Komatsu Skid Steer Loader SK1020-5N SK1020-5NA service & repair manual

Description Komatsu Skid Steer Loader SK1020-5N SK1020-5NA service & repair manual

Komatsu Skid Steer Loader SK1020-5N, SK1020-5NA pdf workshop service repair manual + operation & maintenance manual

Serial numbers:
SK1020-5N A70001 and up
SK1020-5NA A60001 and up

Specifications, testing, troubleshooting, maintenance, technical data, diagrams, schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
GENERAL
DIMENSION DRAWINGS
Machine Dimensions
Working Ranges
SPECIFICATIONS
WEIGHT TABLE
FUEL COOLANT AND LUBRICANTS
SERVICE NOTES

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WORK EQUIPMENT PIVOT POINT CLEARANCES
WHEEL DRIVE SYSTEM
Power Train Flow
Transmission System
Wheel Axles
DRIVE MOTOR SYSTEM
Motor Ports
Motor Structure
Motor Operations
Description
HYDRAULIC PUMPS
Drive Dampener
Maintenance Standard
Pump Internal View
Operation of Main Pump
Shuttle Valve
SAFETY VALVES
Suction Safety Valve Action
Charge Safety Valve Action
ANTI ENGINE-STALL VALVE (AS VALVE)
AS Valve Maintenance Standard
CONTROL VALVES
Standard 3-Spool Valve Port Location
Valve-Sectional Views
Super High-Flow 4-Spool Valve Port Location
Valve-Sectional Views
Control Valve Maintenence Standard
Control Valve (Standard)
Control Valve (Super High-Flow)
CLOSED CENTER LOAD SENSING SYSTEM
Pressure Compensation Control
Hydraulic Circuit Diagram
System in Series Circuit Operation
Self Leveling Function
System in Series-Parallel Circuit Operation
Pressure Compensation Valve
Dividing Function
SOLENOID VALVE
Valve Group
ACCUMULATOR
PATTERN CHANGE VALVE
Maintenance Standard
Pattern Options Arrangement
Pattern ISO
Pattern Optional
R.H. PPC VALVE (STANDARD)
Equipment Control
R.H. PPC Valve Maintenance Standard
R.H. PPC VALVE (PATTERN CHANGE)
Equipment and Travel Control
L.H. PPC VALVE (STANDARD)
Travel Control
Standard
Maintenance Standard
L.H. PPC VALVE (PATTERN CHANGE)
Equipment and Travel Control
Pattern Change
Maintenance Standard
CYLINDERS
Boom
Bucket
Maintenance Standard

STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLE
Standard Service Value Table for Engine
Standard Value Table for Chassis

TESTING AND ADJUSTING
SPECIAL TOOLS
T-ADAPTER PROCEDURES AND KITS
ENGINE COMPONENTS
Measuring Exhaust Smoke
Measuring Exhaust Temperature
Adjusting Valve Clearance
Measuring Compression Pressure
Measuring Crankcase Pressure
Measuring Engine Oil Pressure
Measuring Boost Pressure
Measuring Fuel Pressure
Adjusting Engine Speed Sensor
Bleeding Air From Fuel System
Adjusting Engine Stop Solenoid
Adjusting Engine Speed
ADJUSTING PPC VALVE PRESSURES
Adjusting PPC Valve
ADJUSTING SERVO-CONTROL SAFETY SENSOR
CHAIN TENSION

TESTING AND ADJUSTING THE HYDRAULIC SYSTEM
Relieving Hydraulic Pressure
Bleeding Hydraulic Circuits
HYDRAULIC PUMP
Calibrating Valve
Travel Deviation Check
CONTROL VALVE
Servo-Control Power Supply
AIR CONDITIONING SYSTEM
Environmental Impact
Basic Air Conditioning System (Typical)
Operator Cab Air Conditioning
Principles of Refrigeration
Air Conditioning
The Act of Cooling
The Refrigeration Cycle
Air Conditioner System Components
Compressor (Refrigerant Pump)
Service Valves
Condenser
Receiver-Drier
Thermostatic Expansion Valve
Evaporator
Electrical Circuit
Thermostat
Compressor Clutch
Safety Switches
System Servicing
R-134A Refrigerant Containers
Service Tools And Equipment
Recovery/Recycle Station
Leak Detector
Service Valves
Vacuum Pump
Manifold Gauge Set
Installing Manifold Gauge Set
Purging Air from Service Hoses
Adding Refrigerant to the System (Without a Charging Station)
Stabilizing the AC System
Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling Station)
Recovering and Recycling the Refrigerant
Performing the Recovery Cycle
Performing the Recycling Procedure
Evacuating and Charging the AC System
System Performance Test
System Leak Testing
Electronic Leak Detector
Tracer Dyes
Soap and Water
System Repair
Hoses and Fittings
Lines
Expansion Valve
Receiver-Drier
Thermostat
Clutch
Compressor
Checking Compressor Oil Level
Evacuating The System
Troubleshooting - Air Conditioning System
Pre-Diagnosis Checks
Preparing for Diagnosis
Preliminary Steps
System Performance Test
Diagnosis of Gauge Readings and System Performance
Troubleshooting by Manifold Gauge Set Readings
Preventive Maintenance Schedule for A/C System

