Low idling pressure: >0.6 kg/cm²
a High idling pressure:
3.7–5.2 kg/cm².
5. Remove the adapter [D1] and install the oil
pressure sensor (1).
D2
D1
RKAC5460
SK820-5E0 30-11
Adjusting the stroke of the accelerator cables
Adjusting the stroke of the 2. Check that the lever (2) of iniection pump is
accelerator cables against the adjusting screw (3).
3. Check that the play between the lock pin (A)
a Conditions for the adjustment: an d the st ro ke li mi tin g c l amp (4) o f th e
q Engine: stopped accelerator cable (5) is 1 mm maximum.
q Machine on firm and level ground.
q Arm raised and engaged with safety lock.
q Cab: raised
2
3
a If the cables are replaced, lock in the middle of
adjustment available the position of the
sheaths side lever (or pedal) and the side 4
injection pump before making adjustments. 5
a For adjusting the stroke of the accelerator
cables follow the procedure described below. A
Adjusting the hand accelerator cable is priority
than the foot accelerator cable adjustment.
Adjusting the stroke of the hand accelerator RKAC7480
cable
1. Place the command lever (1) in low idling 4. Place the command lever (1) in high idling
position. position.
Min Max
Min Max
1 1
RKS01190
RKS01190
5. Check on the engine side that the lever (2) of

iniection pump is completely open and against
the adjusting screw (6).
6
2
RKAC5471
30-12 SK820-5E0
In the case that the above conditions are not Adjusting the stroke accelerator pedal
occurring: cable
6. Remove cover (7) on the right side of the cab.
1. Loose the adjusting screw (1).
2. With the accelerator pedal released (low idling)
check that it stays against the adjusting screw
(3).
7
2 1
RKAC7490
7. Register the high and low idling position of 3

lever (1) using adjusting screws (8) and (9). RKAC7510
a After the adjustment, verify that lever (1) is able
to be pushed against the adjusting screws (8) 3. Check on the engine side that the play between
and (9). the lock pin (A) and the stroke limiting clamp (4)
of the accelerator cable (5) is 1 mm maximum.
4. Check that the lever (6) of iniection pump is
against the adjusting screw (7).
8 1 9 5. With the accelerator pedal totally pressed (high
idling) check that the lock pin (A) on the pump
is against the adjusting screw (8).
6. Release the accelerator pedal of about 3-4 mm
in order to reduce the pedal travel and avoid
that the force acting on the pedal damage the
injection pump lever (6).
6
7
RKAC7500
8
4
5
A
RKAC7520
SK820-5E0 30-13
7. Adjust the high idling position of the acelerator

pedal modifying the screw (1) position.
8. After the adjustment, verify that pedal (2) is
able to be pushed against the adjusting screws
(3) and (1).
2 1
3
RKAC7510
30-14 SK820-5E0
Regulation of PPC valves’ drive pressure
Regulation of PPC valves’ drive 4. Remove the joint (7) and retainer plate (8).
pressure [*2]
5. Remove the boot (9) and remove the O-ring
1. Lower the working equipment to the ground (10).
and stop the engine.
2. Turn the ignition key to the I position and move
the command levers in all directions in order to
release all pressure in the hydraulic circuits. 7 9
3. Return the ignition key to the O (OFF) position
and remove it. 8
Gently loosen the oil fill cap to eliminate any
residual pressure.
10
Disassembly and regulation
1. Remove PPC valve (see "50 Disassembly and

assembly" - "Removal and installation of PPC RKSA2380
valve").
2. Lift the boot (1) and mark the position of the 6. Loosen the 4 retaining screws (11) from the
lever (2) in relation to the PPC valve body (3). plate (12) and remove the plate.
[*3]
11
2
1
12
3
RKSA2360
RKSA2390
3. Loosen the screw (4), remove the washer (5)

and pull out the complete handle (6). 7. Remove the stopper (13) and seals.
[*1] [*4]
a Use a soft tool to remove.
8. Remove the complete spool (14).
6 13 14
4
RKSA2370
RKSA2400
SK820-5E0 30-15
Regulation of PPC valves’ drive pressure
9. Remove the retainer (15), spring (16) and Assembly

shims (17) from the spool (14). q To assemble, perform the disassembly
10. Add shims until you reach the admitted procedure in the reverse order.
calibration value (see "20 Standard value
a Thoroughly clean all parts.
2 Cleaner: Loctite 7063
table"); bear in mind that 0.3 mm thickness
corresponds to a variation in pressure of about
[*1]
3 Screw: 64-74 Nm
0.6 bar.
[*2]
a Press down on the stoppers (13) to ease
15 setting into place; tighten the retainer plate (8)
16
until it is properly seated and adjust clearance
17
(see "Adjustment of the PPC valve
14
clearances").
3 Joint: 112.8±14.7 Nm
[*3]
3 Screws: 13.2±1.5 Nm
[*4]
a Lubricate the stoppers (13).
RKSA2410
30-16 SK820-5E0
Adjustment of the PPC valve clearances
Adjustment of the PPC valve

clearances
The clearance of the PPC valve (hand and foot)
levers is adjusted as follows.
k Lower the working equipment to the ground
and stop the engine.
Turn the ignition key to the I position and move
the command levers in all directions in order to
release all pressure in the hydraulic circuits.
Return the ignition key to the O (OFF) position
and remove it.
Gently loosen the oil fill cap to eliminate any
residual pressure.
1. Remove cap (1).
2. Loosen the nut (2) that retains the disc (3).
3. Tighten the disc (3) until it makes light contact
with the 4 push-rods (4).
a During this adjustment, take care not to
activate any of the push-rods (4)
individually.
2
1 3
4
RKS01700
4. Secure this position by tightening the retaining

nut (2) to the specific torque.
3 Retaining nut: 113±15 Nm
SK820-5E0 30-17
Adjusting the position of the servo-control.
Adjusting the position of the

servo-control.
k Lower the working equipment to the ground,
stop the engine and remove starter key.
1. Lower the LH safety bar (1) and adjust the
position of the sensors (2) by loosening and
tightening the adjustment nuts (3).
a Distance between safety bar and sensor
"X": 0.7-1 mm.
2 1
3 X
X
RKA44800
30-18 SK820-5E0
Testing and adjustment of gearing chain tension
Testing and adjustment of gearing Adjustment

chain tension a For greater clarity, the photo opposite shows
t he a d j us t m e nt o pe r a t i on s w i th th e t ir e
Checking removed.
Test conditions: It is not necessary to remove the tires for this
q Machine: raised from the ground adjustment.
q Work equipment: in road-driving position. 1. Screw a screw [A] (M10x50, fully threaded) into
a Check all the wheels. the hole provided on the frame until it makes
1. Position a magnetic comparator to correspond firm contact with the wheel hub.
with the wheel diameter of 600 mm and make 2. Loosen the retaining screws (1) of the wheel
a notch “A” close to the indicator. hub until it can move.
1
00
Ø6
A
A
RKSA0170
RKSA2690
2. Rotate the tire by hand in both directions and 3. Gradually tighten the screw [A] until correct
check that the total play of the notch remains tension has been restored to the chain.
within permissible limits. 4. Tighten the nuts (1).
a Standard play: 4 mm 3 Nuts: 200 Nm
a Permissible play: 2-6 mm
0
60
Ø
2-6 mm
RKS02990
SK820-5E0 30-19
Control and regulation of the pressures in the hydraulic circuits
Control and regulation of the k Before removing the plugs in order to measure
pressures in the hydraulic circuits the pressures, release the residual pressures
in the circuits (see "Elimination of residual
Test conditions: pressures - pressurisation of the tank") and
q Engine: at working temperature. place the safety.
q MIN and MAX. engine speeds: within k After having connected the pressure gauges,
permissible limits. pressurise the tank (see "Elimination of
q Hydraulic oil temperature: 45-55 °C. residual pressures - pressurisation of the
tank").
P1 P2 P3 P4 P5
2 9 bar 20 bar
RKA43260
1- L.H. Travel motor

2- R.H. Travel motor
3- Engine
4- Control valve
q The control valve consists of the spools that

command:
Command Ports 3
Arm (Lower - Raise) A1 - B1 2
Bucket (Dump - Curled) A2 - B2 B 1 A
Equipment (R.H. - L.H.) A3 - B3
RKS01130
30-20 SK820-5E0
Testing the hydraulic pump
Testing the hydraulic pump Check the working pressure of the AS valve
Test conditions:
Check the working pressure of the travel q Engine speed: low idling - 2400 rpm
circuit HST charge valve q Hydraulic oil temperature: 45-55 °C.
Test conditions: q Safety bar: lowered
q Engine speed: maximum q Machine raised from the ground
q Hydraulic oil temperature: 45-55 °C. 1. Remove the plug (1) and mount a pressure
q Safety bar: raised
k Do not activate the travel lever.
adapter [E5].
2. Connect a pressure gauge [E1] (60 bar) and
start the engine at low idling.
1. Remove the plugs (1) and (2) and mount the
3. Push the travel lever full stroke for forward
two pressure adapters [E5].
travel and read the pressure.
a Normal value: 9±10 bar
TOP VIEW
4. Repeat test with the angine at 2400±10 rpm.
1 a Normal value: 11.1±12.1 bar
5. Remove the pressure adapter and tighten the
plug (1).
3 Plugs: 19.8-27.4 Nm
L.H. SIDE VIEW
RKA44690
BOTTOM VIEW
RKS01320
RKA44700
2. Connect two pressure gauges [E1] (60 bar),

start the engine and accelerate to high idling.
k Do not activate the travel lever.
3. Check that the pressure remains within
permissible limits.
a Use the lower of the two pressure values
taken.
a Normal pressure: 19.6-29.4 bar
4. Remove the pressure adapters and tighten the
plugs (1) and (2).
3 Plugs: 19.6-27.4 Nm
SK820-5E0 30-21
Valve calibration
Valve calibration AS valve calibration

1. Pressure adjustment at low idling
HST valve calibration
1. Loosen the nut (1), and adjust the working
1. Loosen the nut (1), taking care not to move the pressure of the AS valve (with the engine at low
adjustment screw (2). idling), proceeding as follows:
2. Adjust the working pressure of the HST valve, q to INCREASE pressure, turn the screw (2)
proceeding as follows: in a CLOCKWISE direction.
q to INCREASE pressure, turn the screw (2) q to REDUCE pressure, turn the screw (2) in
in a CLOCKWISE direction. a COUNTER-CLOCKWISE direction.
q to REDUCE pressure, turn the screw (2) in a One complete turn of the screw (2) varies
a COUNTER-CLOCKWISE direction. the pressure by 3.37 bar.
a One complete turn of the screw (2) varies 2. Tighten the nut (1) and check that the working
the pressure by 15.5 bar. pressure remains within permissible limits.
3 Nut: 34.3-58.8 Nm
3. Tighten the nut (1) and check that the working
pressure remains within permissible limits.
3 Nut: 45-58.8 Nm
A
A
A RKS01350
1
RKA44710
2
2 1
RKS01360
RKS01340
30-22 SK820-5E0
Valve calibration
2. Pressure adjusting at 2400 rpm.

