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Komatsu SK1020-5N, SK1020-5NA Skid Steer Loader Shop Manual CEBM013902 – PDF DOWNLOAD
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Komatsu SK1020-5N, SK1020-5NA Skid Steer Loader Shop Manual
SERIAL NUMBERS:
SK1020-5N A70001 and up
SK1020-5NA A60001 and up
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Description
Komatsu SK1020-5N, SK1020-5NA Skid Steer Loader Shop Manual
FILE DETAILS:
Komatsu SK1020-5N, SK1020-5NA Skid Steer Loader Shop Manual
Brands: Komatsu
Equipment Type: Skid Steer Loader
Manuals Type: Shop Manual
Machine Model: SK1020-5N, SK1020-5NA
Serial Number: A70001 and up, A60001 and up
Book Code: CEBM013902
Language: English
Pages: 370
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu SK1020-5N, SK1020-5NA Skid Steer Loader Shop Manual
GENERAL :
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts.
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 adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
TROUBLESHOOTING:
Troubleshooting charts correlating “Problems” to “Causes” are included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu SK1020-5N, SK1020-5NA Skid Steer Loader Shop Manual
COVER................................................................................................ 1 CONTENTS......................................................................................... 2 SAFETY........................................................................................... 9 SAFETY NOTICE................................................................................ 9 IMPORTANT SAFETY NOTICE...................................................................... 9 GENERAL PRECAUTIONS.......................................................................... 0 PREPARATIONS FOR WORK........................................................................ 0 PRECAUTIONS DURING WORK...................................................................... 10 GENERAL.......................................................................................... 11 HOW TO READ THE SHOP MANUAL...................................................................... 12 Volumes...................................................................................... 12 Distribution and Updating.................................................................... 12 Filing Method................................................................................ 12 Revised Edition Mark......................................................................... 12 Revisions.................................................................................... 12 Symbols...................................................................................... 12 HOISTING INSTRUCTIONS............................................................................ 13 Hoisting..................................................................................... 0 Wire Ropes................................................................................... 0 MAINTENANCE STANDARD TERMINOLOGY................................................................. 14 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS............................................. 16 PUSH PULL COUPLER................................................................................ 0 Type 1....................................................................................... 25 Disconnection............................................................................ 25 Connection............................................................................... 25 Type 2....................................................................................... 26 Disconnection............................................................................ 26 Connection............................................................................... 26 Type 3....................................................................................... 27 Disconnection............................................................................ 27 Connection............................................................................... 27 COATING MATERIALS................................................................................ 28 STANDARD TIGHTENING TORQUE....................................................................... 30 Bolts and Nuts Standard Tightening Torque.................................................... 30 Hose Nuts Tightening Torque.................................................................. 31 Split Flange Bolts Tightening Torque......................................................... 31 Tightening Torque For Flared Nuts............................................................ 31 O-Ring Boss Piping Joints Tightening Torque.................................................. 32 O-Ring Boss Plugs Tightening Torque.......................................................... 32 Hoses (Taper Seal Type And Face Seal Type) Tightening Torque................................. 33 SPECIFIC DRIVING TORQUE.......................................................................... 33 ELECTRIC WIRE CODE............................................................................... 34 Classification by Thickness.................................................................. 34 Classification by Color and Code............................................................. 34 CONVERSION TABLES................................................................................ 35 Method of Using the Conversion Table......................................................... 35 00 FOREWORD.......................................................................................... 2 CONTENTS......................................................................................... 3 SAFETY........................................................................................... 9 SAFETY NOTICE................................................................................ 9 IMPORTANT SAFETY NOTICE...................................................................... 9 GENERAL PRECAUTIONS.......................................................................... 9 PREPARATIONS FOR WORK........................................................................ 9 PRECAUTIONS DURING WORK...................................................................... 10 GENERAL.......................................................................................... 11 HOW TO READ THE SHOP MANUAL...................................................................... 12 Volumes...................................................................................... 12 Distribution and Updating.................................................................... 12 Filing Method................................................................................ 12 Revised Edition Mark......................................................................... 12 Revisions.................................................................................... 12 Symbols...................................................................................... 12 HOISTING INSTRUCTIONS............................................................................ 13 Hoisting..................................................................................... 13 Wire Ropes................................................................................... 13 MAINTENANCE STANDARD TERMINOLOGY................................................................. 14 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS............................................. 16 PUSH PULL COUPLER................................................................................ 25 Type 1....................................................................................... 25 Disconnection............................................................................ 25 Connection............................................................................... 25 Type 2....................................................................................... 