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Points To Remember When Troubleshooting Electrical Circuits
CHECKS BEFORE TROUBLESHOOTING
Troubleshooting Procedure
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
ENGINE COOLANT TEMPERATURE SENSOR FAILURE
ABNORMAL ENGINE OIL PRESSURE INDICATED
AIR CLEANER CLOG INDICATED
ENGINE PREHEAT SYSTEM INOPERABLE
FUEL LEVEL INDICATION IS INCORRECT
FUEL PUMP MOTOR INOPERATIVE
ENGINE DOES NOT SHUT DOWN OR WILL NOT START
ALTERNATOR NOT CHARGING BATTERY
ENGINE WILL NOT CRANK
BACK-UP ALARM WILL NOT FUNCTION
HYDRAULIC FILTER SENSOR WARNING
PPC SYSTEM ELECTRICAL MALFUNCTION
SEAT SAFETY SWITCH MALFUNCTION
SAFETY BAR SWITCH MALFUNCTION
TRAVEL SPEEDS CANNOT BE CHANGED
FLOAT CONTROL MALFUNCTION
PARKING BRAKE SYSTEM MALFUNCTION
PATTERN CHANGE MALFUNCTION
STABALIZER SYSTEM MALFUNCTION
LOW OR WEAK TRAVEL, WEAK BRAKE-OUT FORCE
WEAK TRAVEL, WEAK BREAK-OUT FORCE IN REVERSE
ROTATING BEACON INOPERABLE
REAR WORK LIGHTS WILL NOT OPERATE
HORN DOES NOT SOUND
POSSIBLE DEFECTIVE SAFETY RELAY UNIT

DISASSEMBLY AND ASSEMBLY
Special Tools
CONNECTOR REPAIR PROCEDURES
Stripping Insulation
Wire Inspection
Contact Terminal Removal (HD30 Type)
Crimping Contact Terminal (HD30 Type)
Insertion Of Contact Terminal (HD30 Type)
Contact Terminal Removal (DT Type)
Crimping Contact Terminal (DT Type)
Insertion Of Contact Terminal (DT Type)
ENGINE
Alternator
Cylinder Head
Engine Front Seal
Engine Oil Cooler
Engine Rear Seal
Fuel Injection Pump
Nozzle Holder
Thermostat
Turbocharger
Water Pump
ENGINE HOOD ASSEMBLY
OPERATOR’S CAB ASSEMBLY
WORK EQUIPMENT SYSTEM
REMOVING EQUIPMENT SUPPORT FRAME
BATTERY
STARTER MOTOR
ALTERNATOR
AIR FILTER ASSEMBLY
MUFFLER ASSEMBLY (SK1020-5N)
MUFFLER ASSEMBLY (SK1020-5N TURBO)
RADIATOR ASSEMBLY
FUEL TANK ASSEMBLY
ENGINE-PUMP ASSEMBLY
HYDRAULIC PUMP ASSEMBLY
GEAR PUMP ASSEMBLY
ENGINE-PUMP COUPLING
CONTROL VALVE
PPC VALVES
CAB HEATER ASSEMBLY
WHEEL HUB ASSEMBLY
FINAL DRIVE ASSEMBLY
LIFT AND BUCKET CYLINDERS
WORK EQUIPMENT CYLINDER OVERHAUL
MONITOR PANEL REPLACEMENT

OTHERS
ENGINE ELECTRICAL
FRAME LINE ELECTRICAL
OPERATOR COMPARTMENT ELECTRICAL
TOP OPERATOR CAB ELECTRICAL
HYDRAULIC CIRCUIT
AIR CONDITIONER

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