Komatsu Skid Steer Loader SK1020-5, SK1020-5 turbo Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Skid Steer Loader SK1020-5, SK1020-5 turbo, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Skid Steer Loader SK1020-5, SK1020-5 turbo workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,243 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
WEAM004801 - Skid Steer Loader SK1020-5 Operation & Maintenance Manual....2
COVER....2
1.1 FOREWORD....4
1.2 INFORMATION ON SAFETY....6
1.3 INTRODUCTION....8
1.3.1 INTENDED USES....8
1.3.2 IMPROPER OR UNAUTHORIZED USES....8
1.3.3 MAIN CHARACTERISTICS....9
1.3.4 RUNNING-IN....9
1.4 PRODUCT IDENTIFICATION....10
1.4.1 MACHINE SERIAL NUMBER....10
1.4.2 MACHINE IDENTIFICATION PLATE....10
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE....11
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....11
1.4.5 CAB SERIAL NUMBER....11
1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed)....11
1.4.7 SERIAL NUMBERS AND DISTRIBUTORS ADDRESS....12
TABLE OF CONTENTS....13
SAFETY AND ACCIDENT PREVENTION....20
2.1 SAFETY, NOISE AND VIBRATION PLATES....21
2.1.1 POSITION OF THE SAFETY PLATES....21
2.1.2 POSITION OF THE PICTOGRAMS....39
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS....43
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....47
2.2 GENERAL PRECAUTIONS....48
2.2.1 GENERAL SAFETY RULES....48
2.2.2 SAFETY DEVICES AND GUARDS....48
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....48
2.2.4 UNAUTHORIZED MODIFICATIONS....49
2.2.5 LEAVING THE OPERATORS SEAT....49
2.2.6 GETTING ON AND OFF THE MACHINE....50
2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed)....50
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL....51
2.2.9 PREVENTING BURNS....51
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....52
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....52
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT....53
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....53
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT....53
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....54
2.3.1 SAFETY ON THE WORK SITE....54
2.3.2 FIRE PREVENTION....54
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....54
2.3.4 ROOM VENTILATION....55
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed)....55
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES (if i.....55
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....56
2.4.1 STARTING THE ENGINE....56
2.4.2 RULES TO BE FOLLOWED WHEN TRAVELING ON ROADS (if required)....56
2.4.3 CHECKS FOR TRAVELING IN REVERSE....57
2.4.4 MOVING THE MACHINE....58
2.4.5 WORKING ON SLOPES....58
2.4.6 PREVENTING ELECTROCUTION....60
2.4.7 VISIBILITY....61
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES....61
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....61
2.4.10 WORKING ON LOOSE GROUND....61
2.4.11 PARKING THE MACHINE....62
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....63
2.5.1 LOADING AND UNLOADING THE MACHINE....63
2.5.2 THE ROUTE....63
2.6 BATTERY....64
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....64
2.6.2 STARTING WITH BOOSTER CABLES....64
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....65
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....67
2.8.1 WARNING PLATES....67
2.8.2 TOOLS....67
2.8.3 PERSONNEL....68
2.8.4 EQUIPMENT....68
2.8.5 WORKING UNDER THE MACHINE....68
2.8.6 KEEPING THE MACHINE CLEAN....68
2.8.7 USE OF THE ENGINE DURING MAINTENANCE....69
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....69
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....69
2.8.10 RULES FOR REFUELING AND ADDING OIL....70
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....70
2.8.12 USING LAMPS....70
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....71
2.8.14 PRECAUTIONS CONCERNING THE STARTER....71
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES....72
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS....72
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....72
2.8.18 COOLING FAN AND FAN BELT....73
2.8.19 WASTE MATERIALS....73
2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TIRES....73
2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....74
THE MACHINE AND ITS OPERATIONS....76
3.1 SAFETY LOCKS....77
3.1.1 LOADER LOCKS....77
3.1.2 EXCAVATOR LOCKS (if installed)....79
3.1.3 ASPHALT CUTTER LOCKS (if installed)....81
3.2 GENERAL VIEWS....82
3.2.1 FRONT GENERAL VIEW....82
3.2.2 REAR GENERAL VIEW....83
3.2.3 CAB INSIDE GENERAL VIEW....84
3.3 INSTRUMENTS AND CONTROLS....86
3.3.1 INSTRUMENTS....86
3.3.2 WARNING LIGHTS....88
3.3.3 SWITCHES AND PUSH BUTTONS....93
3.3.4 ELECTRICAL ACCESSORIES....98
3.3.5 MACHINE CONTROLS....100
3.4 FUSES AND RELAYS....118
3.4.1 MACHINE FUNCTION FUSES....118
3.4.2 MAIN FUSE....119
3.4.3 RELAYS....120
3.5 GUARDS AND DRIVERS SEAT....122
3.5.1 ENGINE HOOD....122
3.5.2 REAR PANEL....123
3.5.3 CAB....124
3.5.3.1 RAISING THE CAB....125
3.5.4 STANDARD SEAT....127
3.5.5 SUSPENSION SEAT....127
3.5.6 SAFETY BELT....128
3.5.7 EMERGENCY EXIT....128
3.5.8 TECHNICAL DOCUMENTATION CASE....129
3.5.9 FIRE EXTINGUISHER....129
3.5.10 FIRST AID KIT....129
3.6 USE OF THE MACHINE....130
3.6.1 CHECKS BEFORE STARTING THE ENGINE....130
3.6.1.1 VISUAL CHECKS....130
3.6.1.2 DAILY CHECKS....130
3.6.1.3 OPERATIONAL CHECKS....131
3.6.2 STARTING THE ENGINE....132
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....132
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....133
3.6.3 WARMING THE ENGINE....134
3.6.4 HEATING THE HYDRAULIC OIL....134
3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEM)....134
3.6.5.1 STEERING (CHANGING DIRECTION)....136
3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)....138
3.6.6.1 STEERING (CHANGING DIRECTION)....140
3.6.7 MOVING ON SLOPES....142
3.6.8 MAXIMUM IMMERSION DEPTH....143
3.7 PARKING THE MACHINE....144
3.7.1 PARKING ON LEVEL GROUND....144
3.7.2 PARKING ON SLOPES....145
3.8 STOPPING THE ENGINE....146
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....147
3.9.1 LOADING AND UNLOADING THE MACHINE....147
3.9.2 TRANSPORT....148
3.10 HOW TO LIFT THE MACHINE....149
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....150
3.11.1 FUEL AND LUBRICANTS....150
3.11.2 COOLANT....150
3.11.3 BATTERY....151
3.11.4 OTHER PRECAUTIONS....151
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....151
