Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU SK1026-5N SKID STEER LOADER SERVICE REPAIR MANUAL (SN:A80001 & UP) – PDF Download
Original price was: $79.95.$29.95Current price is: $29.95.
- KOMATSU SK1026-5N SKID STEER LOADER SERVICE REPAIR MANUAL
- Serial Number:A80001 & UP
- Publication Number:CEBM014201
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU SK1026-5N SKID STEER LOADER SERVICE REPAIR MANUAL (SN:A80001 & UP)
KOMATSU SK1026-5N SKID STEER LOADER SERVICE REPAIR MANUAL (SN:A80001 & UP) – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU SK1026-5N SKID STEER LOADER SERVICE REPAIR MANUAL (SN:A80001 & UP)
- 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 also 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 SK1026-5N SKID STEER LOADER SERVICE REPAIR MANUAL (SN:A80001 & UP)
COVER................................................................................................................................................................................................................................................................... 1 CONTENTS................................................................................................................................................................................................................................................................ 2 FOREWORD................................................................................................................................................................................................................................................................ 2 List of Revised Pages............................................................................................................................................................................................................................................... 3 SAFETY.............................................................................................................................................................................................................................................................. 7 Safety Notice................................................................................................................................................................................................................................................... 7 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine................................................................................................................................. 7 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.................................................................................................................... 7 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................................... 7 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inf............................................................................................................................ 7 5. Keep all tools in good condition and learn the correct way to use them................................................................................................................................................................................... 7 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct place............................................................................................................................ 7 1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving........................................................................................................... 7 2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert ............................................................................................................................ 7 3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.................................................................................................................................................. 7 4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders o............................................................................................................................ 7 1. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil fro............................................................................................................................ 7 2. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits...................................................... 7 3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first..................................................................................................................................... 8 4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always ............................................................................................................................ 8 5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove........................................ 8 6. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires........................................................................................................................................ 8 7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.................................................. 8 8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents........................................................................................................................................................ 8 9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.................................................................................................................................................... 8 10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed............... 8 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as g............................................................................................................................ 8 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole......................................................................................................................................... 8 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.................................................................................................................................. 8 14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.................................................................... 8 15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the machine..... 8 GENERAL............................................................................................................................................................................................................................................................. 9 HOW TO READ THE SHOP MANUAL......................................................................................................................................................................................................................................... 10 Volumes......................................................................................................................................................................................................................................................... 10 Distribution And Updating....................................................................................................................................................................................................................................... 10 Filing Method................................................................................................................................................................................................................................................... 10 1. See the page number on the bottom of the page. File the pages in correct order........................................................................................................................................................................... 10 2. Following examples show how to read the page number:..................................................................................................................................................................................................... 10 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example.............................................................................................................................. 10 Revised Edition Mark............................................................................................................................................................................................................................................ 10 Revisions....................................................................................................................................................................................................................................................... 10 Symbols......................................................................................................................................................................................................................................................... 10 HOISTING INSTRUCTIONS............................................................................................................................................................................................................................................... 11 Hoisting........................................................................................................................................................................................................................................................ 11 1. Check for removal of all bolts fastening the part to the relative parts.................................................................................................................................................................................. 11 2. Check for existence of another part causing interface with the part to be removed........................................................................................................................................................................ 11 Wire Ropes...................................................................................................................................................................................................................................................... 11 1. Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:......................................................................................................................................................... 11 2. Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion................... 11 3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load....................................................................................................................................... 11 4. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes,............................................................................................................................ 11 PUSH PULL COUPLER................................................................................................................................................................................................................................................... 12 Type 1.......................................................................................................................................................................................................................................................... 12 1. Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank........................................................................................................... 12 2. Hold the adapter (1) and push the hose joint (2) into the mating adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold the rubber cap portion (4).......................................................................................... 12 3. After the hose joint (2) is pushed into the adapter (3), press the rubber cap portion (4) against the adapter until it clicks............................................................................................................................ 12 4. Hold the hose adapter (1) or hose (5) and pull it out. Since some hydraulic oil flows out, prepare an oil receiving container............................................................................................................................ 12 1. Hold the hose adapter (1) or hose (5) and insert it in the mating adapter (3), aligning them with each other. Do not hold the rubber cap portion (4)..................................................................................................... 12 2. After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality........................... 12 Type 2.......................................................................................................................................................................................................................................................... 13 1. Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end........................................................................ 13 2. Hold in the condition in Step 1, and turn the lever (4) to the right - clockwise......................................................................................................................................................................... 13 3. Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it................................................................................................................................................................. 13 1. Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it.................................................................. 13 Type 3.......................................................................................................................................................................................................................................................... 14 1. Hold the mouthpiece of the tightening portion and push the body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end............................................................................ 14 2. Hold in the condition in Step 1, and push until the cover (3) contacts surface a of the hexagonal portion at the male end................................................................................................................................ 14 3. Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it................................................................................................................................................................. 14 1. Hold the mouthpiece of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it............................................................ 14 COATING MATERIALS................................................................................................................................................................................................................................................... 15 STANDARD TIGHTENING TORQUE.......................................................................................................................................................................................................................................... 