1. Loosen the nut (3), and adjust the working
pressure of the AS valve, proceeding as
follows:
q to INCREASE pressure, turn the screw (4)
in a COUNTER-CLOCKWISE direction.
q to REDUCE pressure, turn the screw (4) in
a CLOCKWISE direction.
a One complete turn of the screw (4) varies
the pressure by 1.18 bar.
2. Tighten the nut (3) and check that the working
pressure remains within permissible limits.
3 Nut: 34.3-58.8 Nm
4 3
RKS01361
SK820-5E0 30-23
Checking the travel deviation
Checking the travel deviation Adjusting the deviation

1. Select the adjustment screw to be re-set:
Test conditions:
q Engine speed: at max. speed
q Hydraulic oil temperature: 45-55 °C. Travel Deviation Screw
q New or wear uniformly tires.
Forwards Left A1
q Tires inflated to the correct pressure.
a Drive the machine onto solid, level ground. Forwards Right A2
Reverse Left B1
Reverse Right B2
A1 A2
RKS02420
Checking the deviation B1 B2

RKA44720
1. Position the boom and bucket in their travelling

positions. 2. Loosen the nut (1) and tighten the screw (2).
a Arm lowered and bucket fully curled. a A 60° turn of the screw (2) will reduce the
2. Bring the engine up to maximum rpm. deviation by about 500 mm.
3. Push the travel lever to full stroke forwards 3. Tighten the nuts (1).
4. Travel for 5 metres, then measure the 3 Nut: 26.5-32.4 Nm
deviation of the machine over the next 10
metres.
5. Check the deviation also in reverse gear and
while accelerating in both directions.
2 1
RKS01380
10 m 5m
RKA44730
30-24 SK820-5E0
SSC device (Slow speed control) calibration
SSC device (Slow speed control)

calibration
k The SSC system is tested and calibrated at the
factory during the testing of the machine. In
case the device is installed in a second time, a
calibration with the following conditions has to 2
be performed after the installation:
q Deviation in standard speed within the
limits prescribed (see "Checking the travel
deviation").
q Leveled ground.
q Machine with standard bucket and arm 4 3
raised.
q New or uniformly wear tires.
q Tires inflated to the correct pressure.
a The same conditions apply to all the following
checks performed if the system does not allow
a straight travel or otherwise does not comply
1
with the tolerance of deviation prescribed.
1. Press both buttons (3) and (4) at the same
time. 6
2. While holding the buttons, turn the ignition key 5
to the ON position (I); RKAC5830
hold down the buttons (3) and (4) until the the
indicator (5) starts flashing continuously. a If during the calibration aany doubts are raised,
it is possible to reset all the values to the
3. Release the buttons (3) and (4), start the
factory default.
engine and turn off the parking brake.
The op erati on is ob tai ned fol lo wing th e
In these conditions, the indicator (5) flash every
procedure described for the calibration until
2 seconds.
step 5, and then pressing simultaneously and
4. Press the button (1) and check that the "Slow holding down buttons (3) and (4) for 8 seconds.
travel" mode is active, highlighted by the
activation of the light (6) (green).
5. Turn the potentiometer (2) until the arrow is in
the first half of scale. In this conditions, the
indicator (5) flashes 2 times every 2 seconds,
entering the programming mode.
6. Begin travel in slow mode moving the left PPC
valve to end of stroke and, if necessary, correct
the deviation with push button (3) or (4).
7. Save this calibration releasing the servocontrol
PPC valve (neutral).
8. Set the parameters pressing both buttons (3)
and (4) and holding them down until the
indicator (5) lights for 2 seconds.
When the indicator (5) turns off, the parameters
are stored.
9. Release buttons (3) and (4).
10. Repeat the procedure with the potentiometer
(2) turned in a clockwise until the arrow is in the
second half of the scale.
SK820-5E0 30-25
Control valve
Control valve Control the operating pressures of the

working equipment
Control of operating pressure (unloading 1. Remove the plug (1) and mount a pressure
valve) adapter.
1. Remove the plug (1) and mount a pressure 2. Connect a pressure gauge [E2] (400 bar or 600
adapter. bar).
2. Connect a pressure gauge [E3] (10 bar).
E2
E3
1
1
RKSA0190
RKSA0180
3. Start the engine and bring it up to high idling.
3. Start the engine and bring it up to high idling 4. Check the pressure for each movement with
with all levers in neutral position. the command lever at the end of its stroke and
4. Check the pressure. with the pressure stabilised.
a Normal pressure: 9.5±1 bar k To check the pressure of the working
k Take care do not operate the equipment equipment, push the piston to the end of its
levers. stroke.
k The unloading valve cannot be re-adjusted.

If the pressure differs from the normal
value the valve must be substituted.
30-26 SK820-5E0
Control valve
Valve adjustment
a The unloading valve cannot be re-adjusted,
only substituted.

If the pressures measured for the working
equipment and machine travel do not fall within
normal values, adjust the main relief valve (1) as
follows:
1. Loosen the lock nut (2) and rotate the adjusting

screw (3).
q To INCREASE pressure, turn in a
CLOCKWISE direction.
q To DECREASE pressure, turn in a
COUNTER-CLOCKWISE direction.
a Each turn of the adjusting screw (3) varies
the pressure by about 55 bar.
2. Lock the nuts (2).
3 Nut: 69±10 Nm
a After adjustment, check the adjustment of

the mai n relief valv e with the s ame
procedures as used for the
measurements.
A A
A-A
RKS01400
SK820-5E0 30-27
Control and regulation of the servo-control power supply
Control and regulation of the 2. Test the pressure of the travel pilot system
servo-control power supply a Test conditions:
q Machine raised from the ground
a Test conditions: 1. Disconnect the pipe (1) of the actuator to be
q Engine: 2550 rpm tested, mount a union tee and a pressure
q Hydraulic oil temperature: 45-55 °C.
k Before removing the plugs in order to measure
adapter, and then reconnect the pipe (1).
a During travel in one direction, two actuators are
the pressures, release the residual pressures nevertheless activated.
in the circuits (see Elimination of residual Always check both pressures:
pressures - pressurisation of the tank) and
Action involved
place the safety.
k After having connected the pressure gauges,
Action
DA1 DA2 DB1 DB2
pressurise the tank (see "Elimination of Forwards Q Q

residual pressures - pressurisation of the Reverse Q Q
tank").
Right Q Q
Checking the pressure of the Left Q Q
servo-controls
1. Disconnetc the delivery pipe (1) and install a
tee and a adapter; riconnect the pipe (1).
2. Connect a pressure gauge [E1] (60 bar). A1 A2
E1
B1 B2
RKA44720

RKSA0200
3. Start the engine and bring it up to 2400 rpm

with all leers in neutral position. E1
4. Lower the safety bars and check the pressure.
a Normal pressure: 25-29 bar
RKSA0210
3. Lower the cab and sit in the driving seat.

4. Start the engine and bring it up to working
speed of 2400 rpm with all the levers in neutral
position.
30-28 SK820-5E0
Control and regulation of the servo-control power supply
5. Lower the safety bar, slowly activate the travel

lever in the direction of the test to be
performed, and then check the following
conditions:
q Pressure of wheels start rotation
q Pressure with the levers at full stroke
a Normal pressures:
- when the wheels start to turn: 4-7 bar
with levers at full stroke: 14±15 bar
Parking brake system pressure check

1. Disconnect the brake control hose (1); connect
a “T” fitting and a pressure tap and reconnect
the hose.
E1
RKSA1480
3. Lower the cab and sit in the driving seat.

4. Start the engine and bring it up to 2550 rpm
with all levers in neutral position.
5. Lower the safety bars; operate the parking
brake control and check the pressure.
a Parking brake pressure: min. 22 bar
SK820-5E0 30-29
Elimination of residual pressures - pressurisation of the tank
Elimination of residual pressures - Pressurising the tank

pressurisation of the tank a This operation should be performed every time
the oil-refuelling cap is moved for removal of
Elimination of pressures from the hydraulic the tubes or other hydraulic equipment.
circuits.
1. Start the engine and position the machine as in
1. Lower the working equipment to the ground the figure.
and stop the engine. 2. Stop the engine, loosen the tank cap (1) and
2. Turn the ignition key to the position I and, with then close it again.
safety bars lower, move the command lever in a This operation lets air into the tank when
all directions to release all pressure in the main the level of the remaining oil is at
hydraulic circuits and the servo-controls . minimum.
3. Return the ignition key to the O (OFF) position 3. Start the engine and lower the working
and remove it. equipment to the ground.
Elimination of pressure in the tank

k The hydraulic oil tank is of the sealed and
pressurised type.
When tubes are to be removed or disconnected
for controls or repairs, or when caps are
removed, tank pressure must be eliminated
using the following method:
1. Rest the working equipment on the ground and
stop the engine.
2. Slowly loosen the oil-refuelling cap (1) in order
to release residual pressure. RKS02430
RKSA0220
30-30 SK820-5E0
Bleeding air from the hydraulic circuits

Sequence of operations or procedures for bleeding the air
Procedures for bleeding air