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....152
3.13 USING THE WORK EQUIPMENT....153
3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE....153
3.13.2 ORGANIZING THE WORK AREA....154
3.13.3 LOADING MATERIAL FROM PILES AND ON LEVEL SURFACES....155
3.13.4 LOADING MATERIAL ON SLOPES....156
3.13.5 DIGGING METHOD....157
3.13.6 CHANGING THE BUCKET WITH STANDARD RAPID COUPLING....158
3.13.6.1 RELEASING THE BUCKET....159
3.13.6.2 COUPLING THE BUCKET....159
3.13.6.3 CHECKING THE POSITION OF THE LOCKING PINS....160
3.13.6.4 ADJUSTING THE LOCKING PINS....161
3.14 LONG PERIODS OF INACTIVITY....162
3.14.1 BEFORE THE PERIOD OF INACTIVITY....162
3.14.2 DURING THE PERIOD OF INACTIVITY....163
3.14.3 AFTER THE PERIOD OF INACTIVITY....163
3.15 TROUBLESHOOTING....164
3.15.1 HOW TO REMOVE THE MACHINE....164
3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....164
3.15.3 IF THE BATTERY IS DEPLETED....165
3.15.3.1 STARTING WITH BOOSTER CABLES....166
3.15.4 OTHER TROUBLES....167
3.15.4.1 ELECTRICAL CIRCUIT....167
3.15.4.2 HYDRAULIC SYSTEM....168
3.15.4.3 ENGINE....169
3.15.4.4 HYDROSTATIC TRANSMISSION....170
MAINTENANCE....172
4.1 GUIDE TO MAINTENANCE....173
4.2 MAINTENANCE NOTES....175
4.2.1 NOTES REGARDING THE ENGINE....175
4.2.1.1 ENGINE OIL....175
4.2.1.2 COOLANT....175
4.2.1.3 FUEL....176
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....176
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....177
4.2.4 NOTES REGARDING LUBRICATION....177
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....178
4.3 FUEL, COOLANT AND LUBRICANTS....179
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES....183
4.4 DRIVING TORQUES FOR SCREWS AND NUTS....184
4.4.1 STANDARD DRIVING TORQUES....184
4.4.2 SPECIFIC DRIVING TORQUES....184
4.5 LUBRICATION....185
4.5.1 LUBRICATION DIAGRAM....185
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....186
4.6.1 CRITICAL PARTS FOR SAFETY....187
4.7 MAINTENANCE PLAN....193
4.7.1 WHEN REQUIRED....196
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....196
4.7.1.b TYRE ROTATION....197
4.7.1.c DRAINING THE FUEL TANK....198
4.7.1.d RELEASING THE PARKING BRAKE....199
4.7.1.e CHECKING THE BATTERY CHARGE LEVEL....200
4.7.2 CHECKS BEFORE STARTING....201
4.7.2.a VARIOUS CHECKS....201
4.7.2.b CHECKING THE COOLANT LEVEL....201
4.7.2.c CHECKING THE FUEL LEVEL....202
4.7.2.d CHECKING THE ENGINE OIL LEVEL....203
4.7.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....204
4.7.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER....205
4.7.2.g CHECKING THE WIRING SYSTEM....205
4.7.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION....206
4.7.3.a CHECK THE DRIVE CHAIN TENSION....208
4.7.3.b CHECK THE TIGHTENING OF THE WHEEL FASTENING NUTS....210
4.7.3.c CHANGING THE HYDRAULIC OIL DRAIN FILTER (ONLY FOR MACHINES FILLED WITH BIODEGRADABLE OIL)....217
4.7.4 MAINTENANCE EVERY 50 HOURS OF OPERATION....206
4.7.4.a CHECKING THE TYRE PRESSURE....206
4.7.4.b CHECKING THE COOLANT LEVEL IN THE RADIATOR....206
4.7.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....207
4.7.5.a CHANGING THE HYDRAULIC OIL DRAIN FILTER (ONLY FOR MACHINES FILLED WITH BIODEGRADABLE OIL)....217
4.7.6 MAINTENANCE EVERY 250 HOURS OF OPERATION....207
4.7.6.a ADJUSTING THE FAN BELT TENSION....207
4.7.6.b CHECKING THE DRIVE CHAIN TENSION....208
4.7.6.c CLEANING THE OUTSIDE OF THE RADIATORS....210
4.7.6.d CHECKING THE WHEEL NUT DRIVING TORQUE....210
4.7.6.e CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS....211
4.7.6.f LUBRICATING THE JOINTS....212
4.7.6.g CHANGING THE ENGINE OIL....213
4.7.6.h CHANGING THE ENGINE OIL FILTER....214
4.7.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic.....215
4.7.7.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....222
4.7.8 MAINTENANCE EVERY 500 HOURS OF OPERATION....215
4.7.8.a CHANGING THE FUEL FILTER....215
4.7.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER....217
4.7.8.c CLEANING THE WATER SEPARATOR....218
4.7.8.d DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oi.....219
4.7.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION....221
4.7.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION....221
4.7.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER....222
4.7.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....224
4.7.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION....225
4.7.10.a CHANGING THE COOLANT....225
4.7.10.b CHANGING THE SUCTION FILTER....227
4.7.10.c CHECKING THE ALTERNATOR AND THE STARTER....228
TECHNICAL SPECIFICATIONS....230
5.1 TECHNICAL DATA....231
5.1.1 STANDARD MACHINE OVERALL DIMENSIONS....231
5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT....233
5.1.3 TECHNICAL CHARACTERISTICS....235
AUTHORISED OPTIONAL EQUIPMENT....238
6.1 AUTHORIZED OPTIONAL EQUIPMENT....239
6.1.1 PRECAUTIONS REGARDING SAFETY....239
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....240
6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT....241
6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH HIGH FLOW AND SUPER-F.....242
6.2 CHANGING THE AUTHORIZED EQUIPMENT....243
6.2.1 CONNECTING THE EXCAVATOR....243
6.2.2 CONNECTING THE HYDRAULIC CIRCUIT....244
6.2.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK....246
6.2.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR....247
6.2.5 USING THE MACHINE WITH THE EXCAVATOR....247
6.3 PALLET FORKS....248
WEAM004803 - Skid Steer Loader SK1020-5 Operation & Maintenance Manual....250
COVER....250
FOREWORD....251
1.1 FOREWORD....251
1.2 INFORMATION ON SAFETY....253
1.3 INTRODUCTION....255
1.3.1 INTENDED USES....255
1.3.2 IMPROPER OR UNAUTHORIZED USES....255
1.3.3 MAIN CHARACTERISTICS....255
1.3.4 RUNNING-IN....256
1.4 PRODUCT IDENTIFICATION....257
1.4.1 MACHINE SERIAL NUMBER....257
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)....257
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE....258
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....258
1.4.5 CAB SERIAL NUMBER....258
1.4.6 BACKHOE IDENTIFICATION PLATE (if installed)....258
1.4.7 SERIAL NUMBERS AND DISTRIBUTORS ADDRESS....259
TABLE OF CONTENTS....261
SAFETY AND ACCIDENT PREVENTION....267
2.1 SAFETY AND WARNING DECALS....268
2.1.1 LOCATION OF THE SAFETY DECALS....268
2.1.2 LOCATION OF THE PICTOGRAM DECALS....283
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS....287
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....289
2.2 GENERAL PRECAUTIONS....290