17 Standard Tightening Torque of Bolts and Nuts.................................................................................................................................................................................................................... 17 Tightening Torque of Hose Nuts.................................................................................................................................................................................................................................. 18 Tightening Torque of Split Flange Bolts......................................................................................................................................................................................................................... 18 Tightening Torque for Flared Nuts............................................................................................................................................................................................................................... 18 Tightening Torques Table for O-Ring Boss Piping Joints.......................................................................................................................................................................................................... 19 Tightening Torques Table for O-Ring Boss Plugs.................................................................................................................................................................................................................. 19 Tightening Torque Table for Hoses (Taper Seal Type and Face Seal Type).......................................................................................................................................................................................... 19 ELECTRIC WIRE CODE.................................................................................................................................................................................................................................................. 20 Classification by Thickness..................................................................................................................................................................................................................................... 20 Classification by Color and Code................................................................................................................................................................................................................................ 20 CONVERSION TABLES................................................................................................................................................................................................................................................... 21 Method of Using the Conversion Table............................................................................................................................................................................................................................ 21 1. Convert 55 mm into inches................................................................................................................................................................................................................................ 21 A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b..................................................................................................................................... 21 B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c............................................................................................................................................ 21 C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches..................................................................................... 21 2. Convert 550 mm into inches............................................................................................................................................................................................................................... 21 A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm......................................................................................................................... 21 B. Carry out the same procedure as above to convert 55 mm to 2.165 inches............................................................................................................................................................................... 21 C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches............................................................ 21 01 GENERAL.............................................................................................................................................................................................................................................................. 27 TECHNICAL DATA...................................................................................................................................................................................................................................................... 28 Standard Machine Overall Dimensions............................................................................................................................................................................................................................. 28 Important................................................................................................................................................................................................................................................... 28 Overall Dimensions with Standard Bucket L 1880 mm (6’ 2”) and Tires (12 x 16.5)............................................................................................................................................................................. 28 Overall Dimensions with Bucket L 1730 mm (5’ 8’) and Tires (12 x 16.5)...................................................................................................................................................................................... 29 Overall Dimensions With Bucket L 2030 mm (6’ 8”) and Tires (33 x 15.5 - 16.5)............................................................................................................................................................................... 29 Machine Overall Dimensions With Optional Equipment.............................................................................................................................................................................................................. 30 Machine Overall Dimensions with Backhoe (E35-2)............................................................................................................................................................................................................. 30 Machine Overall Dimensions with Cold Planer................................................................................................................................................................................................................. 30 Machine Overall Dimensions with Pallet Forks................................................................................................................................................................................................................ 31 Machine Overall Dimensions with Grapple Fork................................................................................................................................................................................................................ 31 Machine Overall Dimensions with Snow Blade.................................................................................................................................................................................................................. 32 Machine Overall Dimensions with Mixing Bucket............................................................................................................................................................................................................... 32 Machine Overall Dimensions with Sweeper..................................................................................................................................................................................................................... 33 Technical Characteristics....................................................................................................................................................................................................................................... 33 Total Mass.................................................................................................................................................................................................................................................. 33 Bucket Capacity............................................................................................................................................................................................................................................. 33 Engine...................................................................................................................................................................................................................................................... 33 Electrical System........................................................................................................................................................................................................................................... 33 Speed....................................................................................................................................................................................................................................................... 34 Tires....................................................................................................................................................................................................................................................... 34 WEIGHT TABLE........................................................................................................................................................................................................................................................ 34 FUEL, COOLANT AND LUBRICANTS........................................................................................................................................................................................................................................ 35 Proper Selection Of Fuel, Coolant And Lubricants................................................................................................................................................................................................................ 35 Lubrication with Grease......................................................................................................................................................................................................................................... 36 Performing KOWA (Komatsu Oil Wear Analysis)..................................................................................................................................................................................................................... 37 HOMOLOGATED (HEES) SYNTHETIC BIODEGRADABLE LUBRICANTS............................................................................................................................................................................................................... 38 SPECIFIC DRIVING TORQUES............................................................................................................................................................................................................................................ 38 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD......................................................................................................................................................................................................................... 39 PTO................................................................................................................................................................................................................................................................. 42 Maintenance Standards........................................................................................................................................................................................................................................... 43 POWER TRAIN......................................................................................................................................................................................................................................................... 44 Maintenance Standards........................................................................................................................................................................................................................................... 45 TRANSMISSION........................................................................................................................................................................................................................................................ 46 Maintenance Standards........................................................................................................................................................................................................................................... 48 FINAL DRIVE......................................................................................................................................................................................................................................................... 49 Description..................................................................................................................................................................................................................................................... 51 Hydraulic Motor................................................................................................................................................................................................................................................. 51 Flushing Relief Valve........................................................................................................................................................................................................................................... 53 Reduction Gearing............................................................................................................................................................................................................................................... 54 Maintenance Standards........................................................................................................................................................................................................................................... 55 HYDRAULIC PUMP...................................................................................................................................................................................................................................................... 56 HST Pump LPV45 + 45 (Standard Flow)............................................................................................................................................................................................................................. 