1 2 3 4 5
Bleeding air Bleeding air
Starting engine Pressurising tank Starting tasks
from pump from cylinders
Substitution of hydraulic oil
Cleaning tank filter Q Q Q Q Q
Substitution filter Q Q Q Q
Repair - substitution pump
Removal of suction tube Q Q Q Q Q
Substitution - repair control valve Q Q Q Q

Repair - Substitution cylinders
Removal of cylinders tube Q Q Q Q
Repair - substitution travel

motors
Removal of tubes from travel Q Q Q
motors
Bleeding air from pump

1. Loosen and remove the cap (1) from the pump
body (2).
2. Pour hydraulic oil through the hole until the
entire casing is full.
3. Replace the cap (1).
RKSA1050
Starting engine
1. Start engine for 2-3 seconds and stop it.
2. Repeat this operation 5-6 times to bleed air in
suction piping.
3. Start the engine and run it at low idle for 10
minutes.
SK820-5E0 30-31
Bleeding air from the cylinders Bleeding air from any optional equipment
1. Run the engine at low idle and extend and a This method must be used for all the optional
retract each cylinder 4-5 times stopping the working equipment, unless otherwise indicated.
cylinder approx. 100 mm before the stroke end. 1. Each time an item of optional working
2. Operate each cylinder 3-4 times to the stroke equipment is installed, operate the equipment
end. repeatedly, with the engine at low idling, until all
3. Run the engine at high idling and operate each air has been completely eliminated.
cylinder 4-5 time to the stroke end to blees the
air completely.
4. Stop the engine and wait for at least 5 minutes.
(This will release the bubbles in the oil inside
the tank).
5. Check the oil level in tank and adjust if
necessary.
RKS02061
RKS02021
30-32 SK820-5E0
Shop Manual
SK820-5E0
SKID-STEER LOADER
SK820-5E0

SK820-5E0 F60003 and up
50 Disassembly and assembly 10-1
SK820-5E0 50-1
50 Disassembly and assembly Contents
Contents 30-2
50 Disassembly and assembly
How to read the manual .............................................................................................................................. 3
Coating materials list................................................................................................................................... 5
Removal and installation of engine hood .................................................................................................... 6
Tilting and lowering of cab .......................................................................................................................... 7
Removal and installation of battery ........................................................................................................... 10
Removal and installation of starting motor ................................................................................................ 11
Removal and installation of alternator....................................................................................................... 12
Removal and installation of muffler ........................................................................................................... 13
Removal and installation of turbocharger.................................................................................................. 14
Removal and installation of air intake filter................................................................................................ 15
Removal and installation of valve cover.................................................................................................... 16
Removal and installation of nozzle holder................................................................................................. 17
Removal and installation of injection pump............................................................................................... 18
Removal and installation of cylinder head................................................................................................. 21
Removal and installation of coolant liquid pump ....................................................................................... 23
Removal and installation of radiator group................................................................................................ 24
Removal and installation of fuel tank ........................................................................................................ 26
Removal and installation of cab ................................................................................................................ 28
Removal and installation of engine-pump group....................................................................................... 32
Removal and installation of hydraulic pump assembly ............................................................................. 35
Removal and installation of gear pump..................................................................................................... 37
Removal and installation of engine-pump coupling................................................................................... 38
Removal and installation of control valve.................................................................................................. 39
Removal and installation of PPC valve ..................................................................................................... 40
Removal and installation of hub wheel...................................................................................................... 41
Removal and installation of final drive....................................................................................................... 45
Removal and installation of lift cylinder ..................................................................................................... 46
Removal and installation of bucket cylinder .............................................................................................. 48
Disassembly and assembly of work equipment cylinders ......................................................................... 50
Removal and installation work equipment assembly ................................................................................ 55
Removal and installation of fulcrum lever ................................................................................................. 57
Removal and installation of lift lever.......................................................................................................... 58
Removal and installation of equipment support frame .............................................................................. 60
50-2 SK820-5E0
How to read the manual 50 Disassembly and assembly
How to read the manual

1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In "Removal" section, the work procedures,
r e mo v a l or i n s ta l l at i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their parts the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is described are described as [1], [2] ••• etc. and their part
in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in "Removal" section
tuted and should always be used are explained and listed below.
k
q : Special tools that will be useful if avail-
: Precautions related to work safety
able and are substitutable with tools
available on the market a: Guidance or precautions for the work
2) Distinction of new and existing special tools
[*1] : This mark shows that instructions or precau-
N: Tools newly developed for this
tions for parts installation work are given in
model. They have a new part num-
"Installation" section.
ber respectively.
R: Tools made available by redesign- 6 : Amount of oil or coolant to be drained
4
ing the existing tools which were
: Weight of part or component
developed for other models. Each
of them has a new part number
assigned by setting forward the Installation
part number of the existing tool. q Unless otherwise instructed, installation of parts
Blank: Tools already available for other is to be done in the reverse order to removal.
models. They can be used without q Instructions and precautions for parts installa-
any modification. tion is shown with the mark ([*1], [*2]...) which
3) Circle mark Q in sketch column: corresponds to the mark in "Removal" section.
q The sketch of the special tool is pre- q Common tools that are necessary for installa-
sented in the section of "Sketches of tion are described as [1], [2] • • • etc. and their
special tools". part numbers, part names and quantities are not
q Part No. of special tools starting with described.
79*T-***-****: q Marks shown in the "Installation" section stand
means that they are not available for the following.
from Komatsu Ltd. (i.e. tools to be
made locally). k : Precautions related to work safety
a: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
SK820-5E0 50-3
50 Disassembly and assembly How to read the manual
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In "Disassembly" section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] • • • etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substituted q The meanings of the symbols used in "Disas-
and should always be used. sembly" section are as follows.
k
q : Special tools that will be useful if avail-
: Precautions related to work safety
able and are substitutable with tools
available on the market. a: Guidance or precautions for the work
6:
2) Distinction of new and existing special tools
Amount of oil or coolant drained
N : Tools newly developed for this
model. They have a new part
number respectively. Assembly
R : Tools made available by redesign- q In "Assembly" section, the work procedures,
ing the existing tools which were precautions and know-how to do the work, and
developed for other models. Each the amount of oil and coolant to be replenished
of them has a new part number are described.
assigned by setting forward the q Common tools that are necessary for assem-
part number of the existing tool. bly are described as [1], [2] •• • etc. and their
Blank : Tools already available for other part numbers, part names and quantities are
models. They can be used without not described.
any modification. q The meanings of the symbols used in "Assem-
3) Circle mark Q in sketch column: bly" section are as follows.
k
q The sketch of the special tool is pre-
sented in the section of "Sketches of : Precautions related to work safety
special tools". a: Guidance or precautions for the work
2
q Part No. of special tools starting with
79*T-***-****: : Type of coating material
means that they are not available 3 : Tightening torque
5
from Komatsu Ltd. (i.e. tools to be
made locally). : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
50-4 SK820-5E0
Coating materials list 50 Disassembly and assembly
Coating materials list

The recommended coating materials prescribed in Komatsu Utility Shop Manuals are listed below:
Nomenclature Code Applications
Bostik 99 Used to apply rubber pads, rubber gaskets and cork plugs.
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is
Loctite 406 needed.
Loctite 222 Used for low resistance locking of screws, check nuts and adjustment nuts.
To prevent the loosening of bolts, nuts and plugs and the leakage of oil. Used for
Loctite 242 medium resistance locking of screws and nuts of every type, and for locking keys and
bearings.
Loctite 262 Used for high resistant of threaded parts that can be removed with normal tools.
Adhesives
Loctite 270 Used for high resistant locking and for sealing threaded parts, bolts and stud bolts.
Loctite 542 Used for sealing the union threads for hydraulic tubes.
Used for sealing rather exact plane surfaces when the option of possible future
Loctite 573 dismantling is required.
Used for high resistant locking of mechanical components that can be removed only
Loctite 601 after heating
Used to lock cylindrical couplings and for the permanent locking of threaded parts,
Loctite 675 and also to lock shafts to bearings, gears, pulleys, pins, bushings, etc.
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings
Loctite 542 in hydraulic circuits of less than 50 mm in diameter.
Used by itself on mounting flat surface

Gasket sealant Loctite 510 (Clearance between surfaces within 0.2 mm)
Used by itself on mounting flat surface

Loctite 518 (Clearance between surfaces within 0.5 mm
Antifriction compound Litio EP MS2 Applied to bearings and taper shaft to facilitate press-fitting and to prevent sticking,
(Lubricant including
NLGI 2 burning or rusting.
Molybdenum disulfide)
Grease Litio EP Applied to bearings, sliding parts and oil seals for lubrication, rust prevention and
(Lithium grease) NLGI 2 facilitation of assembling work.
Vaseline - Used for protecting battery electrode terminals from corrosion
SK820-5E0 50-5
50 Disassembly and assembly Removal and installation of engine hood
Removal and installation of

engine hood
Removal
k Completely lower the working equipment to the
ground and stop the engine.
k Turn the ignition key to position OFF to stop the
engine, wait at least one minute and turn the
battery main switch to OFF and extract it.
1. Remove the retainer screws (1) from hinges (2)
and (3).
2. While keeping the hood lifted, remove the
retainer nut (4) from the shock absorber (5).
[*1]
4 Engine hood: 17 kg
1 5
3
4
2 1
RKSA1800
Installation
q To install, reverse the removal procedure.
[*1]
a Check the centre and the lock engagement
adjustment.
50-6 SK820-5E0
Tilting and lowering of cab 50 Disassembly and assembly
Tilting and lowering of cab 6. Loosen the screws (5) (two to each side) and
raise the cab as far as the safety cables allow.
Tilting [*2]
1. Completely raise the working equipment and 7. Insert the safety pin.
secure them in their safety positions.
5
2. Drain the coolant liquid.
[*1]
6 Coolant liquid: max. 9 l
3. Loosen the four screws (1) and remove the
foot-rest (2).
RKSA1510
1 If the engine or the complete pump are to be

removed, proceed as follows.
2 8. Disconnect the four pipes (6) on the R.H. side,
the two servo-control supply-pipes (7), and the
four pipes (8) on the L.H. side.
[*3]
a To disconnect the pipes, remove the
retainer (9), push the pipe (6) completely
RKSA0240
inside the union (10) and extract the pipe
(6).
If the engine or the complete pump are to be a Mark the tubes to avoid exchanging them
removed. during re-assembly.
4. Remove engine hood (see "Removal and
installation of engine hood"). 10 9
With front door

