Komatsu Skid Steer Loader SK1020-5NA, SK1020-5N Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Skid Steer Loader SK1020-5NA, SK1020-5N, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Skid Steer Loader SK1020-5NA, SK1020-5N 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: 621 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM013902 - Skid Steer Loader SK1020-5NA, SK1020-5N Operation & Maintenance Manual.pdf
CEBM013902 - Skid Steer Loader SK1020-5NA, SK1020-5N Shop Manual.pdf
MAIN SECTIONS
CEAM013902 - Skid Steer Loader SK1020-5NA, SK1020-5N Operation & Maintenance Manual.....2
INTRODUCTION.....4
FOREWORD.....5
SAFETY INFORMATION.....6
APPROVED AND NON-APPROVED USES.....7
Approved.....7
Non-approved.....7
PRODUCT INFORMATION.....8
Main Features.....8
Break-in Period.....8
Synthetic Biodegradable Oil Types.....8
PRODUCT IDENTIFICATION.....9
Machine Serial Number.....9
Machine Identification Plate.....9
Engine Serial Number and Emission Plate.....10
Travel Reduction Gear Serial Number.....10
Cab Serial Number.....10
Excavator Identification Plate.....10
SERIAL NUMBERS AND DISTRIBUTOR INFORMATION.....11
Model: SK1020-5N or SK1020-5NA.....11
CONTENTS.....12
SAFETY.....20
SAFETY LABELS.....21
Example of Safety Label Using Words.....21
Example of Safety Label Using Pictogram.....21
SAFETY AND WARNING DECALS.....22
Location of the Safety Decals.....22
Location of the Pictogram Decals.....40
Decals Defined.....44
Vibrations to Which the Operator is Subjected.....46
SAFETY RULES AND PRECAUTIONS.....46
General Safety Rules.....46
General Safety at Job Site.....46
Working on Loose Ground.....47
Safety Features.....47
Personal Protective Equipment.....47
Fire Extinguisher and First Aid Kit.....48
Checking the Rearview Mirrors (If Installed).....48
Mounting and Dismounting.....48
Precautions for ROPS.....49
Unauthorized Modification.....49
Leaving the Operators Seat.....50
Fire Prevention for Fuel and Oil.....51
Preventing Burns.....51
Dust Hazard Precautions.....52
Crush or Pinch Point Dangers.....52
Fire Extinguisher and First Aid Kit.....52
Precautions Concerning the Equipment.....53
Precautions for Attachments.....53
PRECAUTIONS BEFORE STARTING THE ENGINE.....53
Safety on the Work Site.....53
Seat Belt Inspection.....54
Fire Prevention.....55
Precautions for the Operators Cab.....55
Room Ventilation.....55
Precautions for the Lights.....55
Cleaning the Windows and the Rearview Mirrors - Checking the Windshield Wiper Blades.....55
PRECAUTIONS TO BE TAKEN WHEN WORKING.....56
Starting the Engine.....56
Rules for Traveling in Reverse.....56
Moving the Machine.....56
Working on Slopes.....57
Preventing Electrocution.....58
Visibility.....59
Working on Icy or Snow-covered Surfaces.....59
Preventing Damage Caused by the Work Equipment.....59
Working on Loose Ground.....59
Parking the Machine.....60
TRANSPORTING THE MACHINE.....61
Loading and Unloading the Machine.....61
The Route.....61
BATTERY.....62
Safety Precautions.....62
Removing Battery Cables.....63
Booster Cables.....63
PRECAUTIONS FOR EMERGENCY RECOVERY.....64
PRECAUTIONS DURING MAINTENANCE.....66
Warning Tags.....66
Tools.....66
Personnel.....67
Equipment Storage.....67
Working Under the Machine.....67
Keeping the Machine Clean.....67
Engine Operation During Maintenance.....68
Critical Parts.....68
Stop Engine Before Maintenance Operation or Inspection.....68
Rules for Refueling the Machine.....69
Cooling System Precautions.....69
Using Lamps.....69
Electrical Precautions.....70
Precautions Concerning the Starter.....70
Precautions Concerning High-Pressure Hoses.....71