56 HST Pump LPV45 + 45 (High Flow)................................................................................................................................................................................................................................. 58 Pump Internal View.............................................................................................................................................................................................................................................. 59 Operation....................................................................................................................................................................................................................................................... 60 Shuttle Valve................................................................................................................................................................................................................................................... 62 Maintenance Standards........................................................................................................................................................................................................................................... 63 SAFETY VALVES....................................................................................................................................................................................................................................................... 64 Suction Safety Valve Action..................................................................................................................................................................................................................................... 64 Charge Safety Valve Action...................................................................................................................................................................................................................................... 67 Charge Pump..................................................................................................................................................................................................................................................... 69 ANTI ENGINE-STALL VALVE (AS VALVE).................................................................................................................................................................................................................................. 70 Maintenance Standards........................................................................................................................................................................................................................................... 72 CONTROL VALVES...................................................................................................................................................................................................................................................... 73 Standard 3-Spool Valve Port Location............................................................................................................................................................................................................................ 73 Valve Sectional Views........................................................................................................................................................................................................................................... 74 Super High-Flow 4-Spool Valve Port Location..................................................................................................................................................................................................................... 76 Valve Sectional Views........................................................................................................................................................................................................................................... 77 Maintenance Standards........................................................................................................................................................................................................................................... 80 Standard 3-spool............................................................................................................................................................................................................................................ 80 Super High Flow 4-Spool..................................................................................................................................................................................................................................... 86 CLOSED CENTER LOAD SENSING SYSTEM................................................................................................................................................................................................................................... 93 Pressure Compensation Control................................................................................................................................................................................................................................... 93 Hydraulic Circuit Diagram and Names of Valves............................................................................................................................................................................................................... 94 System Series Circuit Operation................................................................................................................................................................................................................................. 95 Self Leveling Function.......................................................................................................................................................................................................................................... 96 System In Series-Parallel Circuit Operation..................................................................................................................................................................................................................... 97 Pressure Compensation Valve..................................................................................................................................................................................................................................... 99 Dividing Function...............................................................................................................................................................................................................................................100 SOLENOID VALVE......................................................................................................................................................................................................................................................101 Valve Group ST1.................................................................................................................................................................................................................................................101 Valve Group ST2.................................................................................................................................................................................................................................................102 ACCUMULATOR.........................................................................................................................................................................................................................................................103 PARTERN CHANGE VALVE................................................................................................................................................................................................................................................105 Pattern Options Arrangement.....................................................................................................................................................................................................................................108 Pattern ISO.................................................................................................................................................................................................................................................108 Pattern Optional............................................................................................................................................................................................................................................108 Maintenance Standards...........................................................................................................................................................................................................................................109 R.H. PPC VALVE (STANDARD)...........................................................................................................................................................................................................................................110 Equipment Control...............................................................................................................................................................................................................................................110 Maintenance Standards...........................................................................................................................................................................................................................................114 R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)..........................................................................................................................................................................................................................116 Equipment and Travel Control....................................................................................................................................................................................................................................116 L.H. PPC VALVE (STANDARD)...........................................................................................................................................................................................................................................119 Travel Control..................................................................................................................................................................................................................................................119 Maintenance Standards...........................................................................................................................................................................................................................................122 L.H. PPC VALVE (PATTERN CHANGE).....................................................................................................................................................................................................................................124 Equipment and Travel Control....................................................................................................................................................................................................................................124 Pattern Change..............................................................................................................................................................................................................................................125 Maintenance Standards...........................................................................................................................................................................................................................................128 CYLINDERS...........................................................................................................................................................................................................................................................130 Boom............................................................................................................................................................................................................................................................130 Bucket..........................................................................................................................................................................................................................................................130 Maintenance Standards...........................................................................................................................................................................................................................................132 WORKING EQUIPMENT...................................................................................................................................................................................................................................................134 Maintenance Standards...........................................................................................................................................................................................................................................134 20 STANDARD VALUE TABLES................................................................................................................................................................................................................................................137 STANDARD SERVICE VALUE TABLE........................................................................................................................................................................................................................................138 Standard Value Table............................................................................................................................................................................................................................................139 Engine......................................................................................................................................................................................................................................................139 Chassis.....................................................................................................................................................................................................................................................140 30 TESTING AND ADJUSTING................................................................................................................................................................................................................................................145 SPECIAL TOOLS.......................................................................................................................................................................................................................................................146 