5. Loose screws (3), remove the bracket (4) and 6
close the front door.
7
8
6
3 RKSA0261
RKSA1500
SK820-5E0 50-7
50 Disassembly and assembly Tilting and lowering of cab
9. Disconnect, the cable (12) of the accelerator 12. Remove the safety cotter pin (16) and the
command lever from the engine (11). washers (17).
[*4] 13. Remove the safety cotter pin.
14. Push the cab (15) gently towards its “at rest”
position to relieve the tension on the safety
cables (18), and disconnect them from the pins
11 (19).
12 k Apply a slight tension to the hoisting-tackle
c h a i n s t o p re v e n t t h e c a b f r o m m o v i n g
unexpectedly.
19 19
RKSA3070
With front door

18
10. Disconnect the heating system’s feed (13) and 18
return (14) pipes from the engine.
Drain engine coolant from the pipes and
16 17 16 17
disconnect the washer pipe from the washer
tank.
RKSA0283
13
15. Tilt the cab (15) slowly until the distance
between the centres of the dumper fixing hooks
(20) is 1100 mm.
a The distance of 1100 mm corresponds to
the maximum stretch of the dumper
hooks.
14 16. Remove the pins (19) of the dumper fixing
hooks (20).
RKAC5480
11. Attach the cab (15) to some hoisting tackle.
15
20
15
RKSA1820
RKSA1810
50-8 SK820-5E0
Tilting and lowering of cab 50 Disassembly and assembly
17. Position a stand “A”, about 1200 mm high, and [*4]

tilt the cab (15) until it is resting on the stand. a Adjust the stroke of the accelerator lever cable
a Make sure that the connecting cables (see "30 Testing and adjusting" - "Adjusting the
between the cab and the engine are not stroke of the accelerator cables").
being strained.
15
RKSA1830
Lowering
q To lower the cab back into position, reverse the
tilting procedure.
[*1]
1. Fill up the coolant liquid circuit to maximum
level.
5 Coolant liquid: approx. 9 l
2. Start the engine to circulate the coolant, and
check that there are no leaks.
3. Stop the engine, check the levels and, if
necessary, top them up.
[*2]
3 Screws: 110 Nm
[*3]
a Mount the nuts (1) on the hoses and connect
the pipes by pushing them fully home in their
seatings. Check correct connection by trying to
extract them.
RKSA1240
SK820-5E0 50-9
50 Disassembly and assembly Removal and installation of battery
Removal and installation of Installation

battery q To install, reverse the removal procedure.
Removal
1. Disconnect the negative cable (–) (1) and the
positive cable (+) (2) from the battery (3) in that
sequence.
3
1
RKSA3080
2. Loosen the nuts (4) that secure the battery

clamp (5) a release the tie-rods (6) of the
battery support.
4
5
RKSA3090
3. Tilt the battery clamp (5) towards the front of

the machine and lift out the battery.
RKSA3100
50-10 SK820-5E0
Removal and installation of starting motor 50 Disassembly and assembly

starting motor q To install, reverse the removal procedure.
Removal [*1]
1. Tilt the cab and secure it in its safety position. 3 Screws: 78.4-98 Nm
2. Remove the battery (1) (see "Removal and
installation of battery").
RKSA3110
3. Disconnect the cables (2) and (3).

4. Loosen the screws (4) and take out the starting
motor (5).
[*1]
3
5
RKSA0340
SK820-5E0 50-11
50 Disassembly and assembly Removal and installation of alternator

alternator q To install, reverse the removal procedure.
Removal [*1]
1. Tilt the cab and secure it in its safety position. a Adjust the tension of the fan-belt (see "30
Te s t i n g a n d a d j u s t i n g " - " C o n t r o l a n d
2. Remove the battery (see "Removal and
adjustment of the fan belt tension").
3. Disconnect the cable (1) and the connector (2).
RKSA3120
4. Loosen the screws (3) and (4) to leave the

alternator free to turn.
5. Free the pulley (5) from the fan-belt and take
out the alternator (6).
[*1]
3
5
RKSA3130
50-12 SK820-5E0
Removal and installation of muffler 50 Disassembly and assembly
Removal and installation of 4. Loose the screws (8).

muffler 5. Remove the muffler (4).
a A new seal (9) should be fitted each time
Removal
the muffler is removed.
engine, wait at least one minute and turn the 4

battery main switch to OFF and extract it. 7
1. Loosen the three screws (1) and remove the
9
foot-rest (2).
4
8
RKSA2330
2
Installation
1
RKAC5490
2. Loosen and remove the screws (3) fixing the

muffler (4).
RKSA2500
3. Mark the position of bracket (5).

Remove the four nuts (6) fixing the muffler (4)
to the turbocharger (7).
5
5
7
4
RKAC5500
SK820-5E0 50-13
50 Disassembly and assembly Removal and installation of turbocharger
Removal and installation of 4. Loosen the fitting (7) and disconnect the upper
turbocharger lubrication pipe (8) from the turbocharger (4).
a Seals (9) must be replaced at each
Removal
disassembly.
engine, wait at least one minute and turn the 8 7

1. Remove the muffler (see "Removal and 7 9

installation of muffler"). 4
2. Remove the insulating shield (1) from the
intake manifold.
1
4 RKSA2350
5. Loosen the clamp (10) and remove the lower

lubrication pipe (11).
RKAC5730
3. Loosen clamps (2), (3) and disconnect the

intake hose (5) and supply hose (6) from the
turbocharger (4). 10
11
3 6
4 RKSA2480
6. Loosen the nuts (12) and remove the

turbocharger (4).
a A new seal (13) should be fitted each time
the muffler is removed.
4
5
2
RKSA2470
4
13
12
12
RKSA2340
Installation
50-14 SK820-5E0
Removal and installation of air intake filter 50 Disassembly and assembly
Removal and installation of air

intake filter
Removal
1. Disconnect the connector (2) and hose (3) from
the washer tank (1).
2. Remove the tank (1) and disconnect the
connector (4) from the air filter (5) clogging
sensor.
3 2
RKAC5510
3. Loosen the screws (6) and remove the

complete air filter (5).
RKAC5520
Installation
SK820-5E0 50-15
50 Disassembly and assembly Removal and installation of valve cover
Removal and installation of 4. Disconnect the pipe (5), loosen the three
valve cover screws (6), remove the four centering bushings
(7) and the valve cover (8).
Removal
[*2]

5
1. Remove the air filter (1) (see "Removal and
6
installation of air intake filter").
1
8
7
RKAC5540
Installation
RKAC5521 [*1]
3 Pipe union: 29.4-34.3 Nm
2. Loosen the screws (2) and remove the clamp
(3). [*2]
a Check the state of the seal (9) on the valve
4 cover (8), and of the O-rings (10); thoroughly
3
clean the contact surface on the cylinder head.
3 Screw: 22.6-28.4Nm
2
10
8
RKAC5530
3. Remove the high-pressure pipes (4).

[*1]
4
3
4 2 RKA42750
RKSA3230
50-16 SK820-5E0
Removal and installation of nozzle holder 50 Disassembly and assembly

nozzle holder q To install, reverse the removal procedure.
Removal [*1]
k Turn the ignition key to position OFF to stop the 3 Screw: 9.8-11.8 Nm
engine, wait at least one minute and turn the [*2]
3
Screws: 22.6–28.4 Nm
1. Remove the air filter (see "Removal and
installation of air intake filter").
2. Remove the valve cover (see "Removal and
installation of valve cover").
3. Loosen the five screws (1) and remove the fuel
pipe (2).
a Take care to not damage the five gasket
(3).
[*1]
2
1 3
RKSA1680
4. Loosen the screws (4) and remove the four

bracket (5).
[*2]
5. Remove the complete injection nozzles (6).
4 4
5
6 6
RKSA1690
SK820-5E0 50-17
50 Disassembly and assembly Removal and installation of injection pump
Removal and installation of 4. Disconnect the oil dipstick (4) from the cylinder
injection pump head.
Removal
k Close the cock of separator to prevent fuel
leakage.
1. Remove the radiator group (see "Removal and
installation of radiator group").
2. Disconnect connector (1) and accelerator cable
(2).
RKSA3340
[*1]
5. Disconnect from injection pump (5) fuel feeding
pipes (6), return pipes (7), feedback pipe (8)
and the coolant pipes (9) and (10).
6. Disconnect high pressure pipes (11) from
injection pump (5).
2
[*2]
1
7
8 11
11
6
10
RKAC5550
9
3. Remove the air filter (3) (see "Removal and
installation of air intake filter"). 5
3
RKSA3300
7. Disconnect injection pump (5) lubricating pipe

(12).
RKAC5522
12
RKSA3310
50-18 SK820-5E0
Removal and installation of injection pump 50 Disassembly and assembly
8. Remove fan (13) and cover (14). 10. Remove pump (5) driving gear (16).
[*3] a Before removing pump driving gear, mark
position compared to idling gear.
a For removal, use a puller (X1) and tighten
its screws (X2) directly in the gear (16).
a During removal be careful not let key drop
(17) in the housing.
X2
20
14 18
13
RKSA3320
9. Loosen and remove nut (15) and lock washer

17 X1
(16) of pump driving gear.
[*4]
16 X2
a Be careful not let nut (15) and lock washer RKS03780
drop in the housing.

11. Loosen the four nuts (18).
[*5]
12. Loosen the three screws (19) and remove
injection pump (5) with O-rings (20).
[*6]
15
18
19
RKS03770
RKSA3330
SK820-5E0 50-19
50 Disassembly and assembly Removal and installation of injection pump
Installation
[*1]
a Check the stroke of the accelerator lever cable
(see "30 Testing and adjusting" - "Adjusting the
stroke of the accelerator cables").
[*2]
3 High pressure pipe: 29.4-34.3 Nm
[*3]
2 Cover surface: liquid gasket
3 Screws: 9.8–11.8 Nm
[*4]
a Align marks among gears before to install
pump and nut.
3 Nut: 78–88 Nm
[*5]
3 Pump lock nuts: 22.6–28.4Nm
a Check fuel injection timing (see "30 Testing

and adjusting" - "Control and adjustment of the
injection timing").
[*6]
3 Screw: 22.6–28.4 Nm
50-20 SK820-5E0
Removal and installation of cylinder head 50 Disassembly and assembly
Removal and installation of 8. Remove the injection nozzles (8) (see

cylinder head "Removal and installation of nozzle holder").
Removal
1. Drain the engine coolant.
[*1]
2. Remove the water coolant pump (see
"Removal and installation of coolant liquid
pump"). 8 8
RKSA3390
3. Remove filter (1) and bracket (2) (see
"Removal and installation of air intake filter"). 9. Disconnect the pre-heater cable (9).
4. Remove the muffler (3) (see "Removal and
installation of muffler").
1 3
9
RKAC5560
10. Remove the rocker-arm shaft (10).