Precautions for Working on High-Pressure Systems.....71
Precautions for Maintenance Work Involving High Temperatures and Pressures.....71
Rotating Parts.....71
Disposal of Waste Materials.....72
Inflating Tires.....72
Hydraulic Environmental Ester Synthetic (HEES) Oil.....72
OPERATION.....74
SAFETY LOCKS.....75
Loader Arm Support.....75
Backhoe Locks.....77
Cold Planer Lock.....79
GENERAL VIEWS.....80
Front View of Machine.....80
Rear View of Machine.....81
Inside View of Cab.....82
INSTRUMENTS AND CONTROLS.....84
Instruments.....84
Hour Meter.....84
Engine Coolant Temperature Indicator.....85
Fuel Level Indicator.....85
Indicator Lights.....86
Alternator Warning Light.....86
Preheating Warning Light.....87
Engine Oil Pressure Warning Light.....87
Air Cleaner Clogging Warning Light.....87
Hydraulic Oil Filter Clogging Warning Light.....87
Parking Brake Warning Light.....88
Speed Increase Indicator Light.....88
Floating Device Indicator Light.....88
Direction Indicator Light (If Equipped).....88
Working Light Indicator Light.....89
Safety Device Functionality Control Unit.....89
Switches and Push Buttons.....91
Parking Brake Push Button.....92
Rotating Beacon Light Switch (If Equipped).....92
Left Stabilizer Button (If Installed).....93
Right Stabilizer Button (If Installed).....93
Working Light Switch.....93
Emergency (Hazard) Switch (If Installed).....93
Parking Light and Low Beam Switch (If Installed).....94
Direction Indicator Switch (If Installed).....94
Starting Switch.....94
Horn.....94
Front Equipment Super Flow Hydraulic System Momentary Switch (If Installed).....95
Front Equipment Super Flow Hydraulic System Continuous Switch (If Installed).....95
Speed Increase Button.....95
Floating Device Switch.....95
Available for Other Functions.....96
Audible Alarm.....96
12V Electric Outlet.....97
Battery Disconnect Switch.....97
Machine Controls.....98
Safety Bars.....100
ISO Pattern Control System.....101
Left PPC Control Joystick (Travel and Steering).....101
Right PPC Control Joystick (Loader Arm and Bucket).....102
Optional Pattern Control System.....104
Left PPC Control Joystick (Left Wheel Travel, Steering, and Loader Arm Control).....104
Right PPC Control Joystick (Right Wheel Travel, Steering and Bucket Control).....106
Auxiliary Hydraulic Kit Control Pedal (If Installed).....108
Foot Accelerator.....109
Hand Accelerator.....109
Parking Brake.....110
Equipment Control Locking Lever (If Installed).....110
Standard Flow Hydraulic System Control (Two Lines).....111
Super Flow Hydraulic System Control (Five Lines).....112
Speed Increase Control.....113
Floating Device Control.....113
Pattern Shifting Control.....114
Right Stabilizer Control.....116
Left Stabilizer Control.....116
Optional Electrical Connections.....116
Fuses and Relays.....117
Machine Function Fuses.....117
Standard Version.....117
Version with Optional Connections.....118
Main Fuse.....118
Relays.....119
GUARDS AND OPERATORS SEAT.....121
Engine Hood.....121
Rear Panel.....122
Cab.....123
Tilting the Cab.....124
Standard Seat.....126
Suspension Seat.....126
Seat Belt.....127
Emergency Exit.....127
Technical Documentation Case.....128
Fire Extinguisher.....128
First Aid Kit.....128
OPERATING THE MACHINE.....129
Checks Before Starting the Engine.....129
Visual Checks.....129
Daily Checks.....129
Operational Checks.....130
Starting the Engine.....131
Starting with a Warm Engine or in Warm Climates.....131
Starting in Cold Weather or in Cold Climates.....132
Warming the Engine.....133
Heating the Hydraulic Oil.....133
Hydraulic Oil Travel Circuit Warm-up.....133