T-ADAPTER PROCEDURES AND KITS.......................................................................................................................................................................................................................................147 Special Tools Required..........................................................................................................................................................................................................................................147 ENGINE COMPONENTS...................................................................................................................................................................................................................................................148 Measuring Exhaust Smoke.........................................................................................................................................................................................................................................148 Measuring Exhaust Temperature...................................................................................................................................................................................................................................148 Measuring Crankcase Pressure....................................................................................................................................................................................................................................148 Measuring Boost Pressure........................................................................................................................................................................................................................................148 Measuring Fuel Pressure.........................................................................................................................................................................................................................................148 Bleeding Air From Fuel System...................................................................................................................................................................................................................................148 Adjusting Engine Stop Solenoid..................................................................................................................................................................................................................................148 Checking Engine Speed...........................................................................................................................................................................................................................................149 Adjustment of Valve Clearance...................................................................................................................................................................................................................................150 Measurement of the Compression Pressure.........................................................................................................................................................................................................................152 Control and Adjustment of the Fan Belt Tension..................................................................................................................................................................................................................153 Control and Adjustment of the Injection Timing..................................................................................................................................................................................................................154 Checking Engine Oil Pressure....................................................................................................................................................................................................................................156 Adjusting the Stroke of the Accelerator Cables..................................................................................................................................................................................................................157 ADJUSTING PPC VALVE PRESSURES.......................................................................................................................................................................................................................................158 Disassembly and Adjustment......................................................................................................................................................................................................................................158 Assembly........................................................................................................................................................................................................................................................159 PPC Valve Rebuild Specifications................................................................................................................................................................................................................................159 Adjusting PPC Valve.............................................................................................................................................................................................................................................160 ADJUSTING SERVO-CONTROL SAFETY SENSOR...............................................................................................................................................................................................................................161 CHAIN TENSION.......................................................................................................................................................................................................................................................162 Test............................................................................................................................................................................................................................................................162 Adjustment......................................................................................................................................................................................................................................................162 HYDRAULIC SYSTEM....................................................................................................................................................................................................................................................163 HYDRAULIC PUMP......................................................................................................................................................................................................................................................164 Checking Working Pressure of Travel HST Charge Valve............................................................................................................................................................................................................164 Checking Working Pressure Of The AS Valve.......................................................................................................................................................................................................................164 CALIBRATING VALVE...................................................................................................................................................................................................................................................166 HST Valve Calibration...........................................................................................................................................................................................................................................166 AS Valve Calibration............................................................................................................................................................................................................................................166 Pressure Adjustment Made at Low Idle........................................................................................................................................................................................................................166 Pressure Adjustment At Working Pressure.....................................................................................................................................................................................................................167 Travel Deviation Check..........................................................................................................................................................................................................................................168 Checking the Deviation......................................................................................................................................................................................................................................168 Adjusting the Deviation.....................................................................................................................................................................................................................................169 CONTROL VALVE.......................................................................................................................................................................................................................................................170 Valve Adjustment................................................................................................................................................................................................................................................171 Adjustment Of Main Relief Valve.................................................................................................................................................................................................................................171 SERVO-CONTROL POWER SUPPLY..........................................................................................................................................................................................................................................172 Checking Pressure of the Servo-Controls.........................................................................................................................................................................................................................172 Test Pressure of the Travel Pilot System........................................................................................................................................................................................................................172 Parking Brake System Pressure Check.............................................................................................................................................................................................................................173 RELEAVING HYDRAULIC PRESSURE........................................................................................................................................................................................................................................174 Elimination of Pressures in the Hydraulic Circuits..............................................................................................................................................................................................................174 Elimination of Pressure in the Tank.............................................................................................................................................................................................................................174 Elimination of Pressure.........................................................................................................................................................................................................................................174 BLEEDING HYDRAULIC CIRCUITS.........................................................................................................................................................................................................................................175 Bleeding Air From the Pump......................................................................................................................................................................................................................................175 Bleeding Air From the Cylinders.................................................................................................................................................................................................................................175 Bleeding Air From Optional Equipment............................................................................................................................................................................................................................175 40 TROUBLESHOOTING......................................................................................................................................................................................................................................................177 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................................................................................................................................................180 SEQUENCE OF EVENTS IN TROUBLESHOOTING...............................................................................................................................................................................................................................182 PRECAUTIONS WHEN PERFORMING MAINTENANCE.............................................................................................................................................................................................................................183 Precautions When Handling Electrical Equipment..................................................................................................................................................................................................................184 Handling Control Box............................................................................................................................................................................................................................................189 Points to Remember When Troubleshooting Electrical Circuits.....................................................................................................................................................................................................190 Points to Remember When Handling Hydraulic Equipment............................................................................................................................................................................................................191 CHECKS BEFORE TROUBLESHOOTING.......................................................................................................................................................................................................................................193 Using Troubleshooting Charts....................................................................................................................................................................................................................................194 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................................................................................................................................................................................................................195 T-ADAPTER TABLE.....................................................................................................................................................................................................................................................219 TRAVEL MOTOR........................................................................................................................................................................................................................................................222 Motor does not move (The supplied pressure is enough.)