RKAC5524
[*2]
5. Loosen the screws (4) and remove the a Loosen the lock nuts and unscrew the
complete fuel filter (5). valve tappets by 2-3 turns.
6. Remove the valve cover (6) (see "Removal and [*3]
installation of valve cover"). 11. Take out the rocker-arm control rods (11).
7. Disconnect the oil dipstick (7) from the cylinder
head.
10
11
6
7
RKS03810
5
RKAC5531
SK820-5E0 50-21
50 Disassembly and assembly Removal and installation of cylinder head
12. Take out the screws (12) in the sequence Installation

indicated and remove the complete cylinder q To install, reverse the removal procedure.
head (13).
[*4] [*1]
a The cylinder head gasket (14) must be 1. Fill up the coolant liquid circuit to maximum
substituted every time it is dismantled. level.
12 2. Start the engine to circulate the coolant, and

13 check that there are no leaks.
[*2]
3 Screws: 22.6-28.4 Nm
14
[*3]
a Adjust valve clearance (see "30 Testing and
adjusting" - "Adjustment of valve clearance").
RKS03820
[*4]
A: Exhaust side a Raise the cylinder head, keeping it horizontal,
B: Flywheel side and place it on the gasket without shifting
C: Intake side anything.
a Lubricate the screw-threads with engine oil.
a Tighten the screws in two steps in the
sequence given. (See figure).
3 First step: 41.1-46.9 Nm
A
7 16 14 6
Second step: 85.3-91.1 Nm
1 9 18 12 4 A: Exhaust side
B
B: Flywheel side
3 11 17 10 2
5 13 15 8
C: Intake side
RKA42870
A
12 3 5 13
18 10 1 7 15
B
16 8 2 9 17
14 6 4 11
RKA42880
50-22 SK820-5E0
Removal and installation of coolant liquid pump 50 Disassembly and assembly
Removal and installation of 5. Loosen the screws (5) and remove the
coolant liquid pump complete pump (6), the seal (7), and the O-ring
(8).
Removal
[*3]

1. Drain the hydraulic oil.

[*1]
6 Hydraulic oil: max. 38 l
6
[*1]
6 Coolant liquid: max. 9 l 7
5
3. Remove the radiator group (see "Removal and RKS01840
Installation
1 q To install, reverse the removal procedure.
[*1]
1. Fill the hydraulic oil tank up to maximum level.
level.
RKAC5570
3. Start the engine to circulate the oil and the

4. Loosen the screws (2), remove the fan (3) and coolant, and check that there are no leaks.
the spacer (4).
Loosen the alternator drive belt and disengage
the circulation pump pulley.
[*2] 5. Pressurize the hydraulic tank and bleed air
from the hydraulic circuits (see "30 Testing and
adjusting" - "Elimination of residual pressures -
3 pressurisation of the tank" - "Bleeding air from
the hydraulic circuits").
[*2]
a Adjust the tension of the fan-belt (see "30
Te s t i n g a n d a d j u s t i n g " - " C o n t r o l a n d
4 adjustment of the fan belt tension").
2
3 Screws: 9.8-11.8 Nm
[*3]
a A new seal (7) and new O-ring (8) must be
RKS01850
fitted each time the pump is removed.
3 Screw: 22.6-28.4 Nm
SK820-5E0 50-23
50 Disassembly and assembly Removal and installation of radiator group
Removal and installation of 6. Disconnect the cable (4) of the hydraulic-oil

radiator group clogging-sensor filter.
7. Loosen the clamp (5) and disconnect the
Removal
coolant liquid delivery pipe (6).
1. Tilt the cab and secure it in its safety position. 8. Disconnect the coolant liquid return pipe (7)
[*1]
4
[*1] 5
4. Disconnect the hose (2) from the pump (1). 6
a Plug the holes and tubes to prevent entry 7
of impurities.
5. Disconnect the coolant liquid drainage pipe (3)
from the radiator. RKSA0470
9. Insert the safety rear door opening (8) and

1 disconnect the power cord (9).
3
9 8
2
RKSA0460
RKAC5580
10. If provided, disconnect the plate light connector

(10).
10
RKAC5590
50-24 SK820-5E0
Removal and installation of radiator group 50 Disassembly and assembly
11. Remove the lower cover (11). Installation

[*1]
11 2. Fill up the coolant liquid circuit to maximum
level.
coolant, and check that there are no leaks.
RKAC5431
12. Attach the radiator group (12) to some hoisting necessary, top them up.
tackle and apply a slight tension to the cables. 5. Pressurize the hydraulic tank and bleed air
4
Radiator-oil cooler group: 62 kg
13. Loosen the screws (13), raise the radiator pressurisation of the tank" - "Bleeding air from
group (12) until the lower supports can be the hydraulic circuits").
released, and move it a little way away from the
[*2]
3
frame.
[*2] Screws: 190 Nm
12
13
13
RKAC5571
14. Disconnect the pipes (14) and (15) and remove

the complete group (12).
a Plug the holes and tubes to prevent entry
of impurities.
14
15
RKAC5610
SK820-5E0 50-25
50 Disassembly and assembly Removal and installation of fuel tank
Removal and installation of fuel 4. Disconnect the hoses (7) and (8) from level
tank sensor (6).
Removal
1. Drain the fuel.

6 Fuel: approx. 68 l 7 6
[*1]
2. Remove the screws (1) and loosen the screws
(2), leaving them in place.
[*2]
RKAC5630
5. Take off the screw (9) and remove bracket (10).
1
1
9
2
2 10
RKAC5572
3. Disconnect the acoustic alarm (4) connector (3)

and clamp (5). RKAC5640
6. Disconnect the connector (11). Loosen and

5 remove the nuts (12) and the bracket (13).
3
11
13
4
14
RKAC5620
12
RKAC5650
50-26 SK820-5E0
Removal and installation of fuel tank 50 Disassembly and assembly
7. Slide off the tank (14) from the rear.

support (16).
9. Remove the complete tank.
16
15
RKSA2451
Installation
[*1]
1. Fill up the fuel.
5 Fuel: approx. 68 l
[*2]
3 Screws: 190 Nm
SK820-5E0 50-27
50 Disassembly and assembly Removal and installation of cab
Removal and installation of cab With front door

Removal 6. Loose screws (5), remove the bracket (6) and
close the front door.
1. Remove the complete working equipment (see
"Removal and installation work equipment
assembly"). 5
[*1]
6
3. Loosen the nuts (1) and tilt the rear panel (2)
towards the front of the machine.
RKSA1501
1 2 1 7. Disconnect the connectors (7) from the cab

cabling (8) and release the engine cabling (9)
from its retaining clamps.
9
1 1 RKSA0520 8
foot-rest (4).
RKSA0531
8. Loosen the screws (10) (two to each side) and

3 raise the cab as far as the safety cables allow.
[*2]
4
9. Insert the safety pin.
10
RKSA0241
5. Remove engine hood (see "Removal and

installation of engine hood").
RKSA1511
50-28 SK820-5E0
Removal and installation of cab 50 Disassembly and assembly
10. Disconnect the four pipes (11) on the R.H. side, With front door
the two servo-control supply-pipes (12), and 12. Disconnect the heating system’s supply (16)
the four pipes (13) on the L.H. side. and return (17) hoses from the engine and
a To disconnect the pipes, remove the drain any engine coolant from the hoses.
r e t a i n e r ( 1 4 ) , p u s h t h e p i p e ( 11 ) a Mark the hoses to avoid mixing them
completely inside the union (15) and during installation.
extract the pipe (11).
Re-assemble the clamp (14) on the pipe
(11). 16
a Mark the tubes to avoid exchanging them
during re-assembly.
[*3]
11. Pull out the cab cabling (9).
17
RKAC5481
13. Disconnect the hose (19) from the washer tank

(18).
12 11
13
RKSA0541 19
15 18
14
RKAC5511
9 14. Disconnect, the cable (21) of the accelerator

11 command lever from the engine (20).
[*4]
RKSA0551
20
21
RKSA3471
SK820-5E0 50-29
50 Disassembly and assembly Removal and installation of cab
15. Attach the cab (22) to some hoisting tackle. 20. Loosen the nuts (28) and remove the screws
(29) and washers (30).
21. Remove the complete cab (22).
22
30
28 29
RKSA1931
16. Remove the safety cotter pin (23) and the

RKSA1941
washers (24).
17. Push the cab gently towards its “at rest”
position to relieve the tension on the safety
cables (25), and disconnect them from the pins
(26).
k Apply a slight tension to the hoisting-tackle
chains to prevent the cab from moving
unexpectedly.
18. Tilt the cab slowly until the distance between
the centres of the dumper fixing hooks is 1100
mm.
a The distance of 1100 mm corresponds to
the maximum stretch of the dumper
hooks.
19. Remove the pins (26) of the dumper fixing
hooks (27).
26 26
27
27
25
23 24 23 24
RKSA0285
50-30 SK820-5E0
Removal and installation of cab 50 Disassembly and assembly
Installation
q Fill up the coolant liquid circuit to maximum
level.
q Start the engine to circulate the coolant
liquid.
q Stop the engine and top them up.
[*1]
level.
2. Start the engine to circulate the coolant, and
check that there are no leaks.
[*2]
3 Screws: 110 Nm
[*3]
a Mount the nuts (1) on the hoses and connect
the pipes by pushing them fully home in their
seatings. Check correct connection by trying to
extract them.
RKSA1240
[*4]
a Adjust the stroke of the accelerator lever cable
SK820-5E0 50-31
50 Disassembly and assembly Removal and installation of engine-pump group
Removal and installation of 7. Remove the cover of the control unit (1) and
engine-pump group disconnect the connectors (2), (3) and (4) that
connect the control unit (1) to the frame wiring
Removal
harness (5).