Moving the Machine (ISO Pattern Control System).....134
Steering (Changing Direction).....136
How to Move the Machine (Optional Pattern Control System).....138
Steering (Changing Direction).....139
Hand and Foot Control System.....141
Machine Controls.....141
Travel and Steering Control Joysticks.....142
Work Equipment Control Pedals (Loader Arm and Bucket).....144
Auxiliary Hydraulic Control Joystick.....147
How to Move the Machine (Hand and Foot Control System).....150
Steering (Changing Direction).....151
Moving on Slopes.....153
Maximum Immersion Depth.....154
PARKING THE MACHINE.....155
Parking on Level Ground.....155
Parking on Slopes.....156
STOPPING THE ENGINE.....157
TRANSPORTING THE MACHINE.....158
Loading and Unloading.....158
Transport.....159
HOW TO LIFT THE MACHINE.....159
Front Lifting Eye.....160
Rear Lifting Eye.....161
Lifting the Machine.....161
COLD WEATHER PRECAUTIONS.....162
Fuel and Lubricants.....162
Coolant.....162
Hydraulic Oil Travel Circuit Warm-up.....162
Battery.....163
Other Precautions.....163
Precautions at the End of Work.....163
WARM WEATHER PRECAUTIONS.....164
OPERATING THE WORK EQUIPMENT.....164
Lowering the Equipment in Case of Machine Failure.....164
Organizing the Work Area.....165
Loading Heaped and Level Material.....165
Loading Operations on Slopes.....166
Digging Method.....167
Changing the Bucket or Attachment with Standard Quick Coupler.....168
Removing the Bucket or Attachment.....169
Installing the Bucket or Attachment.....170
Checking the Position of the Locking Pins.....171
Adjusting the Locking Pins.....172
Long Periods of Inactivity.....173
Before the Period of Inactivity.....173
During the Period of Inactivity.....173
After the Period of Inactivity.....174
TROUBLESHOOTING.....174
How to Move the Machine.....174
Fuel is Completely Depleted.....174
Discharged Battery.....175
Charging the Battery.....176
Starting the Engine with Jumper Cables.....176
Other Troubles.....178
Electrical Circuit.....178
Hydraulic System.....179
Engine.....180
Hydrostatic Transmission.....181
MAINTENANCE.....184
GUIDE TO MAINTENANCE.....185
MAINTENANCE NOTES.....186
Notes Regarding the Engine.....186
Engine Oil.....186
Coolant.....187
Fuel.....187
Notes Regarding the Hydraulic System.....187
Notes Regarding the Electrical System.....187
Notes Regarding Lubrication.....188
Wear Parts List.....188
FUEL, COOLANT AND LUBRICANTS.....189
Selection According to the Ambient Temperature.....189
Grease.....189
APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES.....192
LUBRICATION DIAGRAMS.....194
General.....194
PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY.....195
Critical Parts for Safety.....196
Fuel Supply System.....196
Standard Flow Hydraulic System.....197
Super Flow Hydraulic System.....199
Operators Safety.....201
TIGHTENING TORQUE.....202
Standard Torque for Bolts and Nuts.....202
Specific Torques.....202
MAINTENANCE PLAN.....203
When Required.....205
Air Cleaner Cartridge.....205
Tire Rotation.....206
Draining the Fuel Tank.....207
Releasing the Parking Brake.....208
Checking the Battery Charge Level.....209
Checks Before Starting.....210
Various Checks.....210
Checking the Coolant Level.....210
Checking the Fuel Level.....211
Engine Oil Level.....212
Hydraulic System Oil Level.....213
Draining Water Separator.....214
Checking the Wiring System.....214
Maintenance After the First 50 Hours of Operation.....215
Maintenance Every 50 Hours of Operation.....215
Checking Tire Pressure.....215
Checking the Coolant Level in the Radiator.....215