2.2.1 GENERAL SAFETY RULES....290
2.2.2 SAFETY DEVICES AND GUARDS....290
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....290
2.2.4 UNAUTHORIZED MODIFICATIONS....291
2.2.5 LEAVING THE OPERATORS SEAT....291
2.2.6 GETTING ON AND OFF THE MACHINE....292
2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed)....292
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL....293
2.2.9 PREVENTING BURNS....293
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....294
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....294
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT....295
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....295
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT....295
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....296
2.3.1 SAFETY ON THE WORK SITE....296
2.3.2 FIRE PREVENTION....296
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....296
2.3.4 ROOM VENTILATION....297
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS....297
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES (if installed)....297
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....298
2.4.1 STARTING THE ENGINE....298
2.4.2 CHECKS FOR TRAVELING IN REVERSE....298
2.4.3 MOVING THE MACHINE....299
2.4.4 WORKING ON SLOPES....299
2.4.5 PREVENTING ELECTROCUTION....301
2.4.6 VISIBILITY....302
2.4.7 WORKING ON ICY OR SNOW-COVERED SURFACES....302
2.4.8 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....302
2.4.9 WORKING ON LOOSE GROUND....302
2.4.10 PARKING THE MACHINE....303
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....304
2.5.1 LOADING AND UNLOADING THE MACHINE....304
2.5.2 THE ROUTE....304
2.6 BATTERY....305
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....305
2.6.2 STARTING WITH BOOSTER CABLES....305
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....306
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....308
2.8.1 WARNING TAGS....308
2.8.2 TOOLS....308
2.8.3 PERSONNEL....309
2.8.4 EQUIPMENT....309
2.8.5 WORKING UNDER THE MACHINE....309
2.8.6 KEEPING THE MACHINE CLEAN....309
2.8.7 USE OF THE ENGINE DURING MAINTENANCE....310
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....310
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....310
2.8.10 RULES FOR REFUELING AND ADDING OIL....311
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....311
2.8.12 USING LAMPS....311
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....312
2.8.14 PRECAUTIONS CONCERNING THE STARTER....312
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES....313
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRES SURE SYSTEMS....313
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSU RES....313
2.8.18 COOLING FAN AND FAN BELT....314
2.8.19 WASTE MATERIALS....314
2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TIRES....314
2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....315
THE MACHINE AND ITS OPERATION....317
3.1 SAFETY LOCKS....318
3.1.1 LOADER ARM SUPPORT....318
3.1.2 BACKHOE LOCKS (if installed)....320
3.1.3 COLD PLANER LOCKS (if installed)....322
3.2 GENERAL VIEWS....323
3.2.1 FRONT GENERAL VIEW....323
3.2.2 REAR GENERAL VIEW....324
3.2.3 CAB INSIDE GENERAL VIEW....325
3.3 INSTRUMENTS AND CONTROLS....327
3.3.1 INSTRUMENTS....327
3.3.2 INDICATOR LIGHTS....329
3.3.3 SWITCHES AND PUSH BUTTONS....334
3.3.4 ELECTRICAL ACCESSORIES....339
3.3.5 MACHINE CONTROLS....341
3.4 FUSES AND RELAYS....363
3.4.1 MACHINE FUNCTION FUSES....363
3.4.2 MAIN FUSE....364
3.4.3 RELAYS....365
3.5 GUARDS AND OPERATORS SEAT....367
3.5.1 ENGINE HOOD....367
3.5.2 REAR PANEL....368
3.5.3 CAB....369
3.5.3.1 TILTING THE CAB....370
3.5.4 STANDARD SEAT....372
3.5.5 CUSHIONED SEAT....372
3.5.6 SEAT BELT....373
3.5.7 EMERGENCY EXIT....373
3.5.8 TECHNICAL DOCUMENTATION CASE....374
3.5.9 FIRE EXTINGUISHER....374
3.5.10 FIRST AID KIT....374
3.6 USE OF THE MACHINE....375
3.6.1 CHECKS BEFORE STARTING THE ENGINE....375
3.6.1.1 VISUAL CHECKS....375
3.6.1.2 DAILY CHECKS....375
3.6.1.3 OPERATIONAL CHECKS....376
3.6.2 STARTING THE ENGINE....377
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....377
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....378
3.6.3 WARMING THE ENGINE....379
3.6.4 HEATING THE HYDRAULIC OIL....379
3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEM)....379
3.6.5.1 STEERING (CHANGING DIRECTION)....381
3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYS TEM)....383
3.6.6.1 STEERING (CHANGING DIRECTION)....385
3.6.7 MOVING ON SLOPES....387
3.6.8 MAXIMUM IMMERSION DEPTH....388
3.7 PARKING THE MACHINE....389
3.7.1 PARKING ON LEVEL GROUND....389
3.7.2 PARKING ON SLOPES....390
3.8 STOPPING THE ENGINE....391
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....392
3.9.1 LOADING AND UNLOADING THE MACHINE....392
3.9.2 TRANSPORT....393
3.10 HOW TO LIFT THE MACHINE....394
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....395
3.11.1 FUEL AND LUBRICANTS....395
3.11.2 COOLANT....395
3.11.3 BATTERY....396
3.11.4 OTHER PRECAUTIONS....396
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....396
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....397
3.13 USING THE WORK EQUIPMENT....398
3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE....398
3.13.2 ORGANIZING THE WORK AREA....399
3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES....400
3.13.4 LOADING MATERIAL ON SLOPES....401
3.13.5 DIGGING METHOD....402
3.13.6 CHANGING THE BUCKET OR ATTACHMENT WITH STANDARD QUICK COUPLER....403
3.13.6.1 REMOVING THE BUCKET OR ATTACH MENT....404
3.13.6.2 ATTACHING THE BUCKET....405
3.13.6.3 CHECKING THE POSITION OF THE LOCKING PINS....406
3.13.6.4 ADJUSTING THE LOCKING PINS....407
3.14 LONG PERIODS OF INACTIVITY....408
3.14.1 BEFORE THE PERIOD OF INACTIVITY....408
3.14.2 DURING THE PERIOD OF INACTIVITY....409
3.14.3 AFTER THE PERIOD OF INACTIVITY....409
3.15 TROUBLESHOOTING....410
3.15.1 HOW TO REMOVE THE MACHINE....410
3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....410
3.15.3 IF THE BATTERY IS DEPLETED....411
3.15.3.1 STARTING WITH BOOSTER CABLES....412
3.15.4 OTHER TROUBLES....413
3.15.4.1 ELECTRICAL CIRCUIT....413
3.15.4.2 HYDRAULIC SYSTEM....414
3.15.4.3 ENGINE....414
3.15.4.4 HYDROSTATIC TRANSMISSION....415
MAINTENANCE....417
4.1 GUIDE TO MAINTENANCE....418
4.2 MAINTENANCE NOTES....420
4.2.1 NOTES REGARDING THE ENGINE....420
4.2.1.1 ENGINE OIL....420
4.2.1.2 COOLANT....420
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....421