..........................................................................................................................................................................................................222 Revolution Speed is Late........................................................................................................................................................................................................................................222 Abnormal Noise..................................................................................................................................................................................................................................................222 Oil Leakage.....................................................................................................................................................................................................................................................222 Excessive Heat Generation.......................................................................................................................................................................................................................................222 Does Not Change to Second Speed.................................................................................................................................................................................................................................223 Does Not Return to First Speed..................................................................................................................................................................................................................................223 Standard for Parts Inspection...................................................................................................................................................................................................................................223 Hydraulic Motor.............................................................................................................................................................................................................................................223 Reduction Gear Section......................................................................................................................................................................................................................................224 AIR CONDITIONING SYSTEM.............................................................................................................................................................................................................................................226 Environmental Impact............................................................................................................................................................................................................................................226 Basic Air Conditioning System (Typical).........................................................................................................................................................................................................................226 Operator Cab Air Conditioning...................................................................................................................................................................................................................................227 Principles of Refrigeration.....................................................................................................................................................................................................................................227 Air Conditioning................................................................................................................................................................................................................................................227 The Act of Cooling..............................................................................................................................................................................................................................................228 The Refrigeration Cycle.........................................................................................................................................................................................................................................228 Air Conditioner System Components...............................................................................................................................................................................................................................229 Compressor (Refrigerant Pump)...............................................................................................................................................................................................................................229 Service Valves..............................................................................................................................................................................................................................................229 Condenser...................................................................................................................................................................................................................................................229 Receiver-Drier..............................................................................................................................................................................................................................................229 Thermostatic Expansion Valve................................................................................................................................................................................................................................230 Evaporator..................................................................................................................................................................................................................................................230 Electrical Circuit..............................................................................................................................................................................................................................................231 Thermostat..................................................................................................................................................................................................................................................231 Compressor Clutch...........................................................................................................................................................................................................................................231 Safety Switches.............................................................................................................................................................................................................................................232 TrinaryTM Switch........................................................................................................................................................................................................................................232 System Servicing................................................................................................................................................................................................................................................233 R-134A Refrigerant Containers...................................................................................................................................................................................................................................233 Service Tools And Equipment.....................................................................................................................................................................................................................................234 Recovery/recycle Station....................................................................................................................................................................................................................................234 Leak Detector...............................................................................................................................................................................................................................................235 Service Valves..............................................................................................................................................................................................................................................235 Vacuum Pump.................................................................................................................................................................................................................................................235 Manifold Gauge Set..........................................................................................................................................................................................................................................236 Low Side Gauge..............................................................................................................................................................................................................................................236 High Side Gauge.............................................................................................................................................................................................................................................236 Installing Manifold Gauge Set...................................................................................................................................................................................................................................237 Purging Air from Service Hoses..................................................................................................................................................................................................................................238 Adding Refrigerant to the System (Without a Charging Station)...................................................................................................................................................................................................239 1. After determining that the system is low and requires additional refrigerant perform the following procedures. Connect the center hose from the manifold gauge set to the refrigerant dispensing valve on the container..................................239 2. Start the engine and set the idle at 1200 to 1500 RPM and then turn on the air conditioning..............................................................................................................................................................239 3. Open the refrigerant dispensing valve on the container and then the low pressure hand valve on the manifold. This will allow ............................................................................................................................239 4. Continue adding refrigerant until the gauge reads in the normal range. Gauge readings will fluctuate as the compressor cycles............................................................................................................................239 Stabilizing the AC System.......................................................................................................................................................................................................................................239 Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling Station)...............................................................................................................................................................................240 Recovering and Recycling the Refrigerant........................................................................................................................................................................................................................240 Draining the Oil from the Previous Recovery Cycle...........................................................................................................................................................................................................240 Performing the Recovery Cycle...............................................................................................................................................................................................................................240 Performing the Recycling Procedure..........................................................................................................................................................................................................................241 Evacuating and Charging the AC System.......................................................................................................................................................................................................................241 Evacuating the System.......................................................................................................................................................................................................................................241 Charging the AC System......................................................................................................................................................................................................................................241 System Performance Test.........................................................................................................................................................................................................................................242 