Komatsu CK20-1 Crawler Skid-Steer Loader Shop Manual WEBM006400 PDF

WEBM006400_CK20-1 1
CONTENTS 2
REVISED PAGES 3
k SAFETY 5
FOREWORD 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
STANDARD TIGHTENING TORQUE 10
COATING MATERIALS 12
ELECTRIC 13
WEIGHT TABLE 14
TABLE OF OIL AND COOLANT QUANTITIES 15
METHOD OF USING THE CONVERSION TABLE 17
10 STRUCTURE AND FUNCTION 25
P T O 26
POWER TRAIN 27
FRAME 28
TRACK TENSIONER IDLER WHEEL 29
TRACK TENSIONER CYLINDER AND BUMPER SPRING 30
LOWER IDLER ROLLER 31
REAR IDLER ROLLER 32
HYDRAULIC CIRCUIT (STANDARD) 33
HYDRAULIC CIRCUIT (FLOAT) 34
HYDRAULIC CIRCUIT (FLOAT + PATTERN CHANGE) 35
HYDRAULIC CIRCUIT (HIGH-FLOW) 36
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW) 37
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW / PATTERN CHANGE) 38
HYDRAULIC PUMP 39
SUCTION SAFETY VALVE (HST Circuit) 45
CHARGE SAFETY VALVE (Charge circuit) 49
CHARGE PUMP 51
ANTI ENGINE-STALL CONTROL VALVE (AS VALVE) 53
SHUTTLE VALVE 55
TRAVEL SYNCHRONIZATION VALVE 56
CONTROL VALVE (3-SPOOL) 57
CONTROL VALVE (4-SPOOL) 67
CLSS 71
SOLENOID VALVE 79
SOLENOID VALVE GROUP ST1 79
SOLENOID VALVE ST2 80
SOLENOID VALVE ST3 81
ACCUMULATOR 82
PATTERN CHANGE VALVE (OPTIONAL) 83
OPERATION 85
PATTERN ISO 85
PATTERN OPTIONAL 85
R H PPC VALVE (STANDARD) 86
EQUIPMENT CONTROL 86
R H PPC VALVE (PATTERN CHANGE) (OPTIONAL) 90
EQUIPMENT AND TRAVEL CONTROL 90
L H PPC VALVE (STANDARD) 94
TRAVEL CONTROL 94
L H PPC VALVE – PATTERN CHANGE (OPTIONAL) 98
EQUIPMENT AND TRAVEL CONTROL 98
EQUIPMENT CONTROL PPC VALVE 102
CYLINDERS 105
ELECTRICAL DIAGRAM (ENGINE LINE) (1/3) 107
ELECTRICAL DIAGRAM (ENGINE LINE) (2/3) 108
ELECTRICAL DIAGRAM (ENGINE LINE) (3/3) 109
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3) 110
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (2/3) 111
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (3/3) 112
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3) 113
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (2/3) 114
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (3/3) 115
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5) 116
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (2/5) 117
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (3/5) 118
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (4/5) 119
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (5/5) 120
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7) 121
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (2/7) 122
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (3/7) 123
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (4/7) 124
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (5/7) 125
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (6/7) 126
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7) 127
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (1/2) 128
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (2/2) 129
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (1/2) 130
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (2/2) 131
20 TESTING AND ADJUSTMENTS 133
NORMAL OR STANDARD TECHNICAL DATA 135
SPECIAL TOOLS 144
CHECKING THE ENGINE SPEED 145
ADJUSTMENT OF VALVE CLEARANCE 146
MEASUREMENT OF THE COMPRESSION PRESSURE 148
CONTROL AND ADJUSTMENT OF THE FAN BELT TENSION 149
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING 150
CHECKING ENGINE OIL PRESSURE 152
ADJUSTING THE STROKE OF THE ACCELERATOR CABLES 153
REGULATION OF PPC VALVES’ DRIVE PRESSURE 154
ADJUSTMENT OF THE PPC VALVE CLEARANCES 156
ADJUSTING THE POSITION OF THE SERVO-CONTROL ENGAGEMENT SAFETY SENSOR 157
CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS 158
TESTING THE HYDRAULIC PUMP 159