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....421
4.2.4 NOTES REGARDING LUBRICATION....422
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....423
4.3 FUEL, COOLANT AND LUBRICANTS....424
4.3.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES....428
4.4 DRIVING TORQUES FOR SCREWS AND NUTS....429
4.4.1 STANDARD DRIVING TORQUES....429
4.4.2 SPECIFIC DRIVING TORQUES....429
4.5 LUBRICATION....430
4.5.1 LUBRICATION DIAGRAM....430
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....431
4.6.1 CRITICAL PARTS FOR SAFETY....432
4.7 MAINTENANCE PLAN....438
4.8 MAINTENANCE PROCEDURE....440
4.8.1 WHEN REQUIRED....440
4.8.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....440
4.8.1.b TIRE ROTATION....441
4.8.1.c DRAINING THE FUEL TANK....442
4.8.1.d RELEASING THE PARKING BRAKE....443
4.8.1.e CHECKING THE BATTERY CHARGE LEVEL....444
4.8.2 CHECKS BEFORE STARTING....445
4.8.2.a VARIOUS CHECKS....445
4.8.2.b CHECKING THE COOLANT LEVEL....445
4.8.2.c CHECKING THE FUEL LEVEL....446
4.8.2.d CHECKING THE ENGINE OIL LEVEL....447
4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....448
4.8.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER....449
4.8.2.g CHECKING THE WIRING SYSTEM....449
4.8.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION....450
4.8.4 MAINTENANCE EVERY 50 HOURS OF OPERATION....450
4.8.4.a CHECKING THE TIRE PRESSURE....450
4.8.4.b CHECKING THE COOLANT LEVEL IN THE RADIATOR....450
4.8.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....451
4.8.6 MAINTENANCE EVERY 250 HOURS OF OPERATION....451
4.8.6.a ADJUSTING THE FAN BELT TENSION....451
4.8.6.b CHECKING THE GEARING CHAIN TEN SION....452
4.8.6.c CLEANING THE OUTSIDE OF THE RADIATORS....454
4.8.6.d CHECKING THE WHEEL NUT DRIVING TORQUE....454
4.8.6.e CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS....455
4.8.6.f LUBRICATING THE JOINTS....456
4.8.6.g CHANGING THE ENGINE OIL....457
4.8.6.h CHANGING THE ENGINE OIL FILTER....458
4.8.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic biodegradable oil type HEES)....459
4.8.8 MAINTENANCE EVERY 500 HOURS OF OPERATION....459
4.8.8.a CHANGING THE FUEL FILTER....459
4.8.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER....461
4.8.8.c CLEANING THE WATER SEPARATOR....462
4.8.8.d DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oil type HEES)....463
4.8.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION....465
4.8.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION....465
4.8.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FIL TER....466
4.8.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....468
4.8.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION....469
4.8.10.a CHANGING THE COOLANT....469
4.8.10.b CHANGING THE SUCTION FILTER....470
4.8.10.c CHECKING THE ALTERNATOR AND THE STARTER....471
TECHNICAL SPECIFICATIONS....473
5.1 TECHNICAL DATA....474
5.1.1 STANDARD MACHINE OVERALL DIMENSIONS....474
5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT....475
5.1.3 TECHNICAL CHARACTERISTICS....476
AUTHORIZED OPTIONAL EQUIPMENT....479
6.1 AUTHORIZED OPTIONAL EQUIPMENT....480
6.1.1 PRECAUTIONS REGARDING SAFETY....480
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....480
6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT....481
6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH SUPER-FLOW HYDRAULIC SYSTEM....482
6.2 CHANGING THE AUTHORIZED EQUIPMENT....483
6.2.1 CONNECTING THE BACKHOE....483
6.2.2 CONNECTING THE HYDRAULIC CIRCUIT....484
6.2.3 CONNECTING THE RETURN CIR CUIT WITH DIRECT DRAINAGE INTO THE TANK....486
6.2.4 PREPARING THE MACHINE FOR THE USE OF THE BACKHOE....487
6.2.5 USING THE MACHINE WITH THE BACKHOE....487
6.3 PALLET FORKS....488
6.4 HAND & FOOT CONTROL SYSTEM....489
6.4.1 MACHINE CONTROLS....489
6.4.1.1 TRAVEL AND STEERING CONTROL LEVERS....490
6.4.1.2 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET)....492
6.4.1.3 AUXILIARY HYDRAULIC CONTROL LEVER....495
6.4.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)....498
6.4.2.1 STEERING (CHANGING DIRECTION)....500
WEAM005205 - Skid Steer Loader SK1020-5 turbo Operation & Maintenance Manual....503
1.1 FOREWORD....505
1.2 INFORMATION ON SAFETY....506
1.3 INTRODUCTION....508
1.3.1 INTENDED USES....508
1.3.2 IMPROPER OR UNAUTHORIZED USES....508
1.3.3 MAIN CHARACTERISTICS....508
1.3.4 RUNNING-IN....509
1.4 PRODUCT IDENTIFICATION....510
1.4.1 MACHINE SERIAL NUMBER....510
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)....510
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE....511
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....511
1.4.5 CAB SERIAL NUMBER....511
1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed)....511
1.4.7 SERIAL NUMBERS AND DEALERS ADDRESS....512
TABLE OF CONTENTS....513
2.1 SAFETY, NOISE AND VIBRATION PLATES....520
2.1.1 POSITION OF THE SAFETY PLATES....520
2.1.1.1 SAFETY PLATES....520
2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR....522
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS....524
2.1.3 POSITION OF THE NOISE PLATES....527
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....527
2.2 GENERAL PRECAUTIONS....528
2.2.1 GENERAL SAFETY RULES....528
2.2.2 SAFETY DEVICES AND GUARDS....528
2.2.3 CLOTHING AND PERSONAL PRO TECTION ITEMS....528
2.2.4 UNAUTHORIZED MODIFICATIONS....529
2.2.5 LEAVING THE OPERATORS SEAT....529
2.2.6 GETTING ON AND OFF THE MACHINE....530
2.2.7 CHECKING THE REAR-VIEW MIR RORS (if installed)....530
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL....531
2.2.9 PREVENTING BURNS....531
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....532
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....532
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT....533
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....533
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT....533
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....534
2.3.1 SAFETY ON THE WORK SITE....534
2.3.2 FIRE PREVENTION....534
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....534
2.3.4 ROOM VENTILATION....535
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed)....535
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES (if installed)....535
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....536
2.4.1 STARTING THE ENGINE....536
2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS....536