battery main switch to OFF and extract it. 1 3 4
2
[*1]
[*1]
3. Drain the fuel. 5
6 Fuel: approx. 68 l RKSA0570
[*1] 8. Loosen the nuts (6) and disconnect the control

4. Tilt the cab until it is resting on a support (see unit from the frame (7).
"Tilting and lowering of cab").
[*2]
6
6
RKSA0580
RKSA1831
9. Disconnect the connector (8) from the fuel level
sensor (9) and remove the screw (10) retaining
5. Remove the battery (see "Removal and the electric harness (11).
6. Remove the radiator group (see "Removal and
11
8
9
10
RKAC5660
50-32 SK820-5E0
Removal and installation of engine-pump group 50 Disassembly and assembly
10. Disconnect the servo-control pressure sensor 14. Disconnect the pipes (24), (25), (26), and (27)
connectors (12) and disconnect the support from the pump.
(13) from the engine (14). a Mark the tubes to avoid exchanging them
11. Disconnect the accelerator pedal cable (15) during re-assembly.
from the engine (14).
14 27
13
12
15 25
26
24 RKAC5690
RKAC5670
With front door
12. Disconnect the delivery (18) and return (19) 15. Disconnect the heating system’s supply (28)
pipes from the prefilter (16) and the filter (17). and return (29) hoses from the engine and
drain any engine coolant from the hoses.
28
18
17
16
29
18
RKAC5551
RKAC5482
13. Disconnect the pipes (21), (22) and (23) from
the pump (20). 16. Attach the engine-pump group to some hoisting
a Mark the tubes to avoid exchanging them tackle and apply a slight tension to the cables.
during re-assembly. 17. Loosen the four nuts (30) that secure the
engine and remove the complete group.
[*3]
4 Engine-pump group: 290 kg
20
30
23
21 22
RKAC5680
RKSA3620
SK820-5E0 50-33
50 Disassembly and assembly Removal and installation of engine-pump group
Installation
[*1]
level.
3. Fill up the fuel.
5 Fuel: approx. 68 l
6. Pressurize the hydraulic tank and bleed air
pressurisation of the tank" - "Bleeding air from
[*2]
[*3]
3 Nuts: 60-75 Nm
50-34 SK820-5E0
Removal and installation of hydraulic pump assembly 50 Disassembly and assembly
Removal and installation of 5. Disconnect the pipes (5), (6), (7), and (8) from
hydraulic pump assembly the pump.
a Mark the hoses to avoid mixing them
Removal
during installation.

8
[*1]
7
[*1]
3. Tilt the cab until it is resting on a support (see 5
6
"Tilting and lowering of cab"). RKAC5691
[*2]
6. Disconnect the servo-control pressure sensor
connectors (9) and disconnect the support (10)
from the engine (11).
11
10
RKSA1831
4. Disconnect the pipes (2), (3) and (4) from the 9

pump (1). RKSA3550
a Mark the hoses to avoid mixing them With front door

during installation.
7. Disconnect the heating system’s supply (12)
and return (13) hoses from the engine and
drain any coolant from the hoses.
1 during installation.
12
4
2 3
RKAC5681
13
RKAC5483
SK820-5E0 50-35
50 Disassembly and assembly Removal and installation of hydraulic pump assembly
8. Attach the pump (1) to some hoisting tackle Installation

and apply a slight tension to the cables. q To install, reverse the removal procedure.
[*1]
2. Bleed the air from the pump (see "30 Testing
and adjusting" - "Bleeding air from pump").
level.
1 6. Pressurize the hydraulic tank and bleed air
pressurisation of the tank" - "Bleeding air from
[*2]
RKSA1960
9. Loosen the eight screws (14) and remove the [*3]
pump (1) complete with the flange (15). 3 Screws: 80 Nm
2
[*3]
Screws: Loctite 262
4 Pump: max. 88 kg 2 Pump shaft: Lithium EP MS2 NLGI 2
10. Loosen the screws (16) and disconnect the [*4]
pump (1) from the flange (15). 3 Screw: 195 Nm
2
[*4]
Screw: Loctite 262
15
1
16
14
RKSA0651
50-36 SK820-5E0
Removal and installation of gear pump 50 Disassembly and assembly
Removal and installation of gear Installation

pump a To install, reverse the removal procedure.
Removal [*1]
k Turn the ignition key to position OFF to stop the 1. Fill the hydraulic oil tank up to maximum level.
5
battery main switch to OFF and extract it. Hydraulic oil: max. 38 l
level.
[*1]
5
6 Coolant liquid: max. 9 l Coolant liquid: approx. 9 l
2. Drain the hydraulic oil. 3. Start the engine to circulate the oil and the
[*1] coolant, and check that there are no leaks.
6 Hydraulic oil: max. 38 l 4. Stop the engine, check the levels and, if
3. Tilt the cab and secure it in its safety position.
4. Disconnect from the pump (1) the suction pipe from the hydraulic circuits (see "30 Testing and
(2) and the pipe (3) (one for the normal version, adjusting" - "Elimination of residual pressures -
two for the High-flow version). pressurisation of the tank" - "Bleeding air from
1 [*2]
3
2 Screws: 59-74 Nm
4
3
RKSA0660
5. Loosen the two screws (4) and remove the

pump (1) complete with the O-ring (5).
[*2]
4 RKS01740
SK820-5E0 50-37
50 Disassembly and assembly Removal and installation of engine-pump coupling

engine-pump coupling q To install, reverse the removal procedure.
Removal [*1]
k Turn the ignition key to position OFF to stop the 1. Fill the hydraulic oil tank up to maximum level.
5
battery main switch to OFF and extract it. Hydraulic oil: max. 38 l
level.
[*1]
5
6 Coolant liquid: max. 9 l Coolant liquid: approx. 9 l
2. Drain the hydraulic oil. 3. Start the engine to circulate the oil and the
[*1] coolant, and check that there are no leaks.
6 Hydraulic oil: max. 38 l 4. Stop the engine, check the levels and, if
3. Tilt the cab (see "Tilting and lowering of cab").
4. Remove the pump (see "Removal and from the hydraulic circuits (see "30 Testing and
installation of hydraulic pump assembly"). adjusting" - "Elimination of residual pressures -
5. Take out the three screws (1) and remove the pressurisation of the tank" - "Bleeding air from
coupling (2). the hydraulic circuits").
[*2] [*2]
3
a Replace screws (1) every dismantling. Screws: 80 Nm
2
1
RKAC5700
50-38 SK820-5E0
Removal and installation of control valve 50 Disassembly and assembly
Removal and installation of 5. Loosen the three screws (6) and remove the
control valve control valve (3).
[*2]
Removal
k Release residual pressures from all circuits and
from the tank (see "30 Testing and adjusting" -
"Elimination of residual pressures -
pressurisation of the tank").
[*1]
RKS01880

foot-rest (2).
Installation
[*1]
1
5
2. Start the engine to circulate the oil and check
that there are no leaks.
RKSA0240
3. Tilt the cab and secure it in its safety position. adjusting" - "Elimination of residual pressures -
4. Disconnect from the control valve (3) the pressurisation of the tank" - "Bleeding air from
servocontrol pipes (4), the delivery pipes to the the hydraulic circuits").
actuators and the delivery and return pipes (5. [*2]
3
Control valve screws: 35 Nm
during re-assembly.
3
4
5
RKAC5711
SK820-5E0 50-39
50 Disassembly and assembly Removal and installation of PPC valve
Removal and installation of PPC 8. Disconnect the six pipes (10) from the PPC
valve valve and plug the tubes to prevent entry of
impurities.
Removal a Check the marks on the tubes to avoid
1. Lower the working equipment until it is resting exchanging them during re-assembly.
on the ground, stop the engine and remove the [*1]
ignition key.
k Turn the ignition key to position OFF to stop the Installation
engine, wait at least one minute and turn the q To install, reverse the removal procedure.
[*1]
2. Release residual pressures from all circuits and a Check very carefully the positions for the pipe
from the tank (see "30 Testing and adjusting" - connections.
"Elimination of residual pressures -
pressurisation of the tank"). L.H. PPC valve
3. If provided, remove the heater group.
4. Raise the switch-box cover (1) disconnect the
connectors (2) and remove the cover (1).
5. Remove cap (3).
a Take care not to damage the frame (4).
6. Loosen the four screws (5) and remove the P2
P T
casing (6).
2 P4
1 P3 P1
6 RKSA0710
Position
P T P1 P2 P3 P4
3 M S A R L R
White White Yellow Yellow Blue Blue
4
R.H. PPC valve
5 RKAC5720
7. Take out the three screws (7) and disconnect

the PPC valve (8) from the support (9).
P2
P T
9 7 P4
P3
P1
RKSA0720
8 Position
P T P1 P2 P3 P4
10
RKSA0700
M S D S C A
White White Red Red Yellow Yellow
k If the union pieces are dismantled from the

PPC valves, make sure that a union with a filter
is mounted at the P inlet.
50-40 SK820-5E0
Removal and installation of hub wheel 50 Disassembly and assembly
Removal and installation of hub 4. Loosen the nuts (5) and remove the cover (6).
wheel [*2]
a Check the condition of the seal (7) and
Removal install a new one if necessary.
1. Place the machine on blocks that are high
enough to raise the wheels from the ground,
and fully raise the working equipment. 5
5
6
7
RKSA0740
5. Start the engine and allow the pinion (8) to turn