26 Disconnection............................................................................ 26 Connection............................................................................... 26 Type 3....................................................................................... 0 Disconnection............................................................................ 27 Connection............................................................................... 27 COATING MATERIALS................................................................................ 28 STANDARD TIGHTENING TORQUE....................................................................... 30 Bolts and Nuts Standard Tightening Torque.................................................... 30 Hose Nuts Tightening Torque.................................................................. 31 Split Flange Bolts Tightening Torque......................................................... 31 Tightening Torque For Flared Nuts............................................................ 31 Tightening Torque For Flared Nuts............................................................ 32 O-Ring Boss Piping Joints Tightening Torque.................................................. 32 O-Ring Boss Plugs Tightening Torque.......................................................... 32 Hoses (Taper Seal Type And Face Seal Type) Tightening Torque................................. 33 SPECIFIC DRIVING TORQUE.......................................................................... 33 ELECTRIC WIRE CODE............................................................................... 34 Classification by Thickness.................................................................. 34 Classification by Color and Code............................................................. 34 CONVERSION TABLES................................................................................ 35 Method of Using the Conversion Table......................................................... 35 01 GENERAL........................................................................................... 41 DIMENSION DRAWINGS............................................................................... 42 Machine Dimensions........................................................................... 42 Working Ranges............................................................................... 43 SPECIFICATIONS................................................................................... 44 WEIGHT TABLE..................................................................................... 46 FUEL COOLANT AND LUBRICANTS...................................................................... 47 SERVICE NOTES.................................................................................... 48 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...................................................... 49 WORK EQUIPMENT PIVOT POINT CLEARANCES............................................................ 51 WHEEL DRIVE SYSTEM............................................................................... 53 Power Train Flow............................................................................. 53 Transmission System.......................................................................... 54 Wheel Axles.................................................................................. 55 DRIVE MOTOR SYSTEM............................................................................... 56 Motor Ports.................................................................................. 56 Motor Structure.............................................................................. 57 Motor Operations............................................................................. 58 Description.............................................................................. 58 HYDRAULIC PUMPS.................................................................................. 61 Drive Dampener............................................................................... 61 Maintenance Standard..................................................................... 61 Charge Pump.................................................................................. 62 HST Pump LPV45 + 45 (Standard and High Flow)................................................. 63 Maintenance Standard..................................................................... 63 Pump Internal View........................................................................... 65 Operation of Main Pump....................................................................... 66 Shuttle Valve................................................................................ 68 SAFETY VALVES.................................................................................... 69 Suction Safety Valve Action.................................................................. 69 Charge Safety Valve Action................................................................... 72 ANTI ENGINE-STALL VALVE (AS VALVE)............................................................... 74 AS Valve Maintenance Standard................................................................ 76 CONTROL VALVES................................................................................... 77 Standard 3-Spool Valve Port Location......................................................... 77 Valve-Sectional Views........................................................................ 78 Super High-Flow 4-Spool Valve Port Location.................................................. 80 Valve-Sectional Views........................................................................ 81 Control Valve Maintenence Standard........................................................... 84 Control Valve (Standard)................................................................. 92 Control Valve (Super High-Flow).......................................................... 94 CLOSED CENTER LOAD SENSING SYSTEM................................................................ 96 Pressure Compensation Control................................................................ 96 Hydraulic Circuit Diagram.................................................................... 98 System in Series Circuit Operation........................................................... 99 Self Leveling Function.......................................................................100 System in Series-Parallel Circuit Operation..................................................101 Pressure Compensation Valve..................................................................102 Dividing Function............................................................................103 SOLENOID VALVE...................................................................................104 Valve Group ST1..............................................................................104 ACCUMULATOR......................................................................................105 PATTERN CHANGE VALVE.............................................................................106 Maintenance Standard.........................................................................106 Pattern Options Arrangement..................................................................108 Pattern ISO..................................................................................108 Pattern Optional.............................................................................108 R.H. PPC VALVE (STANDARD)........................................................................109 Equipment Control............................................................................109 R.H. PPC Valve Maintenance Standard..........................................................110 R.H. PPC VALVE (PATTERN CHANGE)..................................................................112 Equipment and Travel Control.................................................................112 L.H. PPC VALVE (STANDARD)........................................................................115 Travel Control...............................................................................115 Standard.....................................................................................116 Maintenance Standard.........................................................................117 L.H. PPC VALVE (PATTERN CHANGE)..................................................................120 Equipment and Travel Control.................................................................120 Pattern Change...............................................................................121 Maintenance Standard.........................................................................122 CYLINDERS........................................................................................124 Boom.........................................................................................124 Bucket.......................................................................................124 Maintenance Standard.........................................................................125 20 STANDARD VALUE TABLES............................................................................. 