2.4.3 CHECKS FOR TRAVELLING IN REVERSE....537
2.4.4 MOVING THE MACHINE....538
2.4.5 WORKING ON SLOPES....538
2.4.6 PREVENTING ELECTROCUTION....540
2.4.7 VISIBILITY....541
2.4.8 WORKING ON ICY OR SNOW-COVERED SURFACES....541
2.4.9 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....541
2.4.10 WORKING ON LOOSE GROUND....541
2.4.11 PARKING THE MACHINE....542
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....543
2.5.1 LOADING AND UNLOADING THE MACHINE....543
2.5.2 THE ROUTE....543
2.6 BATTERY....544
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....544
2.6.2 STARTING WITH BOOSTER CABLES....544
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....545
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....547
2.8.1 WARNING PLATES....547
2.8.2 TOOLS....547
2.8.3 PERSONNEL....548
2.8.4 EQUIPMENT....548
2.8.5 WORKING UNDER THE MACHINE....548
2.8.6 KEEPING THE MACHINE CLEAN....548
2.8.7 USE OF THE ENGINE DURING MAINTENANCE....549
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....549
2.8.9 STOP THE ENGINE BEFORE CAR RYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....549
2.8.10 RULES FOR REFUELLING AND ADDING OIL....550
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....550
2.8.12 USING LAMPS....550
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....551
2.8.14 PRECAUTIONS CONCERNING THE STARTER....551
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES....552
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRES SURE SYSTEMS....552
2.8.17 PRECAUTIONS FOR MAINTE NANCE WORK INVOLVING HIGH TEMPERATURES AND PRES SURES....552
2.8.18 COOLING FAN AND FAN BELT....553
2.8.19 WASTE MATERIALS....553
2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TYRES....553
2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODE GRADABLE OIL TYPE HEES....554
3.1 SAFETY LOCKS....556
3.1.1 LOADER LOCKS....556
3.1.2 EXCAVATOR LOCKS (if installed)....558
3.1.3 ASPHALT CUTTER LOCKS (if installed)....560
3.2 GENERAL VIEWS....561
3.2.1 FRONT GENERAL VIEW....561
3.2.2 REAR GENERAL VIEW....562
3.2.3 CAB INSIDE GENERAL VIEW....563
3.3 INSTRUMENTS AND CONTROLS....565
3.3.1 INSTRUMENTS....565
3.3.2 WARNING LIGHTS....567
3.3.3 SWITCHES UND PUSH BUTTONS....572
3.3.4 ELECTRICAL ACCESSORIES....578
3.3.5 MACHINE CONTROLS....580
3.4 FUSES AND RELAYS....600
3.4.1 MACHINE FUNCTION FUSES....600
3.4.2 MAIN FUSE....601
3.4.3 RELAYS....602
3.5 GUARDS AND DRIVERS SEAT....604
3.5.1 ENGINE HOOD....604
3.5.2 REAR PANEL....605
3.5.3 CAB....606
3.5.3.1 STANDARD CAB....606
3.5.3.2 CAB WITH FRONT DOOR AND SIDE WINDOWS (available on request)....606
3.5.3.3 WINDSHIELD DETERGENT RESER VOIR (only for cab with front door)....608
3.5.3.4 RAISING THE CAB....609
3.5.4 STANDARD SEAT....611
3.5.5 CUSHIONED SEAT....611
3.5.6 SAFETY BELT....612
3.5.7 EMERGENCY EXIT....612
3.5.8 TECHNICAL DOCUMENTATION CASE....613
3.5.9 FIRE EXTINGUISHER....613
3.5.10 FIRST AID KIT....613
3.6 USE OF THE MACHINE....614
3.6.1 CHECKS BEFORE STARTING THE ENGINE....614
3.6.1.1 VISUAL CHECKS....614
3.6.1.2 DAILY CHECKS....614
3.6.1.3 OPERATIONAL CHECKS....615
3.6.2 STARTING THE ENGINE....616
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....616
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....617
3.6.3 WARMING THE ENGINE....618
3.6.4 HEATING THE HYDRAULIC OIL....618
3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEMERN)....618
3.6.5.1 STEERING (CHANGING DIRECTION)....620
3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYS TEM)....622
3.6.6.1 STEERING (CHANGING DIRECTION)....624
3.6.7 MOVING ON SLOPES....626
3.6.8 MAXIMUM IMMERSION DEPTH....627
3.7 PARKING THE MACHINE....628
3.7.1 PARKING ON LEVEL GROUND....628
3.7.2 PARKING ON SLOPES....629
3.8 STOPPING THE ENGINE....630
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....631
3.9.1 LOADING AND UNLOADING THE MACHINE....631
3.9.2 TRANSPORT....632
3.10 HOW TO LIFT THE MACHINE....633
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....634
3.11.1 FUEL AND LUBRICANTS....634
3.11.2 COOLANT....634
3.11.3 BATTERY....635
3.11.4 OTHER PRECAUTIONS....635
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....635
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....636
3.13 USING THE WORK EQUIPMENT....637
3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE....637
3.13.2 ORGANIZING THE WORK ARE....638
3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES....639
3.13.4 LOADING MATERIAL ON SLOPES....640
3.13.5 DIGGING METHOD....641
3.13.6 CHANGING THE BUCKET OR THE EQUIPMENT WITH STANDARD RAPID COUPLING....642
3.13.6.1 REMOVING THE BUCKET OR THE EQUIPMENT....643
3.13.6.2 CONNECTING THE BUCKET....644
3.13.6.3 CHECKING THE POSITION OF THE LOCKING PINS....645
3.13.6.4 ADJUSTING THE LOCKING PINS....646
3.14 LONG PERIODS OF INACTIVITY....647
3.14.1 BEFORE THE PERIOD OF INACTIV ITY....647
3.14.2 DURING THE PERIOD OF INACTIVITY....648
3.14.3 AFTER THE PERIOD OF INACTIVITY....648
3.15 TROUBLESHOOTING....649
3.15.1 HOW TO REMOVE THE MACHINE....649
3.15.2 IF THE FUEL HAS BEEN COM PLETELY DEPLETED....649
3.15.3 IF THE BATTERY IS DEPLETED....650
3.15.3.1 STARTING WITH BOOSTER CABLES....651
3.15.4 OTHER TROUBLES....652
3.15.4.1 ELECTRICAL CIRCUIT....652
3.15.4.2 HYDRAULIC SYSTEM....652
3.15.4.3 ENGINE....653
3.15.4.4 HYDROSTATIC TRANSMISSION....654
4.1 GUIDE TO MAINTENANCE....658
4.2 MAINTENANCE NOTES....660
4.2.1 NOTES REGARDING THE ENGINE....660
4.2.1.1 ENGINE OIL....660
4.2.1.2 COOLANT....660
4.2.1.3 FUEL....661
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....661
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....661
4.2.4 NOTES REGARDING LUBRICATION....662
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....662
4.3 FUEL, COOLANT AND LUBRICANTS....663
4.3.1 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES....665
4.4 DRIVING TORQUES FOR SCREWS AND NUTS....666
4.4.1 STANDARD DRIVING TORQUES....666
4.4.2 SPECIFIC DRIVING TORQUES....666
4.5 LUBRICATION....667
4.5.1 LUBRICATION DIAGRAM....667
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....668
4.6.1 CRITICAL PARTS FOR SAFETY....669
4.7 MAINTENANCE PLAN....675
4.8 MAINTENANCE PROCEDURE....677
4.8.1 WHEN REQUIRED....677
4.8.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....677
4.8.1.b TYRE ROTATION....678
4.8.1.c DRAINING THE FUEL TANK....679
4.8.1.d RELEASING THE PARKING BRAKE....680
4.8.1.e CHECKING THE BATTERY CHARGE LEVEL....681
4.8.2 CHECKS BEFORE STARTING....682
4.8.2.a VARIOUS CHECKS....682