System Leak Testing.............................................................................................................................................................................................................................................243 Electronic Leak Detector....................................................................................................................................................................................................................................243 Tracer Dyes.................................................................................................................................................................................................................................................243 Soap and Water..............................................................................................................................................................................................................................................243 System Repair...................................................................................................................................................................................................................................................244 Hoses and Fittings..........................................................................................................................................................................................................................................244 Lines.......................................................................................................................................................................................................................................................244 Expansion Valve.............................................................................................................................................................................................................................................244 Receiver-Drier..............................................................................................................................................................................................................................................244 Thermostat..................................................................................................................................................................................................................................................244 Clutch......................................................................................................................................................................................................................................................245 Compressor..................................................................................................................................................................................................................................................245 Checking Compressor Oil Level...................................................................................................................................................................................................................................245 Evacuating The System...........................................................................................................................................................................................................................................246 Troubleshooting - Air Conditioning System.......................................................................................................................................................................................................................248 Pre-Diagnosis Checks........................................................................................................................................................................................................................................248 Preparing for Diagnosis.....................................................................................................................................................................................................................................248 Preliminary Steps...........................................................................................................................................................................................................................................248 System Performance Test.....................................................................................................................................................................................................................................248 Diagnosis of Gauge Readings and System Performance..........................................................................................................................................................................................................249 Troubleshooting by Manifold Gauge Set Readings..............................................................................................................................................................................................................250 Trouble: Insufficient Cooling...........................................................................................................................................................................................................................250 Trouble: Little or No Cooling...........................................................................................................................................................................................................................250 Extremely Low Refrigerant Charge in the System..........................................................................................................................................................................................................250 Air and/or Moisture in the System.......................................................................................................................................................................................................................251 Excessive Air and/or Moisture in the System.............................................................................................................................................................................................................251 Expansion Valve Stuck or Plugged........................................................................................................................................................................................................................252 Expansion Valve Stuck Open..............................................................................................................................................................................................................................252 System High Pressure Side Restriction...................................................................................................................................................................................................................253 Compressor Malfunction..................................................................................................................................................................................................................................253 Condenser Malfunction or System Overcharge..............................................................................................................................................................................................................253 Thermostatic Switch Malfunction.........................................................................................................................................................................................................................254 Preventive Maintenance Schedule for A/C System..................................................................................................................................................................................................................256 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................................................................................................259 HOW TO READ THIS SECTION............................................................................................................................................................................................................................................262 Removal and Installation of Assemblies..........................................................................................................................................................................................................................262 Special Tools...............................................................................................................................................................................................................................................262 Removal.....................................................................................................................................................................................................................................................262 Installation................................................................................................................................................................................................................................................262 Disassembly and Assembly of Assemblies..........................................................................................................................................................................................................................263 Special Tools...............................................................................................................................................................................................................................................263 Disassembly.................................................................................................................................................................................................................................................263 Assembly....................................................................................................................................................................................................................................................263 PRECAUTIONS DURING OPERATION........................................................................................................................................................................................................................................266 Precautions When During Removal Work............................................................................................................................................................................................................................266 Precautions When Performing Installation Work...................................................................................................................................................................................................................267 Precautions When Completing the Operations......................................................................................................................................................................................................................267 Other Precautions...............................................................................................................................................................................................................................................268 CONNECTOR REPAIR PROCEDURES.........................................................................................................................................................................................................................................269 Stripping Insulation............................................................................................................................................................................................................................................269 Wire Inspection.................................................................................................................................................................................................................................................269 Contact Terminal Removal (HD30 Type)............................................................................................................................................................................................................................270 Crimping Contact Terminal (HD30 Type)...........................................................................................................................................................................................................................271 Insertion of Contact Terminal (HD30 Type).......................................................................................................................................................................................................................272 Contact Terminal Removal (DT Type)..............................................................................................................................................................................................................................273 Crimping Contact Terminal (DT Type).............................................................................................................................................................................................................................274 Insertion of Contact Terminal (DT Type).........................................................................................................................................................................................................................275 ENGINE..............................................................................................................................................................................................................................................................277 Engine Front Seal...............................................................................................................................................................................................................................................277 Engine Oil Cooler...............................................................................................................................................................................................................................................277 Engine Rear Seal................................................................................................................................................................................................................................................277 Thermostat......................................................................................................................................................................................................................................................277 