0 STANDARD SERVICE VALUE TABLE.....................................................................129 Standard Service Value Table for Engine..........................................................130 Standard Value Table for Chassis.................................................................131 30 TESTING AND ADJUSTING............................................................................. 0 SPECIAL TOOLS....................................................................................137 T-ADAPTER PROCEDURES AND KITS....................................................................138 ENGINE COMPONENTS................................................................................139 Measuring Exhaust Smoke......................................................................139 Measuring Exhaust Temperature................................................................139 Adjusting Valve Clearance....................................................................139 Measuring Compression Pressure...............................................................139 Measuring Crankcase Pressure.................................................................139 Measuring Engine Oil Pressure................................................................139 Measuring Boost Pressure.....................................................................139 Measuring Fuel Pressure......................................................................139 Adjusting Engine Speed Sensor................................................................139 Bleeding Air From Fuel System................................................................139 Adjusting Engine Stop Solenoid...............................................................139 Adjusting Engine Speed.......................................................................140 ADJUSTING PPC VALVE PRESSURES....................................................................141 Adjusting PPC Valve..........................................................................143 ADJUSTING SERVO-CONTROL SAFETY SENSOR............................................................144 CHAIN TENSION....................................................................................145 Test.........................................................................................145 Adjustment...................................................................................145 TESTING AND ADJUSTING THE HYDRAULIC SYSTEM.......................................................146 Relieving Hydraulic Pressure.................................................................147 Bleeding Hydraulic Circuits..................................................................148 HYDRAULIC PUMP...................................................................................149 Calibrating Valve............................................................................150 Travel Deviation Check.......................................................................151 CONTROL VALVE....................................................................................154 Servo-Control Power Supply...................................................................156 AIR CONDITIONING SYSTEM..........................................................................160 Environmental Impact.........................................................................160 Basic Air Conditioning System (Typical)......................................................161 Operator Cab Air Conditioning................................................................162 Principles of Refrigeration..................................................................162 Air Conditioning.............................................................................162 The Act of Cooling...........................................................................162 The Refrigeration Cycle......................................................................163 Air Conditioner System Components............................................................163 Compressor (Refrigerant Pump)............................................................163 Service Valves...........................................................................163 Condenser................................................................................164 Receiver-Drier...........................................................................164 Thermostatic Expansion Valve.............................................................164 Evaporator...............................................................................165 Electrical Circuit.......................................................................165 Thermostat...............................................................................166 Compressor Clutch........................................................................166 Safety Switches..........................................................................166 System Servicing.........................................................................167 R-134A Refrigerant Containers................................................................168 Service Tools and Equipment..............................................................168 Recovery/Recycle Station.............................................................168 Leak Detector........................................................................169 Service Valves.......................................................................169 Vacuum Pump..........................................................................169 Manifold Gauge Set...................................................................170 Installing Manifold Gauge Set........................................................171 Purging Air from Service Hoses.......................................................172 Adding Refrigerant to the System (Without a Charging Station)........................173 Stabilizing the AC System............................................................173 Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling Station)....174 Recovering and Recycling the Refrigerant.............................................174 Performing the Recovery Cycle........................................................174 Performing the Recycling Procedure...................................................175 Evacuating and Charging the AC System................................................175 System Performance Test..............................................................176 System Leak Testing......................................................................177 Electronic Leak Detector.............................................................177 Tracer Dyes..........................................................................177 Soap and Water.......................................................................177 System Repair............................................................................178 