4.8.2.b CHECKING THE COOLANT LEVEL....682
4.8.2.c CHECKING THE FUEL LEVEL....683
4.8.2.d CHECKING THE ENGINE OIL LEVEL....684
4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....685
4.8.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER....686
4.8.2.g CHECKING THE WIRING SYSTEM....686
4.8.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION....687
4.8.4 MAINTENANCE EVERY 50 HOURS OF OPERATION....687
4.8.4.a CHECKING THE TYRE PRESSURE....687
4.8.4.b CHECKING THE COOLANT LEVEL IN THE RADIATOR....687
4.8.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....688
4.8.6 MAINTENANCE EVERY 250 HOURS OF OPERATION....688
4.8.6.a ADJUSTING THE FAN BELT TENSION....688
4.8.6.b CHECKING THE GEARING CHAIN TEN SION....689
4.8.6.c CLEANING THE OUTSIDE OF THE RADIATORS....691
4.8.6.d CHECKING THE WHEEL NUT DRIVING TORQUE....691
4.8.6.e CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS....692
4.8.6.f LUBRICATING THE JOINTS....693
4.8.6.g CHANGING THE ENGINE OIL....694
4.8.6.h CHANGING THE ENGINE OIL FILTER....695
4.8.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic biodegradable oil type HEES)....696
4.8.8 MAINTENANCE EVERY 500 HOURS OF OPERATION....696
4.8.8.a CHANGING THE FUEL FILTER....696
4.8.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER....698
4.8.8.c CLEANING THE WATER SEPARATOR....699
4.8.8.d DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oil type HEES)....700
4.8.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION....701
4.8.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION....701
4.8.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FIL TER....702
4.8.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....703
4.8.10 MANUTENZIONE OGNI 2000 ORE....704
4.8.10.a CHANGING THE COOLANT....704
4.8.10.b CHANGING THE SUCTION FILTER....705
4.8.10.c CHECKING THE ALTERNATOR AND THE STARTER....706
5.1 TECHNICAL DATA....708
5.1.1 STANDARD MACHINE OVERALL DIMENSIONS....708
5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT....709
5.1.3 TECHNICAL CHARACTERISTICS....710
6.1 AUTHORIZED OPTIONAL EQUIPMENT....712
6.1.1 PRECAUTIONS REGARDING SAFETY....712
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....713
6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT....714
6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH HIGH FLOW AND SUPER-FLOW HYDRAU LIC SYSTEM....715
6.2 CHANGING THE AUTHORIZED EQUIPMENT....716
6.2.1 CONNECTING THE EXCAVATOR....716
6.2.2 CONNECTING THE HYDRAULIC CIRCUIT....717
6.2.3 CONNECTING THE RETURN CIR CUIT WITH DIRECT DRAINAGE INTO THE TANK....719
6.2.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR....720
6.2.5 USING THE MACHINE WITH THE EXCAVATOR....720
6.3 PALLET FORKS....721
6.4 CHANGING THE OPERATING PATTERN....722
6.4.1 HOW TO CHANGE THE OPERAT ING PATTERN....724
6.5 HAND & FOOT CONTROL SYSTEM....725
6.5.1 MACHINE CONTROLS....725
6.5.1.1 TRAVEL AND STEERING CONTROL LEVERS....726
6.5.1.2 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET)....728
6.5.1.3 AUXILIARY HYDRAULIC KIT CONTROL....731
6.5.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)....734
6.5.2.1 STEERING (CHANGING DIRECTION)....736
WEAM005502 - Skid Steer Loader SK1020-5 turbo Operation & Maintenance Manual....741
COVER....741
FOREWORD....742
1.1 FOREWORD....742
1.2 INFORMATION ON SAFETY....744
1.3 INTRODUCTION....746
1.3.1 INTENDED USES....746
1.3.2 IMPROPER OR UNAUTHORIZED USES....746
1.3.3 MAIN CHARACTERISTICS....746
1.3.4 RUNNING-IN....747
1.4 PRODUCT IDENTIFICATION....748
1.4.1 MACHINE SERIAL NUMBER....748
1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)....748
1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE....749
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER....749
1.4.5 CAB SERIAL NUMBER....749
1.4.6 BACKHOE IDENTIFICATION PLATE (if installed)....749
1.4.7 SERIAL NUMBERS AND DISTRIBUTORS ADDRESS....750
TABLE OF CONTENTS....752
SAFETY AND ACCIDENT PREVENTION....758
2.1 SAFETY AND WARNING DECALS....759
2.1.1 LOCATION OF THE SAFETY DECALS....759
2.1.2 LOCATION OF THE PICTOGRAM DECALS....774
2.1.3 PICTOGRAMS AND RELEVANT MEANINGS....778
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED....780
2.2 GENERAL PRECAUTIONS....781
2.2.1 GENERAL SAFETY RULES....781
2.2.2 SAFETY DEVICES AND GUARDS....781
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS....781
2.2.4 UNAUTHORIZED MODIFICATIONS....782
2.2.5 LEAVING THE OPERATORS SEAT....782
2.2.6 GETTING ON AND OFF THE MACHINE....783
2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed)....783
2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL....784
2.2.9 PREVENTING BURNS....784
2.2.10 PREVENTING DAMAGE DUE TO ASBESTOS POWDER....785
2.2.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....785
2.2.12 FIRE EXTINGUISHERS AND FIRST AID KIT....786
2.2.13 PRECAUTIONS CONCERNING THE CAB STRUCTURE....786
2.2.14 PRECAUTIONS CONCERNING THE EQUIPMENT....786
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE....787
2.3.1 SAFETY ON THE WORK SITE....787
2.3.2 FIRE PREVENTION....787
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB....787
2.3.4 ROOM VENTILATION....788
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS....788
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS - CHECKING THE WINDSHIELD WIPER BLADES (if installed)....788
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING....789
2.4.1 STARTING THE ENGINE....789
2.4.2 CHECKS FOR TRAVELING IN REVERSE....789
2.4.3 MOVING THE MACHINE....790
2.4.4 WORKING ON SLOPES....790
2.4.5 PREVENTING ELECTROCUTION....792
2.4.6 VISIBILITY....793
2.4.7 WORKING ON ICY OR SNOW-COVERED SURFACES....793
2.4.8 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT....793
2.4.9 WORKING ON LOOSE GROUND....793
2.4.10 PARKING THE MACHINE....794
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES....795
2.5.1 LOADING AND UNLOADING THE MACHINE....795
2.5.2 THE ROUTE....795
2.6 BATTERY....796
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES....796
2.6.2 STARTING WITH BOOSTER CABLES....796
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY....797
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE....799
2.8.1 WARNING TAGS....799
2.8.2 TOOLS....799
2.8.3 PERSONNEL....800
2.8.4 EQUIPMENT....800
2.8.5 WORKING UNDER THE MACHINE....800
2.8.6 KEEPING THE MACHINE CLEAN....800
2.8.7 USE OF THE ENGINE DURING MAINTENANCE....801
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY....801