Engine Assembly - Complete......................................................................................................................................................................................................................................278 Removal.....................................................................................................................................................................................................................................................278 Installation................................................................................................................................................................................................................................................281 Valve Cover.....................................................................................................................................................................................................................................................282 Removal.....................................................................................................................................................................................................................................................282 Installation................................................................................................................................................................................................................................................283 Nozzle Holder...................................................................................................................................................................................................................................................284 Removal.....................................................................................................................................................................................................................................................284 Installation................................................................................................................................................................................................................................................284 Fuel Injection Pump.............................................................................................................................................................................................................................................285 Removal.....................................................................................................................................................................................................................................................285 Installation................................................................................................................................................................................................................................................287 Cylinder Head...................................................................................................................................................................................................................................................288 Removal.....................................................................................................................................................................................................................................................288 Installation................................................................................................................................................................................................................................................290 Water Pump......................................................................................................................................................................................................................................................291 Removal.....................................................................................................................................................................................................................................................291 Installation................................................................................................................................................................................................................................................291 Starter Motor...................................................................................................................................................................................................................................................292 Removal.....................................................................................................................................................................................................................................................292 Installation................................................................................................................................................................................................................................................292 Turbocharger....................................................................................................................................................................................................................................................293 Removal.....................................................................................................................................................................................................................................................293 Installation................................................................................................................................................................................................................................................293 Alternator......................................................................................................................................................................................................................................................294 Removal.....................................................................................................................................................................................................................................................294 Installation................................................................................................................................................................................................................................................294 ENGINE HOOD ASSEMBLY................................................................................................................................................................................................................................................295 Removal.........................................................................................................................................................................................................................................................295 Installation....................................................................................................................................................................................................................................................295 OPERATOR’S CAB ASSEMBLY.............................................................................................................................................................................................................................................296 Tilting the Cab.................................................................................................................................................................................................................................................296 Lowering the Cab................................................................................................................................................................................................................................................298 Removing the Cab Assembly.......................................................................................................................................................................................................................................299 Installing the Cab..............................................................................................................................................................................................................................................301 BATTERY.............................................................................................................................................................................................................................................................302 Removal.........................................................................................................................................................................................................................................................302 Installation....................................................................................................................................................................................................................................................302 AIR CLEANER ASSEMBLY................................................................................................................................................................................................................................................303 Removal.........................................................................................................................................................................................................................................................303 Installation....................................................................................................................................................................................................................................................303 MUFFLER ASSEMBLY....................................................................................................................................................................................................................................................304 Removal.........................................................................................................................................................................................................................................................304 Installation....................................................................................................................................................................................................................................................305 RADIATOR ASSEMBLY...................................................................................................................................................................................................................................................306 Removal.........................................................................................................................................................................................................................................................306 Installation....................................................................................................................................................................................................................................................307 FUEL TANK ASSEMBLY..................................................................................................................................................................................................................................................308 Removal.........................................................................................................................................................................................................................................................308 Installation....................................................................................................................................................................................................................................................309 HYDRAULIC PUMP ASSEMBLY.............................................................................................................................................................................................................................................310 Removal.........................................................................................................................................................................................................................................................310 Installation....................................................................................................................................................................................................................................................312 GEAR PUMP ASSEMBLY..................................................................................................................................................................................................................................................313 Removal.........................................................................................................................................................................................................................................................313 Installation....................................................................................................................................................................................................................................................313 ENGINE-PUMP COUPLING................................................................................................................................................................................................................................................314 Removal.........................................................................................................................................................................................................................................................314 Installation....................................................................................................................................................................................................................................................314 CONTROL VALVE.......................................................................................................................................................................................................................................................315 Removal.........................................................................................................................................................................................................................................................315 