Hoses and Fittings...................................................................178 Lines................................................................................178 Expansion Valve......................................................................178 Receiver-Drier.......................................................................178 Thermostat...........................................................................178 Clutch...............................................................................179 Compressor...........................................................................179 Checking Compressor Oil Level............................................................179 Evacuating The System....................................................................180 Troubleshooting - Air Conditioning System................................................181 Pre-Diagnosis Checks.................................................................181 Preparing for Diagnosis..............................................................181 Preliminary Steps....................................................................181 System Performance Test..............................................................181 Diagnosis of Gauge Readings and System Performance...................................182 Troubleshooting by Manifold Gauge Set Readings...........................................183 Preventive Maintenance Schedule for A/C System...........................................188 40 TROUBLESHOOTING...................................................................................191 POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................................192 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................194 Points To Remember When Troubleshooting Electrical Circuits..................................195 CHECKS BEFORE TROUBLESHOOTING....................................................................196 Troubleshooting Procedure....................................................................197 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................................198 T-ADAPTER TABLE..................................................................................222 ENGINE COOLANT TEMPERATURE SENSOR FAILURE........................................................225 ABNORMAL ENGINE OIL PRESSURE INDICATED...........................................................226 AIR CLEANER CLOG INDICATED.......................................................................227 ENGINE PREHEAT SYSTEM INOPERABLE.................................................................228 FUEL LEVEL INDICATION IS INCORRECT...............................................................230 FUEL PUMP MOTOR INOPERATIVE......................................................................231 ENGINE DOES NOT SHUT DOWN OR WILL NOT START......................................................232 ALTERNATOR NOT CHARGING BATTERY..................................................................234 ENGINE WILL NOT CRANK............................................................................236 BACK-UP ALARM WILL NOT FUNCTION..................................................................238 HYDRAULIC FILTER SENSOR WARNING..................................................................240 PPC SYSTEM ELECTRICAL MALFUNCTION................................................................242 SEAT SAFETY SWITCH MALFUNCTION...................................................................244 SAFETY BAR SWITCH MALFUNCTION....................................................................245 TRAVEL SPEEDS CANNOT BE CHANGED..................................................................246 FLOAT CONTROL MALFUNCTION........................................................................248 PARKING BRAKE SYSTEM MALFUNCTION.................................................................250 PATTERN CHANGE MALFUNCTION.......................................................................252 STABALIZER SYSTEM MALFUNCTION....................................................................254 LOW OR WEAK TRAVEL, WEAK BRAKE-OUT FORCE.........................................................258 WEAK TRAVEL, WEAK BREAK-OUT FORCE IN REVERSE.....................................................260 ROTATING BEACON INOPERABLE.......................................................................262 REAR WORK LIGHTS WILL NOT OPERATE................................................................264 HORN DOES NOT SOUND..............................................................................266 POSSIBLE DEFECTIVE SAFETY RELAY UNIT.............................................................268 50 DISASSEMBLY AND ASSEMBLY..........................................................................271 HOW TO READ THIS MANUAL..........................................................................274 Removal And Installation Of Assemblies.......................................................274 Special Tools............................................................................274 Removal..................................................................................274 Installation.............................................................................274 Disassembly And Assembly Of Assemblies.......................................................275 Special Tools............................................................................275 Disassembly..............................................................................275 Assembly.................................................................................276 CONNECTOR REPAIR PROCEDURES......................................................................277 Stripping Insulation.........................................................................277 Wire Inspection..............................................................................277 Contact Terminal Removal (HD30 Type).........................................................278 Crimping Contact Terminal (HD30 Type)........................................................279 Insertion Of Contact Terminal (HD30 Type)....................................................280 Contact Terminal Removal (DT Type)...........................................................281 Crimping Contact Terminal (DT Type)..........................................................282 Insertion Of Contact Terminal (DT Type)......................................................283 ENGINE...........................................................................................284 Alternator...................................................................................284 Cylinder Head................................................................................284 Engine Front Seal............................................................................284 Engine Oil Cooler............................................................................284 Engine Rear Seal.............................................................................284 Fuel Injection Pump..........................................................................284 Nozzle Holder................................................................................284 Thermostat...................................................................................284 Turbocharger.................................................................................284 Water Pump...................................................................................284 ENGINE HOOD ASSEMBLY.............................................................................285 Removal of Engine Hood.......................................................................285 Installation of Engine Hood..................................................................285 OPERATOR’S CAB ASSEMBLY..........................................................................286 Tilting the Cab..............................................................................286 