RKS02530 slowly until the master links (9) are both
positioned on the upper section of the chain.
2. Loosen the nuts (1) and remove the wheel (2). 6. Remove the pins (10) and pull out the master
[*1] link (9).
[*3]
9
9
8
10
1
2
RKSA0730
RKSA0750
3. Loosen the drainage plug (3) in order to drain

the chain-gearing lubrication oil.
6 Gear-box oil: max. 15.5 l
a To facilitate oil drainage, remove the vent
plug (4).
RKSA1190
SK820-5E0 50-41
50 Disassembly and assembly Removal and installation of hub wheel
7. Turn the wheel hub (11) to release it from the Installation

chain. q To install, reverse the removal procedure.
8. Attach the complete hub (11) to some hoisting
[*1]
tackle and apply a slight tension to the cables.
3 Nuts: 186 Nm
9. Loosen the nuts (12) and remove the hub (11).
[*4] [*2]
a Check the condition of the O-ring and put 3 Nuts: 45 Nm
in a new one if necessary. [*3]
4 Hub: 55 kg a Make sure that the master link (9) is in the
correct position with respect to the pinion.
12 11
9 9
12 11
RKSA0760
RKS01760
1. Adjust the tension of the chain (see "30 Testing

and adjusting" - "Testing and adjustment of
gearing chain tension").
2. Fill the oil up to maximum level (A).
5 Gear-box oil: max. 15.5 l
RKA42860
[*4]
3 Nuts: 196 Nm
50-42 SK820-5E0
Disassembly and assembly of wheel hub 50 Disassembly and assembly
Disassembly and assembly of 5. Position the wheel hub (1) beneath a press and
wheel hub slowly extract the axle shaft (6) until it is
released from the inner ring (7).
Disassembly a Place the wheel hub (1) on two supports
1. Remove the wheel hub (1) (see "Removal and [A], about 520 mm high.
installation of hub wheel"). 6. Remove the inner ring (7).
7. Proceed with the extraction of the axle shaft (6)
until it is released from the bearing (8).
[*3]
6 7
A A
RKSA0761
8
2. Place the wheel hub (1) in a vice and loosen
the screws (2). RKS01860
[*1]
3. Remove the disk (3) and the shims (4). 8. Place the hub (1) in a vice and extract the seal
a Make a note of the number and positions ring (9).
of the shims (4). a Mount a new seal ring (9) each time the
[*2] hub is dismantled.
[*4]
1 9. Extract the outer rings (7) and (8).
2 1
9
7
3
4
RKSA0780 8
4. Remove the ring bevel gear (5).
a Make a note of which way the ring bevel RKSA0800
gear (5) is facing with respect to the hub

(1).
RKSA0790
SK820-5E0 50-43
50 Disassembly and assembly Disassembly and assembly of wheel hub
Assembly
q To assembly, reverse disassembly procedure.
[*1]
3 Screw: 294±10 Nm
2 Loctite 262
[*2]
1. Take the existing measurement “X” between
the axle shaft (6) and the ring bevel gear (5).
x
5
RKSA0810
2. Calculate the thickness of shim that should be

inserted between the disc (3) and the ring bevel
gear (5) using the following formula:
Z=X–S
S = the shim pack
X = the measurement taken
Z = residual clearance (0.05–0.125)
q For example: clearance measured X = 0.570
addition of two shims of 0.2 and one of 0.1
3. Check that the measurement X lies within the
permissible limits.
[*3]
a Grease the bearings (7) and (8).
2 Bearings: Lithium EP NLGI 2
[*4]
a Grease the lip of the seal ring (9).
2 Seal ring: Lithium EP NLGI 2
50-44 SK820-5E0
Removal and installation of final drive 50 Disassembly and assembly
Removal and installation of final 4. Attach the final drive (2) to some hoisting tackle
drive and apply a slight tension to the ropes.
Removal
1. Disconnect the gearing chains (1) from the final
drive (2) (see "Removal and installation of hub 2
wheel").
RKSA0840
2 5. Loosen the ten screws (6) and take out the

complete final drive (2).
a Check the condition of the O-ring (7) and
substitute a new one if necessary.
4 Final drive: 54 kg
1
RKSA0820
2. Remove the hydraulic pump assembly (see 2

"Removal and installation of hydraulic pump
assembly"). 7
3. Disconnect from the final drive (2) the supply
pipes (3), the speed increment pipe (4) and the
drainage pipe (5).
a Plug the tubes to prevent entry of 6
impurities.
RKSA0850
Installation
2
[*1]
a Grease the O-ring.
3 2 O-ring: Lithium EP NLGI 2
3 Screws: 120 Nm
4 2 Screws: Loctite 270
RKSA0830
SK820-5E0 50-45
50 Disassembly and assembly Removal and installation of lift cylinder
Removal and installation of lift 5. Loosen the 4 screws (7) and remove the lower
lock.
cylinder
Removal
k Lower the working equipment until it is resting
on the ground.
k Release residual pressures from all circuits
(see "30 Testing and adjusting").
k Turn the ignition key to position OFF to stop the 7
1. Remove the complete working equipment.

(See "Removal and installation work equipment RKSA2040
assembly").
2. Remove the lift lever. (See "Removal and 6. Remove the clamps (9); disconnect the hoses
installation of lift lever"). (10) from the fittings (11).
3. Loosen the screws (1) and remove the front a Mark the hoses to avoid mixing them
bracket (2) retaining the plate (3). during installation.
a Plug the hoses (10) and fittings (11) to
prevent foreign material from entering.
1 10
2
9
10 11
3
10
RKSA2020
4. Push the cylinder (4) towards the front of the 9 RKSA2050
machine, loosen the screws (5), remove the rear

bracket (6) retaining the plate (3) and remove the 7. Connect the cylinder (4) to a hoist, tension the
plate. belt, loosen the screw (12) and remove the pin
(13).
[*1][*2]
8. Remove the cylinder (4) together with the hoses
4 5 (10).
4 12
13
6
10
3
RKSA2030
RKSA2060
50-46 SK820-5E0
Removal and installation of lift cylinder 50 Disassembly and assembly
Installation
[*1]
2 Inside the bushings: Lithium EP MS2 NLGI 2
3 Screws: 49 Nm
[*2]
k When aligning the positions between the hole
and the pin, run the engine at low idling.
Do not insert fingers into the holes to check
alignment.
1. Start the engine and bleed the air from the
cylinder (see "30 Testing and adjusting").
a After bleeding the air, check the level of oil
in the tank.
SK820-5E0 50-47
50 Disassembly and assembly Removal and installation of bucket cylinder
Removal and installation of 2. Disconnect the pipes (4) and (5) from the
bucket cylinder cylinder (3).
a Plug the tubes to prevent entry of
Removal
k Lower the working equipment and rest the
impurities.
equipment support frame on the ground. during re-assembly.
RKSA0920

RKSA2070
3. Remove the pin (6) and take away the cylinder

engine, wait at least one minute and turn the (3).
battery main switch to OFF and extract it. [*1][*3]
a Check and make a note of the position of
1. Remove the pin (1) and fully retract the piston the adjustments to a given clearance.
rod (2).
[*1][*2]
the adjustments to a given clearance.
6 3
2
RKSA0930
RKSA0910
50-48 SK820-5E0
Removal and installation of bucket cylinder 50 Disassembly and assembly
Installation
[*1]
and the pin, do not insert fingers into the holes
to check alignment.
3 Screws: 49 Nm
[*2]
a Insert the removed shims and, if necessary,
add more until the residual clearance is about 1
mm.
MAX 1mm MAX 1mm
RKS03830
[*3]
a Insert the removed shims and, if necessary,
add more until the residual clearance is about 1
mm.
1. Start the engine and bleed the air from the
cylinder (see "30 Testing and adjusting").
a After bleeding the air, check the level of oil
in the tank.
MAX 1mm MAX 1mm RKS02460
SK820-5E0 50-49
50 Disassembly and assembly Disassembly and assembly of work equipment cylinders
Disassembly and assembly of 4. Unscrew the head (3) and extract it completely
work equipment cylinders from the cylinder (2).
Disassembly
1. Take off the guard rings (1) from both sides of
the cylinder and from the piston rod. 2 3
a Make sure that the tube unions are not
plugged.
RKSA1080
5. Raise the cylinder and hook the piston rod to

the mobile group of the tool [A].
6. Extract the piston rod group (4) from the
cylinder.
1
RKS01660 7. Remove the cylinder (2) and the piston rod
group.
2. Place the cylinder (2) on the apparatus [A].
Engage the cylinder in the tools [B], having the
same bushing diameter.
B 4
2 A
RKSA1060
2
3. Attach the special wrench [C] (adjusted to fit
the cylinder) to the head (3) and apply the
dynamometric tool [D].
D
C
3
RKSA1090
RKSA1070
50-50 SK820-5E0
Disassembly and assembly of work equipment cylinders 50 Disassembly and assembly
8. Lock the complete piston rod (4) onto the 2. Mount the snap ring (8).
apparatus [A]. 3. Using the tool [G], mount the lip-seal (9).
9. Attach the socket wrench [E] to the lock nut (5) a Check that the lips face into the cylinder.
of the piston (6) and, using the dynamometric
tool with a multiplier [D], remove the nut.
a Socket wrench measurement: 32 mm
8
10. Take all the groups to pieces and remove all
the seals, guard rings and guide rings.
k The seals, guard rings, and guide rings cannot G
be used again.
9
4 6
RKSA1120
4. Mount the O-ring (10), the anti-extrusion ring

(11) and the O-ring (12) onto the cylinder head
5 (3).
E D
10 3 11 12
RKSA1100
Assembly
a Take great care not to damage the seal and the
sliding surfaces. 8
a Prepare each individual component before
commencing the final assembly.
7 9
RKS01800
1. Assembly of the cylinder head
1. Position the guard ring (7) and, using a press
and the push rod [F], press it home in the head
(3).
a Check the orientation carefully.
7
F
3 3
RKSA1110
SK820-5E0 50-51
2. Piston assembly 3. Piston rod group assembly