Maintenance After the First 250 Hours of Operation.....216
Maintenance Every 250 Hours of Operation.....216
Fan Belt Tension.....216
Checking the Drive Chain Tension.....217
Adjusting the Chains.....218
Cleaning the Outside of the Radiator.....219
Checking the Wheel Nut Torque.....219
Checking the Oil Level in the Chain Cases.....220
Lubricating the Joints.....221
Changing the Engine Oil.....222
Changing the Engine Oil Filter.....223
Maintenance After the First 500 Hours of Operation.....223
Maintenance Every 500 Hours of Operation.....224
Changing the Fuel Filter.....224
Changing the Hydraulic Oil Drain Filter.....225
Cleaning the Water Separator.....226
Draining Condensation from the Hydraulic Oil Tank.....227
Maintenance Every 1000 Hours of Operation.....229
Changing the Oil in the Chain Case.....229
Changing the Hydraulic System Oil and Cleaning the Suction Filter.....230
Checking and Adjusting the Engine Valve Clearance.....232
Maintenance Every 2000 Hours of Operation.....233
Changing the Coolant.....233
Changing the Suction Filter.....234
Checking the Alternator and the Starter.....235
SPECIFICATIONS.....236
SPECIFICATIONS.....237
Standard Machine Overall Dimensions.....237
Machine Overall Dimensions with Optional Equipment.....239
Technical Specifications.....241
OPTIONAL ATTACHMENTS.....242
OPTIONAL EQUIPMENT.....243
Basic Precautions.....243
Precautions Regarding the Installation of Equipment.....244
Optional Equipment Measurements.....244
Optional Equipment Measurements with the Super-flow Hydraulic System.....245
Changing the Equipment.....246
Connecting the Excavator.....246
Connecting the Hydraulic Circuit.....247
Connecting the Return Circuit with Direct Drainage into the Tank.....249
Preparing the Machine for the Use of the Excavator.....249
Using the Machine with the Excavator.....250
Pallet Forks.....250
CEBM013902 - Skid Steer Loader SK1020-5NA, SK1020-5N Shop Manual.....252
COVER.....252
CONTENTS.....253
SAFETY.....260
SAFETY NOTICE.....260
IMPORTANT SAFETY NOTICE.....260
GENERAL.....262
HOW TO READ THE SHOP MANUAL.....263
Volumes.....263
Distribution and Updating.....263
Filing Method.....263
Revised Edition Mark.....263
Revisions.....263
Symbols.....263
HOISTING INSTRUCTIONS.....264
MAINTENANCE STANDARD TERMINOLOGY.....265
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.....267
PUSH PULL COUPLER.....0
Type 1.....276
Disconnection.....276
Connection.....276
Type 2.....277
Disconnection.....277
Connection.....277
Type 3.....278
Disconnection.....278
Connection.....278
COATING MATERIALS.....279
STANDARD TIGHTENING TORQUE.....281
Bolts and Nuts Standard Tightening Torque.....281
Hose Nuts Tightening Torque.....282
Split Flange Bolts Tightening Torque.....282
Tightening Torque For Flared Nuts.....282
O-Ring Boss Piping Joints Tightening Torque.....283
O-Ring Boss Plugs Tightening Torque.....283
Hoses (Taper Seal Type And Face Seal Type) Tightening Torque.....284
SPECIFIC DRIVING TORQUE.....284
ELECTRIC WIRE CODE.....285
Classification by Thickness.....285
Classification by Color and Code.....285
CONVERSION TABLES.....286
Method of Using the Conversion Table.....286
00 FOREWORD.....253
CONTENTS.....254
SAFETY.....260
SAFETY NOTICE.....260
IMPORTANT SAFETY NOTICE.....260
GENERAL PRECAUTIONS.....260
PREPARATIONS FOR WORK.....260
PRECAUTIONS DURING WORK.....261
GENERAL.....262
HOW TO READ THE SHOP MANUAL.....263
Volumes.....263
Distribution and Updating.....263
Filing Method.....263
Revised Edition Mark.....263
Revisions.....263
Symbols.....263
HOISTING INSTRUCTIONS.....264
Hoisting.....264
Wire Ropes.....264