Lowering the Cab.............................................................................288 Removing the Cab Assembly....................................................................289 Installing the Cab...........................................................................291 WORK EQUIPMENT SYSTEM............................................................................292 Removing Lift Arms...........................................................................292 Installation of Lift Arms....................................................................293 REMOVING EQUIPMENT SUPPORT FRAME.................................................................294 Installing Support Frame.....................................................................294 BATTERY..........................................................................................295 Removal......................................................................................295 Installation.................................................................................295 STARTER MOTOR....................................................................................296 Removal......................................................................................296 Installation.................................................................................296 ALTERNATOR.......................................................................................297 Removal......................................................................................297 Installation.................................................................................297 Check and Adjust Fan Belt Tension............................................................297 AIR FILTER ASSEMBLY..............................................................................298 Removal......................................................................................298 Installation.................................................................................298 MUFFLER ASSEMBLY (SK1020-5N).....................................................................299 Removal......................................................................................299 Installation.................................................................................300 MUFFLER ASSEMBLY (SK1020-5N TURBO)...............................................................301 Removal......................................................................................301 Installation.................................................................................302 RADIATOR ASSEMBLY................................................................................303 Removal......................................................................................303 Installation.................................................................................304 FUEL TANK ASSEMBLY...............................................................................305 Removal......................................................................................305 Installation.................................................................................306 ENGINE-PUMP ASSEMBLY.............................................................................307 Removal......................................................................................307 Installation.................................................................................310 HYDRAULIC PUMP ASSEMBLY..........................................................................311 Removal......................................................................................311 GEAR PUMP ASSEMBLY...............................................................................314 Removal......................................................................................314 Installation.................................................................................314 ENGINE-PUMP COUPLING.............................................................................315 Removal......................................................................................315 Installation.................................................................................315 CONTROL VALVE....................................................................................316 Removal......................................................................................316 Installation.................................................................................316 PPC VALVES.......................................................................................317 Removal......................................................................................317 Installation.................................................................................317 CAB HEATER ASSEMBLY..............................................................................318 Removal......................................................................................318 Installation.................................................................................319 WHEEL HUB ASSEMBLY...............................................................................320 Removal......................................................................................320 Installation.................................................................................321 Adjusting the Chains.........................................................................322 Disassembly of the Wheel Hub.................................................................323 Assembly of the Wheel Hub....................................................................324 FINAL DRIVE ASSEMBLY.............................................................................325 Removal......................................................................................325 Installation.................................................................................326 LIFT AND BUCKET CYLINDERS........................................................................327 Removal of Lift Cylinder.....................................................................327 Installation of the Lift Cylinder............................................................327 Removal of Bucket Cylinder...................................................................328 Installation of Bucket Cylinder..............................................................329 WORK EQUIPMENT CYLINDER OVERHAUL.................................................................330 Disassembly..................................................................................330 Assembly.....................................................................................332 MONITOR PANEL REPLACEMENT........................................................................336 Removal......................................................................................336 Installation.................................................................................337 90 OTHERS............................................................................................339 ENGINE ELECTRICAL................................................................................340 FRAME LINE ELECTRICAL............................................................................344 FRAME LINE ELECTRICAL (OPTIONAL).................................................................348 OPERATOR COMPARTMENT ELECTRICAL..................................................................352 OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL).......................................................358 TOP OPERATOR CAB ELECTRICAL......................................................................366 HYDRAULIC CIRCUIT................................................................................368 AIR CONDITIONER..................................................................................369
KOMATSU SK1020-5N, SK1020-5NA SKID STEER LOADER SHOP MANUAL CEBM013902 – PDF DOWNLOAD:
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