1. Using the tool [H], mount the piston seal. Mount 1. Using a press and the tool [B] adapted to the
in sequence the rubber ring (13), the outer seal diameter, insert the bushing (17) into the piston
(14) and the anti-extrusion rings (15). rod (4).
2. Insert the support [K] beneath the piston rod.
4
17
13 14 15
B
RKSA1130 K
RKSA1150
2. Mount the guide ring (16).
3. Calibrate the diameter of the gasket (14) of the 3. Mount the pilot boss [L] adapted to the
piston (6), mounting the group beneath the diameter onto the extremity of the piston rod.
press and using the calibrating ring [J] adapted 4. Slide the head (3) onto the piston rod (4).
to fit the piston diameter.
5. Remove the pilot boss [L] from the extremity of
the piston rod.
15 14 15 16
J
4 L 4 3
13
RKSA1140
RKSA1160
6. Mount the complete piston (6).
RKSA1170
50-52 SK820-5E0
Disassembly and assembly of work equipment cylinders 50 Disassembly and assembly
7. Mount the nut (5) that secures the piston and 4. Cylinder assembly
tighten it with the socket wrench [E] and the
1. Mount the tools [A] onto the apparatus [B].
dynamometric tool with a multiplier [D].
2 Nut: Loctite 262 2. Position the bushing (19) and mount it onto the
3 Nut:
cylinder (2).
Lifting cylinder: 422±42 Nm a Leave the cylinder in position, ready for
Bucket cylinder: 343±34 Nm the next assembly operation.
2 A
5 D
E
19
RKSA1061
RKSA1101
3. Lubricate the threading and the first part of the

cylinder (2).
4. Mount the two halves of the tool [M], adapted to
the diameter, onto the mouthpiece of the
cylinder (2).
2 M
RKSA1180
SK820-5E0 50-53
5. Mount the piston rod group (4) onto the tool [A] 8. Remove the tool [M] from the cylinder and then
and raise the mobile part up to the end of its lower the apparatus [A] even further, until the
stroke. head (3) and the piston rod approach the
6. Put the cylinder (2) into a vertical position and cylinder.
guide the piston into the tool [M]. 9. Place the cylinder (2) in position for screwing in
7. Lower the apparatus supporting the piston rod the head (3).
(4) in order to insert the piston into the cylinder 10. Insert the head into the cylinder and screw it in
liner (2). by hand for a few turns.
11. Attach the special wrench [C] to the
dynamometric tool [D] and screw the head (3)
fully home.
3 Head:
Lifting cylinder: 412±41 Nm
4 Bucket cylinder: 441±44 Nm
12. Mount the guard rings (1) on both sides of the
A cylinder and the piston rod.
M D
C
3
2
2
RKSA1071
RKSA1091
50-54 SK820-5E0
Removal and installation work equipment assembly 50 Disassembly and assembly
Removal and installation work 4. Disconnect the hoses (7) and (8).
equipment assembly during installation.
Removal a
Plug hoses (7) (8) and pipes (9), (10) to
prevent foreign bodies from entering.
on the ground.
k Release residual pressures from all circuits 8
7 10
(see "30 Testing and adjusting"). 9
Road-homologation version
1. Remove the rear headlight support (1).
rear-view mirrors (3).
1
RKSA2100
5. Connect the complete arm (4) to a hoist and

tension the cables.
2
a Cable length: 2 m
4
RKSA2080
3. HIGH-FLOW version: Disconnect the power

socket (5) and electrical harness (6) from the arm
(4).
6
5 RKSA2110
6. Remove the snap ring (11) and 6 shims (12).

7. Loosen the screw (14) and remove the pin (15).
a Check for a damaged seal (13). Replace if
necessary.
4 [*1]
11
RKSA2090
12
14
13
15
RKSA2290
SK820-5E0 50-55
50 Disassembly and assembly Removal and installation work equipment assembly
8. Introduce wooden shims [A] between the lift lever Installation

(16) and fulcrum lever (17).
[*1]
A
16 alignment.
17
[*2]
a Insert shims between the boom and the frame
until the residual clearance is less than 1 mm.
RKSA2120
MAX 1mm MAX 1mm

9. Lift the arm until the tool holder frame fulcrum pin
and the arm fulcrum pin line up.
RKS02480
1. Start the engine to circulate the oil, and bleed

the air from the circuits.
RKS02470
a After bleeding the air, stop the engine and
check the level of oil in the tank.
10. Loosen the screw (18), remove the pin (19) and
remove the working equipment.
a Check for damaged seals (20); replace if
necessary.
a Check and make a note of the position of the
adjustments to a given clearance.
[*1][*2]
4 Working equipment (without bucket):
approx. 300 kg
19
20 18
RKSA2300
50-56 SK820-5E0
Removal and installation of fulcrum lever 50 Disassembly and assembly

fulcrum lever q To install, reverse the removal procedure.
Removal [*1]
k Lower the working equipment until it is resting k When aligning the positions between the hole
on the ground. and the pin, run the engine at low idling.
k Release residual pressures from all circuits Do not insert fingers into the holes to check
(see "30 Testing and adjusting"). alignment.
(See "Removal and installation work equipment 3 Screws: 49 Nm
assembly"). [*2]
2. Connect the lever (1) to a hoist and slightly a Insert shims between the boom and the frame
tension the cable. until the residual clearance is less than 1 mm.
[*1] MAX 1mm MAX 1mm
3
2
1
RKS02490
RKSA2130 1. Start the engine to circulate the oil, and bleed

a Check for damaged seals (4); replace if
necessary.
[*2]
RKS02500
SK820-5E0 50-57
50 Disassembly and assembly Removal and installation of lift lever
Removal and installation of lift 4. Lift the lever (1) until the centre hole on the
lever lever and the fulcrum hole on the frame line up.
Removal
on the ground.
k Release residual pressures from all circuits
(see "30 Testing and adjusting").
(See "Removal and installation work equipment
assembly").
2. Introduce a pin into the centre hole on the lever
(1), connect a hoist and slightly tension the
RKS02510
cables.
5. Loosen the screw (4), remove the pin (5) and
remove the lever (1).
1 a Check for damaged seals (6); replace if
necessary.
[*1][*2]
RKSA2140
6
[*1]
5 4
2 RKSA2310
RKSA2150
50-58 SK820-5E0
Removal and installation of lift lever 50 Disassembly and assembly
Installation
[*1]
alignment.
3 Screws: 49 Nm
[*2]
a Insert shims between the boom and the frame
until the residual clearance is less than 1 mm.
MAX 1mm MAX 1mm RKS02520
1. Start the engine to circulate the oil, and bleed

SK820-5E0 50-59
50 Disassembly and assembly Removal and installation of equipment support frame

equipment support frame q To install, reverse the removal procedure.
Removal [*1]
1. Lower the working equipment until the a Insert the removed shims and if necessary add
supporting frame is lying flat on some blocks more until the residual clearance is less than 3
[A]. mm.
[*2]
alignment.
A
RKSA2160
2. Remove the pins (1) and retract the cylinder

piston rods (2).
[*1][*2]
RKSA0990
3. Remove the pins (3) and take off the complete

working equipment support frame (4).
[*3]
4 Equipment support frame: 57 kg
3
4
RKSA1000
50-60 SK820-5E0
Shop Manual
SK820-5E0
SKID-STEER LOADER
SK820-5E0

SK820-5E0 F60003 and up
90 Diagrams and drawings 30-1
SK820-5E0 90-1
Contents
Contents 30-2
90 Diagrams and drawings
Hydraulic diagrams ..................................................................................................................................... 3
Hydraulic diagram (float).......................................................................................................................... 3
Hydraulic diagram (float - road homologation)......................................................................................... 5
Hydraulic diagram (float - road homologation - Slow Speed control)....................................................... 7
Hydraulic diagram (High-flow).................................................................................................................. 9
Hydraulic diagram (High-flow - road homologation)............................................................................... 11
Hydraulic diagram (High-flow - road homologation - Slow Speed control) ............................................ 13
Electrical circuit diagrams ......................................................................................................................... 15
90-2 SK820-5E0
Hydraulic diagrams Diagrams and Drawings
Hydraulic diagram (float)
Hydraulic diagrams
Hydraulic diagram (float)
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Hydraulic diagram (float - road homologation)
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Hydraulic diagram (float - road homologation - Slow Speed control)
Hydraulic diagram (float - road homologation - Slow Speed control)
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Hydraulic diagram (High-flow)
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Hydraulic diagram (High-flow - road homologation)
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Hydraulic diagram (High-flow - road homologation - Slow Speed control)
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90-13
Electrical circuit diagrams Diagrams and Drawings
Electrical circuit diagram (1/2)
Electrical circuit diagrams

#. &S
8P
(2

( 2

"6

3

" .
4/

8 2 .
P '.$
"

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90-17

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WEBM009101

Machine Model Serial number

00 Index and foreword 0 -1

10 Structure, function and maintenance standard

20 Standard value table

30 Testing and adjusting

Checking engine oil pressure ................................................................................................................ 11

50 Disassembly and assembly

90 Diagrams and drawings

Hydraulic diagram (float - road homologation)......................................................................................... 5

Foreword and general information 0 -12

4. Precautions for slinging work and making signals

How to read the shop manual 0 -17

1. Composition of shop manual

00. Index and foreword

10. Structure and function

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

60. Maintenance standard

2. Revision and distribution

Symbol Item Description

Special technical precautions or other precautions for preserving standards which

Explanation of terms for maintenance standard 0 -19

q Usually, the dimension of a hole and the di-

4. Repair limit and allowable value or allowable

Handling of hydraulic components 0 -21

1. Be careful of the operating environment

2. Disassembly and maintenance work in the

4. Preventing intrusion of foreign materials

5. Replacing hydraulic oil while its temperature is high

Method of disconnecting and connecting push-pull type coupler 0 -23

Handling of electric equipment 0 -26

Points to remember when handling electric equipment 0 -26

4) High-pressure water entering connector

3. Removing, installing, and drying connectors

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connectors

3) Deutsch connector (DT 8-pin, 12-pin)

4) Drying wiring harness

2] Dry the inside of the connector with a

3] Perform a continuity test on the

4. Handling of connectors used on engine

1) Slide, lock type (FRAMATOME-3, FRAM- 2) Pull lock type (PACKARD-2)

4) Push lock type (2)

a If the lock is located on the underside, use

5) Push lock type (3) Example) Intake air pressure sensor in

Example) Injection pressure control valve of

Examples) Speed sensor of fuel supply

6. Points to remember when troubleshooting

How to read electric wire code 0 -36

Indicates colour of wire by colour code.

Indicates size of wire by nominal No.

Indicates type of wire by symbol.

1. Type, symbol, and material

d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0