VALVE CALIBRATION 160
CHECKING THE TRAVEL DEVIATION 162
CONTROL VALVE 164
CONTROL AND REGULATION OF THE SERVO-CONTROLPOWER SUPPLY 165
ELIMINATION OF RESIDUAL PRESSURES – PRESSURISATION OF THE TANK 167
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS 168
TRACK TENSION TEST AND ADJUSTMENT 170
30 REMOVAL AND INSTALLATION 171
HOW TO READ THE MANUAL 173
PRECAUTIONS TO BE TAKEN WHILE WORKING 174
ENGINE HOOD 175
Removal 175
Installation 175
CAB 176
Removal 180
Installation 183
BATTERY 184
Removal 184
Installation 184
STARTING MOTOR 185
Removal 185
Installation 185
ALTERNATOR 186
Removal 186
Installation 186
AIR INTAKE FILTER 187
Removal 187
Installation 187
MUFFLER 188
Removal 188
Installation 189
VALVE COVER 190
Removal 190
Installation 190
INJECTORS 191
Removal 191
Installation 191
INJECTION PUMP 192
Removal 192
Installation 194
CYLINDER HEAD 195
Removal 195
Installation 197
COOLANT LIQUID PUMP 198
Removal 198
Installation 198
RADIATOR GROUP 199
Removal 199
Installation 200
FUEL TANK 201
Removal 201
Installation 202
ENGINE-PUMP GROUP 203
Removal 203
Installation 206
COMPLETE HYDRAULIC PUMP 207
Removal 207
Installation 209
GEAR PUMP 210
Removal 210
Installation 210
ENGINE-PUMP COUPLING 211
Removal 211
Installation 211
CONTROL VALVE 212
Removal 212
Installation 212
PPC VALVES 213
Removal 213
Installation 213
LIFT CYLINDER 214
Removal 214
Installation 214
BUCKET CYLINDER 215
Removal 215
Installation 216
WORK EQUIPMENT CYLINDERS 217
Assembly 219
COMPLETE WORKING EQUIPMENT 223
Removal 223
Installation 224
WORKING EQUIPMENT SUPPORT FRAME 225
Removal 225
Installation 225
HEATING SYSTEM BLOWER FAN 226
Removal 226
Installation 227
TRACK 228
Removal 228
Installation 229
LOWER IDLER ROLLER 230
Removal 230
Installation 230
IDLER WHEELS 231
Removal 231
Installation 231
DRIVE WHEEL 232
Removal 232
Installation 232
TRACK TENSIONER CYLINDER 233
Removal 233
Installation 233
FINAL DRIVE 234
Removal 234
Installation 236
Disassembly 237
Assembly 249
40 STANDARD MAINTENANCE 263
P T O 264
FRAME AND BUMPER SPRING 265
TRACK TENSIONER IDLER WHEEL 266
DRIVE WHEEL 267
LOWER IDLER ROLLERS 268
REAR IDLER WHEEL 269
HYDRAULIC PUMP 270
CONTROL VALVE 272
R H PPC VALVE 285
L H PPC VALVE 286
PATTERN CHANGE VALVE (OPTIONAL) 288
CYLINDERS 289
WORKING EQUIPMENT 290
90 OTHER 293
ELECTRICAL DIAGRAM (STANDARD) 295
ELECTRICAL DIAGRAM (OPTIONAL) 297

GENERAL PRECAUTIONS :

Mistakes in operation extremely dangerous. Read all the Operation and Maintenance Manual carefully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions written on the decals which are suck on the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

• Always wear safety glasses when hitting parts with a hammer.

• Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.

4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.

5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

7. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels to prevent the machine from moving.

8. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible, use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.

9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.

10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK :

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the hydraulic circuit and engine cooling circuit, first remove the pressure completely from the circuit.

12. The water and oil in the circuits are not hot when the engine in stopped, so be careful not to get burned. Wait for the oil water to cool before carrying out any work on the cooling water circuits.

13. Before starting work, remove the leads from the battery. Always remove the lead from the negative ( – ) terminal first.