Komatsu SK1020-5N SK1020-5NA Skid Steer Loader Shop Manual CEBM013902 PDF

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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 CEBM013902 – PDF DOWNLOAD 

Language : English
Pages : 370
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu SK1020-5N SK1020-5NA Skid Steer Loader Shop Manual CEBM013902 – PDF DOWNLOAD 

SERIAL NUMBERS

SK1020-5N A70001 and up
SK1020-5NA A60001 and up
ENGINE S4D98E-2

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 maingroup 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 CEBM013902 – PDF DOWNLOAD

SERIAL NUMBERS

SK1020-5N A70001 and up
SK1020-5NA A60001 and up
ENGINE S4D98E-2

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

S.V 15/12/24