Installation....................................................................................................................................................................................................................................................315 PPC VALVES..........................................................................................................................................................................................................................................................316 Removal.........................................................................................................................................................................................................................................................316 Installation....................................................................................................................................................................................................................................................316 CAB HEATER ASSEMBLY.................................................................................................................................................................................................................................................318 Removal.........................................................................................................................................................................................................................................................318 Installation....................................................................................................................................................................................................................................................319 WHEEL HUB ASSEMBLY..................................................................................................................................................................................................................................................320 Removal.........................................................................................................................................................................................................................................................320 Installation....................................................................................................................................................................................................................................................321 Disassembly.....................................................................................................................................................................................................................................................322 Assembly........................................................................................................................................................................................................................................................323 FINAL DRIVE ASSEMBLY................................................................................................................................................................................................................................................324 Removal.........................................................................................................................................................................................................................................................324 Installation....................................................................................................................................................................................................................................................325 CYLINDER ASSEMBLIES.................................................................................................................................................................................................................................................326 Lift Cylinder Assembly..........................................................................................................................................................................................................................................326 Removal.....................................................................................................................................................................................................................................................326 Installation................................................................................................................................................................................................................................................327 Bucket Cylinder Asssembly.......................................................................................................................................................................................................................................328 Removal.....................................................................................................................................................................................................................................................328 Installation................................................................................................................................................................................................................................................329 Disassembly of the Cylinder Assembly............................................................................................................................................................................................................................330 Assembly of the Cylinder Assembly...............................................................................................................................................................................................................................332 Assembly of the Cylinder Head...............................................................................................................................................................................................................................332 Piston Assembly.............................................................................................................................................................................................................................................333 Piston Rod Assembly.........................................................................................................................................................................................................................................333 Cylinder Assembly...........................................................................................................................................................................................................................................334 WORK EQUIPMENT SYSTEM...............................................................................................................................................................................................................................................336 Removal of the Complete Work Equipment..........................................................................................................................................................................................................................336 Installation of the Complete Work Equipment.....................................................................................................................................................................................................................338 Removal of the Fulcrum Lever....................................................................................................................................................................................................................................339 Installation of the Fulcrum Lever...............................................................................................................................................................................................................................339 Removal of the Lift Lever.......................................................................................................................................................................................................................................340 Installation of the Lift Lever..................................................................................................................................................................................................................................341 Removal of the Work Equipment Support Frame.....................................................................................................................................................................................................................342 Installation of the Work Equipment Support Frame................................................................................................................................................................................................................342 90 DIAGRAMS AND SCHEMATICS..............................................................................................................................................................................................................................................343 HYDRAULIC SYSTEM....................................................................................................................................................................................................................................................345 Road Specification..............................................................................................................................................................................................................................................345 Standard + Pattern Change.......................................................................................................................................................................................................................................346 Super-Flow + Float + Pattern Change.............................................................................................................................................................................................................................347 Standard + Float + Pattern Change...............................................................................................................................................................................................................................348 Standard + Float................................................................................................................................................................................................................................................349 High-Flow + Float...............................................................................................................................................................................................................................................350 ELECTRICAL SYSTEM...................................................................................................................................................................................................................................................351 Engine Line.....................................................................................................................................................................................................................................................351 Frame Line - Standard...........................................................................................................................................................................................................................................352 Frame Line - Optional...........................................................................................................................................................................................................................................353 Cab Line - Standard (1 of 2)....................................................................................................................................................................................................................................354 Cab Line - Standard (2 of 2)....................................................................................................................................................................................................................................355 Cab Line - Optional (1 of 3)....................................................................................................................................................................................................................................356 Cab Line - Optional (2 of 3)....................................................................................................................................................................................................................................357 Cab Line - Optional (3 of 3)....................................................................................................................................................................................................................................358 Top-Cab Light Line - Standard...................................................................................................................................................................................................................................359 Top-Cab Light Line - Optional...................................................................................................................................................................................................................................360 Rear Light Line.................................................................................................................................................................................................................................................361 Standard........................................................................................................................................................................................................................................................362 Optional (1 of 2)...............................................................................................................................................................................................................................................363 Optional (2 of 2)...............................................................................................................................................................................................................................................364
PLEASE NOTE:
⦁ This is the SAME MANUAL used by the dealerships to diagnose your vehicle
⦁ No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
⦁ Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
⦁ So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
1 review for KOMATSU SK1026-5N SKID STEER LOADER SERVICE REPAIR MANUAL (SN:A80001 & UP) – PDF Download
Add a review
Wade Cain –