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION....801
2.8.10 RULES FOR REFUELING AND ADDING OIL....802
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR....802
2.8.12 USING LAMPS....802
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR....803
2.8.14 PRECAUTIONS CONCERNING THE STARTER....803
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES....804
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS....804
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES....804
2.8.18 COOLING FAN AND FAN BELT....805
2.8.19 WASTE MATERIALS....805
2.8.20 PRECAUTIONS TO BE TAKEN WHEN INFLATING THE TIRES....805
2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE OIL TYPE HEES....806
THE MACHINE AND ITS OPERATIONS....808
3.1 SAFETY LOCKS....809
3.1.1 LOADER ARM SUPPORT....809
3.1.2 BACKHOE LOCKS (if installed)....811
3.1.3 COLD PLANER LOCKS (if installed)....813
3.2 GENERAL VIEWS....814
3.2.1 FRONT GENERAL VIEW....814
3.2.2 REAR GENERAL VIEW....815
3.2.3 CAB INSIDE GENERAL VIEW....816
3.3 INSTRUMENTS AND CONTROLS....818
3.3.1 INSTRUMENTS....818
3.3.2 INDICATOR LIGHTS....820
3.3.3 SWITCHES AND PUSH BUTTONS....825
3.3.4 ELECTRICAL ACCESSORIES....830
3.3.5 MACHINE CONTROLS....832
3.4 FUSES AND RELAYS....854
3.4.1 MACHINE FUNCTION FUSES....854
3.4.2 MAIN FUSE....855
3.4.3 RELAYS....856
3.5 GUARDS AND OPERATORS SEAT....858
3.5.1 ENGINE HOOD....858
3.5.2 REAR PANEL....859
3.5.3 CAB....860
3.5.3.1 TILTING THE CAB....861
3.5.4 STANDARD SEAT....863
3.5.5 CUSHIONED SEAT....863
3.5.6 SEAT BELT....864
3.5.7 EMERGENCY EXIT....864
3.5.8 TECHNICAL DOCUMENTATION CASE....865
3.5.9 FIRE EXTINGUISHER....865
3.5.10 FIRST AID KIT....865
3.6 USE OF THE MACHINE....866
3.6.1 CHECKS BEFORE STARTING THE ENGINE....866
3.6.1.1 VISUAL CHECKS....866
3.6.1.2 DAILY CHECKS....866
3.6.1.3 OPERATIONAL CHECKS....867
3.6.2 STARTING THE ENGINE....868
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES....868
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES....869
3.6.3 WARMING THE ENGINE....870
3.6.4 HEATING THE HYDRAULIC OIL....870
3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEM)....870
3.6.5.1 STEERING (CHANGING DIRECTION)....872
3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)....874
3.6.6.1 STEERING (CHANGING DIRECTION)....876
3.6.7 MOVING ON SLOPES....878
3.6.8 MAXIMUM IMMERSION DEPTH....879
3.8 STOPPING THE ENGINE....882
3.7 PARKING THE MACHINE....880
3.7.1 PARKING ON LEVEL GROUND....880
3.7.2 PARKING ON SLOPES....881
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES....883
3.9.1 LOADING AND UNLOADING THE MACHINE....883
3.9.2 TRANSPORT....884
3.10 HOW TO LIFT THE MACHINE....885
3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON....886
3.11.1 FUEL AND LUBRICANTS....886
3.11.2 COOLANT....886
3.11.3 BATTERY....887
3.11.4 OTHER PRECAUTIONS....887
3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK....887
3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON....888
3.13 USING THE WORK EQUIPMENT....889
3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE....889
3.13.2 ORGANIZING THE WORK AREA....890
3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES....891
3.13.4 LOADING MATERIAL ON SLOPES....892
3.13.5 DIGGING METHOD....893
3.13.6 CHANGING THE BUCKET OR ATTACHMENT WITH STANDARD QUICK COUPLER....894
3.13.6.1 REMOVING THE BUCKET OR ATTACH MENT....895
3.13.6.2 ATTACHING THE BUCKET....896
3.13.6.3 CHECKING THE POSITION OF THE LOCKING PINS....897
3.13.6.4 ADJUSTING THE LOCKING PINS....898
3.14 LONG PERIODS OF INACTIVITY....899
3.14.1 BEFORE THE PERIOD OF INACTIVITY....899
3.14.2 DURING THE PERIOD OF INACTIVITY....900
3.14.3 AFTER THE PERIOD OF INACTIVITY....900
3.15 TROUBLESHOOTING....901
3.15.1 HOW TO REMOVE THE MACHINE....901
3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED....901
3.15.3 IF THE BATTERY IS DEPLETED....902
3.15.3.1 STARTING WITH BOOSTER CABLES....903
3.15.4 OTHER TROUBLES....904
3.15.4.1 ELECTRICAL CIRCUIT....904
3.15.4.2 HYDRAULIC SYSTEM....905
3.15.4.3 ENGINE....905
3.15.4.4 HYDROSTATIC TRANSMISSION....906
MAINTENANCE....908
4.1 GUIDE TO MAINTENANCE....909
4.2 MAINTENANCE NOTES....911
4.2.1 NOTES REGARDING THE ENGINE....911
4.2.1.1 ENGINE OIL....911
4.2.1.2 COOLANT....911
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM....912
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM....912
4.2.4 NOTES REGARDING LUBRICATION....913
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING....914
4.3 FUEL, COOLANT AND LUBRICANTS....915
4.3.1 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES....919
4.4 DRIVING TORQUES FOR SCREWS AND NUTS....920
4.4.1 STANDARD DRIVING TORQUES....920
4.4.2 SPECIFIC DRIVING TORQUES....920
4.5 LUBRICATION....921
4.5.1 LUBRICATION DIAGRAM....921
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY....922
4.6.1 CRITICAL PARTS FOR SAFETY....923
4.7 MAINTENANCE PLAN....929
4.8 MAINTENANCE PROCEDURE....931
4.8.1 WHEN REQUIRED....931
4.8.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE....931
4.8.1.b TIRE ROTATION....932
4.8.1.c DRAINING THE FUEL TANK....933
4.8.1.d RELEASING THE PARKING BRAKE....934
4.8.1.e CHECKING THE BATTERY CHARGE LEVEL....935
4.8.2 CHECKS BEFORE STARTING....936
4.8.2.a VARIOUS CHECKS....936
4.8.2.b CHECKING THE COOLANT LEVEL....936
4.8.2.c CHECKING THE FUEL LEVEL....937
4.8.2.d CHECKING THE ENGINE OIL LEVEL....938
4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT....939
4.8.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER....940
4.8.2.g CHECKING THE WIRING SYSTEM....940
4.8.3 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION....941
4.8.4 MAINTENANCE EVERY 50 HOURS OF OPERATION....941
4.8.4.a CHECKING THE TIRE PRESSURE....941
4.8.4.b CHECKING THE COOLANT LEVEL IN THE RADIATOR....941
4.8.5 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION....942
4.8.6 MAINTENANCE EVERY 250 HOURS OF OPERATION....942
4.8.6.a ADJUSTING THE FAN BELT TENSION....942
4.8.6.b CHECKING THE GEARING CHAIN TEN SION....943
4.8.6.c CLEANING THE OUTSIDE OF THE RADIATORS....945
4.8.6.d CHECKING THE WHEEL NUT DRIVING TORQUE....945
4.8.6.e CHECKING THE OIL LEVEL IN THE FINAL TRANSMISSIONS....946
4.8.6.f LUBRICATING THE JOINTS....947
4.8.6.g CHANGING THE ENGINE OIL....948
4.8.6.h CHANGING THE ENGINE OIL FILTER....949
4.8.7 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic biodegradable oil type HEES)....950
4.8.8 MAINTENANCE EVERY 500 HOURS OF OPERATION....950