MAINTENANCE STANDARD TERMINOLOGY.....265
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.....267
PUSH PULL COUPLER.....276
Type 1.....276
Disconnection.....276
Connection.....276
Type 2.....277
Disconnection.....277
Connection.....277
Type 3.....0
Disconnection.....278
Connection.....278
COATING MATERIALS.....279
STANDARD TIGHTENING TORQUE.....281
Bolts and Nuts Standard Tightening Torque.....281
Hose Nuts Tightening Torque.....282
Split Flange Bolts Tightening Torque.....282
Tightening Torque For Flared Nuts.....282
Tightening Torque For Flared Nuts.....283
O-Ring Boss Piping Joints Tightening Torque.....283
O-Ring Boss Plugs Tightening Torque.....283
Hoses (Taper Seal Type And Face Seal Type) Tightening Torque.....284
SPECIFIC DRIVING TORQUE.....284
ELECTRIC WIRE CODE.....285
Classification by Thickness.....285
Classification by Color and Code.....285
CONVERSION TABLES.....286
Method of Using the Conversion Table.....286
01 GENERAL.....292
DIMENSION DRAWINGS.....293
Machine Dimensions.....293
Working Ranges.....294
SPECIFICATIONS.....295
WEIGHT TABLE.....297
FUEL COOLANT AND LUBRICANTS.....298
SERVICE NOTES.....299
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.....300
WORK EQUIPMENT PIVOT POINT CLEARANCES.....302
WHEEL DRIVE SYSTEM.....304
Power Train Flow.....304
Transmission System.....305
Wheel Axles.....306
DRIVE MOTOR SYSTEM.....307
Motor Ports.....307
Motor Structure.....308
Motor Operations.....309
Description.....309
HYDRAULIC PUMPS.....312
Drive Dampener.....312
Maintenance Standard.....312
Charge Pump.....313
HST Pump LPV45 + 45 (Standard and High Flow).....314
Maintenance Standard.....314
Pump Internal View.....316
Operation of Main Pump.....317
Shuttle Valve.....319
SAFETY VALVES.....320
Suction Safety Valve Action.....320
Charge Safety Valve Action.....323
ANTI ENGINE-STALL VALVE (AS VALVE).....325
AS Valve Maintenance Standard.....327
CONTROL VALVES.....328
Standard 3-Spool Valve Port Location.....328
Valve-Sectional Views.....329
Super High-Flow 4-Spool Valve Port Location.....331
Valve-Sectional Views.....332
Control Valve Maintenence Standard.....335
Control Valve (Standard).....343
Control Valve (Super High-Flow).....345
CLOSED CENTER LOAD SENSING SYSTEM.....347
Pressure Compensation Control.....347
Hydraulic Circuit Diagram.....349
System in Series Circuit Operation.....350
Self Leveling Function.....351
System in Series-Parallel Circuit Operation.....352
Pressure Compensation Valve.....353
Dividing Function.....354
SOLENOID VALVE.....355
Valve Group ST1.....355
ACCUMULATOR.....356
PATTERN CHANGE VALVE.....357
Maintenance Standard.....357
Pattern Options Arrangement.....359
Pattern ISO.....359
Pattern Optional.....359
R.H. PPC VALVE (STANDARD).....360
Equipment Control.....360
R.H. PPC Valve Maintenance Standard.....361
R.H. PPC VALVE (PATTERN CHANGE).....363
Equipment and Travel Control.....363
L.H. PPC VALVE (STANDARD).....366
Travel Control.....366
Standard.....367
Maintenance Standard.....368
L.H. PPC VALVE (PATTERN CHANGE).....371
Equipment and Travel Control.....371
Pattern Change.....372
Maintenance Standard.....373
CYLINDERS.....375
Boom.....375
Bucket.....375
Maintenance Standard.....376
20 STANDARD VALUE TABLES.....0
STANDARD SERVICE VALUE TABLE.....380
Standard Service Value Table for Engine.....381
Standard Value Table for Chassis.....382
30 TESTING AND ADJUSTING.....0
SPECIAL TOOLS.....388
T-ADAPTER PROCEDURES AND KITS.....389
ENGINE COMPONENTS.....390
Measuring Exhaust Smoke.....390
Measuring Exhaust Temperature.....390
Adjusting Valve Clearance.....390
Measuring Compression Pressure.....390
Measuring Crankcase Pressure.....390
Measuring Engine Oil Pressure.....390
Measuring Boost Pressure.....390
Measuring Fuel Pressure.....390
Adjusting Engine Speed Sensor.....390
Bleeding Air From Fuel System.....390
Adjusting Engine Stop Solenoid.....390
Adjusting Engine Speed.....391
ADJUSTING PPC VALVE PRESSURES.....392
Adjusting PPC Valve.....394
ADJUSTING SERVO-CONTROL SAFETY SENSOR.....395
CHAIN TENSION.....396
Test.....396
Adjustment.....396
TESTING AND ADJUSTING THE HYDRAULIC SYSTEM.....397
Relieving Hydraulic Pressure.....398
Bleeding Hydraulic Circuits.....399
HYDRAULIC PUMP.....400
Calibrating Valve.....401
Travel Deviation Check.....402
CONTROL VALVE.....405
Servo-Control Power Supply.....407
AIR CONDITIONING SYSTEM.....411
Environmental Impact.....411
Basic Air Conditioning System (Typical).....412
Operator Cab Air Conditioning.....413
Principles of Refrigeration.....413
Air Conditioning.....413
The Act of Cooling.....413
The Refrigeration Cycle.....414
Air Conditioner System Components.....414
Compressor (Refrigerant Pump).....414
Service Valves.....414
Condenser.....415
Receiver-Drier.....415
Thermostatic Expansion Valve.....415
Evaporator.....416
Electrical Circuit.....416
Thermostat.....417
Compressor Clutch.....417
Safety Switches.....417
System Servicing.....418
R-134A Refrigerant Containers.....419
Service Tools and Equipment.....419
Recovery/Recycle Station.....419
Leak Detector.....420
Service Valves.....420
Vacuum Pump.....420
Manifold Gauge Set.....421
Installing Manifold Gauge Set.....422
Purging Air from Service Hoses.....423
Adding Refrigerant to the System (Without a Charging Station).....424
Stabilizing the AC System.....424
Adding Refrigerant and Stabilizing the System (With a Recovery/Recycling Station).....425
Recovering and Recycling the Refrigerant.....425
Performing the Recovery Cycle.....425
Performing the Recycling Procedure.....426
Evacuating and Charging the AC System.....426
System Performance Test.....427
System Leak Testing.....428
Electronic Leak Detector.....428
Tracer Dyes.....428
Soap and Water.....428
System Repair.....429
Hoses and Fittings.....429
Lines.....429
Expansion Valve.....429
Receiver-Drier.....429
Thermostat.....429
Clutch.....430
Compressor.....430
Checking Compressor Oil Level.....430
Evacuating The System.....431
Troubleshooting - Air Conditioning System.....432
Pre-Diagnosis Checks.....432
Preparing for Diagnosis.....432
Preliminary Steps.....432
System Performance Test.....432
Diagnosis of Gauge Readings and System Performance.....433
Troubleshooting by Manifold Gauge Set Readings.....434
Preventive Maintenance Schedule for A/C System.....439
40 TROUBLESHOOTING.....442
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....443
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....445
Points To Remember When Troubleshooting Electrical Circuits.....446
CHECKS BEFORE TROUBLESHOOTING.....447
Troubleshooting Procedure.....448
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....449
T-ADAPTER TABLE.....473
ENGINE COOLANT TEMPERATURE SENSOR FAILURE.....476
ABNORMAL ENGINE OIL PRESSURE INDICATED.....477
AIR CLEANER CLOG INDICATED.....478
ENGINE PREHEAT SYSTEM INOPERABLE.....479
FUEL LEVEL INDICATION IS INCORRECT.....481
FUEL PUMP MOTOR INOPERATIVE.....482
ENGINE DOES NOT SHUT DOWN OR WILL NOT START.....483
ALTERNATOR NOT CHARGING BATTERY.....485
ENGINE WILL NOT CRANK.....487
BACK-UP ALARM WILL NOT FUNCTION.....489
HYDRAULIC FILTER SENSOR WARNING.....491
PPC SYSTEM ELECTRICAL MALFUNCTION.....493
SEAT SAFETY SWITCH MALFUNCTION.....495
SAFETY BAR SWITCH MALFUNCTION.....496