4.8.8.a CHANGING THE FUEL FILTER....950
4.8.8.b CHANGING THE HYDRAULIC OIL DRAIN FILTER....952
4.8.8.c CLEANING THE WATER SEPARATOR....953
4.8.8.d DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oil type HEES)....954
4.8.9 MAINTENANCE EVERY 1000 HOURS OF OPERATION....956
4.8.9.a CHANGING THE OIL IN THE FINAL TRANSMISSION....956
4.8.9.b CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FIL TER....957
4.8.9.c CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE....959
4.8.10 MAINTENANCE EVERY 2000 HOURS OF OPERATION....960
4.8.10.a CHANGING THE COOLANT....960
4.8.10.b CHANGING THE SUCTION FILTER....961
4.8.10.c CHECKING THE ALTERNATOR AND THE STARTER....962
TECHNICAL SPECIFICATIONS....964
5.1 TECHNICAL DATA....965
5.1.1 STANDARD MACHINE OVERALL DIMENSIONS....965
5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT....966
5.1.3 TECHNICAL CHARACTERISTICS....967
AUTHORIZED OPTIONAL EQUIPMENT....970
6.1 AUTHORIZED OPTIONAL EQUIPMENT....971
6.1.1 PRECAUTIONS REGARDING SAFETY....971
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT....971
6.1.3 CHARACTERISTICS OF THE STANDARD MACHINE OPTIONAL EQUIPMENT....972
6.1.4 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT OF THE MACHINE VERSION WITH SUPER-FLOW HYDRAULIC SYSTEM....973
6.2 CHANGING THE AUTHORIZED EQUIPMENT....974
6.2.1 CONNECTING THE BACKHOE....974
6.2.2 CONNECTING THE HYDRAULIC CIRCUIT....975
6.2.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK....977
6.2.4 PREPARING THE MACHINE FOR THE USE OF THE BACKHOE....978
6.2.5 USING THE MACHINE WITH THE BACKHOE....978
6.3 PALLET FORKS....979
6.4 HAND & FOOT CONTROL SYSTEM....980
6.4.1 MACHINE CONTROLS....980
6.4.1.1 TRAVEL AND STEERING CONTROL LEVERS....981
6.4.1.2 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET)....983
6.4.1.3 AUXILIARY HYDRAULIC CONTROL LEVER....986
6.4.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)....989
6.4.2.1 STEERING (CHANGING DIRECTION)....991
WEBM005300 - Skid Steer Loader SK1020-5, SK1020-5 turbo Shop Manual....994
COVER....994
CONTENTS....995
SAFETY....998
FOREWORD....1000
HOW TO READ THE SHOP MANUAL....1001
HOISTING INSTRUCTIONS....1002
STANDARD TIGHTENING TORQUE....1003
COATING MATERIALS....1005
WEIGHT TABLE....1007
TABLE OF OIL AND COOLANTS QUANTITIES....1008
CONVERSION TABLE....1010
10 STRUCTURE AND FUNCTION....1018
P.T.O....1019
POWER TRAIN....1020
TRANSMISSION....1021
FINAL DRIVE....1023
HYDRAULIC CIRCUIT....1030
CONTROL VALVE (3-SPOOL)....1049
CONTROL VALVE (4-SPOOL)....1052
CLSS....1056
SOLENOID VALVE....1064
ACCUMULATOR....1066
PATTERN CHANGE VALVE....1067
R.H. PPC VALVE (STANDARD)....1071
R.H. PPV VALVE (PATTERN CHANGE)....1075
L.H. PPC VALVE (STANDARD)....1079
L.H. PPC VALVE (PATTERN CHANGE)....1083
CYLINDERS....1087
ELECTRICAL DIAGRAM (ENGINE LINE)....1088
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) ....1092
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL)....1096
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) ....1100
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL)....1106
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE)....1114
20 TESTING AND ADJUSTMENTS....1116
NORMAL OR STANDARD TECHNICAL DATA....1117
SPECIAL TOOLS....1129
CHECKING THE ENGINE SPEED....1130
ADJUSTMENT OF VALVE CLEARANCE....1131
MEASUREMENT OF THE COMPRESSION PRESSURE....1133
CONTROL AND ADJUSTMENT OF THE FAN BELT TENSION....1134
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING....1135
CHECKING ENGINE OIL PRESSURE....1137
ADJUSTING THE STROKE OF THE ACCELERATOR CABLES....1138
REGULATION OF PPC VALVES' DRIVE PRESSURE....1139
ADJUSTMENT OF THE PPC VALVE CLEARANCES....1141
ADJUSTING THE POSITION OF THE SERVO-CONTROL ENGAGEMENT SAFETY SENSOR....1142
TESTING AND ADJUSTMENT OF GEARING CHAIN TENSION....1143
CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS....1144
TESTING THE HYDRAULIC PUMP....1145
VALVE CALIBRATION....1146
CHECKING THE TRAVEL DEVIATION....1148
CONTROL VALVE....1150
CONTROL AND REGULATION OF THE SERVO-CONTROL POWER SUPPLY....1151
ELIMINATION OF RESIDUAL PRESSURES - PRESSURIZATION OF THE TANK....1153
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS....1154
30 REMOVAL AND INSTALLATION....1156
HOW TO READ THE MANUAL....1158
PRECAUTIONS TO BE TAKEN WHILE WORKING....1159
ENGINE HOOD....1160
REMOVAL AND INSTALLATION....1160
CAB....1161
TILTING....1161
LOWERING....1164
BATTERY....1165
REMOVAL AND INSTALLATION....1165
STARTING MOTOR....1166
REMOVAL AND INSTALLATION....1166
ALTERNATOR....1167
REMOVAL AND INSTALLATION....1167
AIR INTAKE FILTER....1168
REMOVAL AND INSTALLATION....1168
MUFFLER (SK1050-5)....1169
REMOVAL....1169
INSTALLATION....1170
MUFFLER (SK1020-5 TURBO)....1171
REMOVAL....1171
INSTALLATION....1172
VALVE COVER....1173
REMOVAL....1173
INSTALLATION....1174
NOZZLE....1175
REMOVAL....1175
INSTALLATION....1175
INJECTION PUMP....1176
REMOVAL....1176
INSTALLATION....1178
CYLINDER HEAD....1179
REMOVAL....1179
INSTALLATION....1181
TURBOCHARGER (SK1020-5 TURBO)....1182
REMOVAL AND INSTALLATION....1182
COOLANT LIQUID PUMP....1183
REMOVAL AND INSTALLATION....1183
RADIATOR GROUP....1184
REMOVAL....1184
INSTALLATION....1185
FUEL TANK....1186
REMOVAL....1186
INSTALLATION....1187
CAB....1188
REMOVAL....1188
INSTALLATION....1191
ENGINE-PUMP GROUP....1192
REMOVAL....1192
INSTALLATION....1195
COMPLETE HYDRAULIC PUMP....1196
REMOVAL....1196
INSTALLATION....1198
GEAR PUMP....1199
REMOVAL AND INSTALLATION....1199
ENGINE-PUMP COUPLING....1200
REMOVAL AND INSTALLATION....1200
CONTROL VALVE....1201
REMOVAL AND INSTALLATION....1201
PPC VALVES....1202
REMOVAL AND INSTALLATION....1202
HEATING FAN....1203
REMOVAL....1203
INSTALLATION....1204
HUB WHEEL....1205
REMOVAL....1205
INSTALLATION....1206
DISMANTLING....1207
ASSEMBLY....1208
FINAL DRIVE....1209
REMOVAL....1209
INSTALLATION....1210
RAISING CYLINDER....1211
REMOVAL AND INSTALLATION....1211
BUCKET CYLINDER....1212
REMOVAL....1212
INSTALLATION....1213
DISASSEMBLY....1214
ASSEMBLY....1216
COMPLETE WORKING EQUIPMENT....1220
REMOVAL....1220
INSTALLATION....1221
WORKING EQUIPMENT SUPPORT FRAME....1222
REMOVAL AND INSTALLATION....1222
40 STANDARD MAINTENANCE....1224
P.T.O....1225
TRANSMISSION....1226
FINAL DRIVE....1227
HYDRAULIC PUMP....1228
CONTROL VALVE (SUPER HIGH-FLOW VERSION)....1230
R.H. PPC VALVE....1236
L.H. PPC VALVE (STANDARD)....1237
L.H. PPC VALVE (PATTERN CHANGE)....1238
PATTERN CHANGE VALVE....1239
CYLINDERS....1240
WORKING EQUIPMENT....1241