TRAVEL SPEEDS CANNOT BE CHANGED.....497
FLOAT CONTROL MALFUNCTION.....499
PARKING BRAKE SYSTEM MALFUNCTION.....501
PATTERN CHANGE MALFUNCTION.....503
STABALIZER SYSTEM MALFUNCTION.....505
LOW OR WEAK TRAVEL, WEAK BRAKE-OUT FORCE.....509
WEAK TRAVEL, WEAK BREAK-OUT FORCE IN REVERSE.....511
ROTATING BEACON INOPERABLE.....513
REAR WORK LIGHTS WILL NOT OPERATE.....515
HORN DOES NOT SOUND.....517
POSSIBLE DEFECTIVE SAFETY RELAY UNIT.....519
50 DISASSEMBLY AND ASSEMBLY.....522
HOW TO READ THIS MANUAL.....525
Removal And Installation Of Assemblies.....525
Special Tools.....525
Removal.....525
Installation.....525
Disassembly And Assembly Of Assemblies.....526
Special Tools.....526
Disassembly.....526
Assembly.....527
CONNECTOR REPAIR PROCEDURES.....528
Stripping Insulation.....528
Wire Inspection.....528
Contact Terminal Removal (HD30 Type).....529
Crimping Contact Terminal (HD30 Type).....530
Insertion Of Contact Terminal (HD30 Type).....531
Contact Terminal Removal (DT Type).....532
Crimping Contact Terminal (DT Type).....533
Insertion Of Contact Terminal (DT Type).....534
ENGINE.....535
Alternator.....535
Cylinder Head.....535
Engine Front Seal.....535
Engine Oil Cooler.....535
Engine Rear Seal.....535
Fuel Injection Pump.....535
Nozzle Holder.....535
Thermostat.....535
Turbocharger.....535
Water Pump.....535
ENGINE HOOD ASSEMBLY.....536
Removal of Engine Hood.....536
Installation of Engine Hood.....536
OPERATORS CAB ASSEMBLY.....537
Tilting the Cab.....537
Lowering the Cab.....539
Removing the Cab Assembly.....540
Installing the Cab.....542
WORK EQUIPMENT SYSTEM.....543
Removing Lift Arms.....543
Installation of Lift Arms.....544
REMOVING EQUIPMENT SUPPORT FRAME.....545
Installing Support Frame.....545
BATTERY.....546
Removal.....546
Installation.....546
STARTER MOTOR.....547
Removal.....547
Installation.....547
ALTERNATOR.....548
Removal.....548
Installation.....548
Check and Adjust Fan Belt Tension.....548
AIR FILTER ASSEMBLY.....549
Removal.....549
Installation.....549
MUFFLER ASSEMBLY (SK1020-5N).....550
Removal.....550
Installation.....551
MUFFLER ASSEMBLY (SK1020-5N TURBO).....552
Removal.....552
Installation.....553
RADIATOR ASSEMBLY.....554
Removal.....554
Installation.....555
FUEL TANK ASSEMBLY.....556
Removal.....556
Installation.....557
ENGINE-PUMP ASSEMBLY.....558
Removal.....558
Installation.....561
HYDRAULIC PUMP ASSEMBLY.....562
Removal.....562
GEAR PUMP ASSEMBLY.....565
Removal.....565
Installation.....565
ENGINE-PUMP COUPLING.....566
Removal.....566
Installation.....566
CONTROL VALVE.....567
Removal.....567
Installation.....567
PPC VALVES.....568
Removal.....568
Installation.....568
CAB HEATER ASSEMBLY.....569
Removal.....569
Installation.....570
WHEEL HUB ASSEMBLY.....571
Removal.....571
Installation.....572
Adjusting the Chains.....573
Disassembly of the Wheel Hub.....574
Assembly of the Wheel Hub.....575
FINAL DRIVE ASSEMBLY.....576
Removal.....576
Installation.....577
LIFT AND BUCKET CYLINDERS.....578
Removal of Lift Cylinder.....578
Installation of the Lift Cylinder.....578
Removal of Bucket Cylinder.....579
Installation of Bucket Cylinder.....580
WORK EQUIPMENT CYLINDER OVERHAUL.....581
Disassembly.....581
Assembly.....583
MONITOR PANEL REPLACEMENT.....587
Removal.....587
Installation.....588
90 OTHERS.....590
ENGINE ELECTRICAL.....591
FRAME LINE ELECTRICAL.....595
FRAME LINE ELECTRICAL (OPTIONAL).....599
OPERATOR COMPARTMENT ELECTRICAL.....603
OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL).....609
TOP OPERATOR CAB ELECTRICAL.....617
HYDRAULIC CIRCUIT.....619
AIR CONDITIONER.....620
