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Komatsu sk1020 5 n skid steer loader service repair manual sn a70001 and up

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This document provides specifications and dimension drawings for Komatsu SK1020-5N and SK1020-5NA skid steer loaders including: - Dimensions for the machine and its components such as overall length, width, height, and ground clearances. - Operating weight of about 3435 kg (7,573 lb) for both models. - An SAE rated 0.47 m3 (0.61 yd3) standard bucket capacity for the SK1020-5N and pallet forks for the SK1020-5NA. - A 52.2 kW @ 2800 rpm (60.0 kW @ 2800 rpm optional turbo) Komatsu 4D98E-1

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CEBM013902 Shop Manual SK1020-5N SK1020-5NA SKID STEER LOADER SERIAL NUMBERS SK1020-5N A70001 and up SK1020-5NA A60001 and up ENGINE S4D98E-2 ® www.KomatsuAmerica.com
FOREWORD CONTENTS 00-2 c SK1020-5N, SK1020-5NA 12 CONTENTS 00 01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1 20 STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1 90 DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
FOREWORD SAFETY SK1020-5N, SK1020-5NA 00-3 c 12 SAFETY 00 SAFETY NOTICE 00 GENERAL PRECAUTIONS 00 Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 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. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang "UNDER REPAIR" signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 00 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. 2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. IMPORTANT SAFETY NOTICE 00 Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. WARNING! Never modify, weld, cut, or drill on any part of a ROPS structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation
FOREWORD SAFETY 00-4 c SK1020-5N, SK1020-5NA 4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad- ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 00 1. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 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. 3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 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. 6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 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. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents. 9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 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. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 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. 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.
FOREWORD GENERAL SK1020-5N, SK1020-5NA 00-5 c 12 GENERAL 00 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 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. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
FOREWORD HOW TO READ THE SHOP MANUAL 00-6 c SK1020-5N, SK1020-5NA 12 HOW TO READ THE SHOP MANUAL 00 Volumes 00 Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available. Distribution and Updating 00 Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. Filing Method 00 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number: Example: 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example: Revised Edition Mark 00 When a manual is revised, an edition mark (bcd…) is recorded on the bottom outside corner of the pages. Revisions 00 Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page. Symbols 00 So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. 10-4 10-4-1 Added pages 10-4-2 10-5 Symbol Item Remarks Safety Special safety precautions are necessary when performing the work. ★ Caution Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc. Tightening torque Places that require special attention for tightening torque during assembly. Coat Places to be coated with adhesives and lubricants etc. Oil, water Places where oil, water or fuel must be added, and the capacity. Drain Places where oil or water must be drained, and quantity to be drained.
01 GENERAL 01-1C DIMENSION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8 SK1020-5N, SK1020-5NA
GENERAL DIMENSION DRAWINGS 01-2 2 SK1020-5N, SK1020-5NA 12 DIMENSION DRAWINGS Machine Dimensions * Weights, lengths and widths will vary depending on the attachment used on the machine. * * With standard bucket, full fuel tank and 80 kg (176 lb) operator. Item Unit SK1020-5N Standard Bucket 1880 mm (74 in) SK1020-5N Pallet Forks 1219 mm (48 in) * * Operating weight kg (lb) 3435 (7,573) 3435 (7,573) Bucket capacity (standard SAE rated) m3 (yd3 ) 0.47 (0.61) N/A Diesel engine --- KOMATSU 4D98E-1FD [4SD98E-1FD Optional Turbo] Engine horsepower kW @ rpm 52.2 @ 2800 [60.0 @ 2800] A * Overall length mm (in) 3547 (140) 3547 (140) B * Overall width mm (in) 1880 (75) 1880 (75) C Overall height mm (in) 2230 (88) 2230 (88) D Cab height mm (in) 2050 (81) 2050 (81) E Ground clearance (chassis) mm (in) 237 (9.3) 237 (9.3) F Ground clearance (drive motor) mm (in) 190 (7.5) 190 (7.5) G Axle width (no tires) mm (in) 1504 (59.2) 1504 (59.2) H Axle length (center to center) mm (in) 1162 (46) 1162 (46) I Front axle center to bucket cutting edge mm (in) 1358 (53.5) 1358 (53.5) J Rear axle center to counter weight face mm (in) 1027 (40.4) 1027 (40.4)
GENERAL DIMENSION DRAWINGS SK1020-5N, SK1020-5NA 01-3 2 12 Working Ranges * All dimensions, weights and performance values based on SAE J72c and J742b standards. Static tipping load and operating weight shown include 12.00 X 16.5 8PR tires, lubricant, coolant, full fuel tank, ROPS canopy and operator. Machine stabil- ity and operating weight are affected by counterweight, tire size and other attachments. Bucket Base Machine with 1880 mm (74 in) bucket Base Machine with 120 kg (265 lb) weights and 1880 bucket Base Machine with 120 kg (265 lb) weights and 1291 mm (48 in) pallet forks Bucket capacity (SAE rated) 0.47m3 (0.61 yd3 ) 0.47m3 (0.61 yd3 ) N/A N/A Bucket width 1880 mm (74 in) 1880 mm (74 in) N/A N/A Bucket weight 1219 mm (48 in) pallet fork weights 211 kg (465 lb 211 kg (465 lb 172 kg (378 lb) Stacked tipping load 1814 kg (4,000 lb) 1916 kg (4,400 lb) 1309 kg (2,880 lb) Operating capacity - 50% of tipping load 907 kg (2,000 lb) 998 kg (2,200 lb) 655 kg (1,440 lb) Dump clearance, maximum height and 45o dump angle 2300 mm (90.5 in) 2300 mm (90.5 in) N/A N/A Height to bucket hinge pin 3100 mm (122 in) 3100 mm (122 in) 3100 mm (122 in) Reach at maximum height and 45o dump angle 690 mm (27.1 in) 690 mm (27.1 in) N/A N/A Operating height (fully raised) 4100 mm (161 in) 4100 mm (161 in) N/A N/A Clearance circle-front 2265 mm (89.2 in) 2265 mm (89.2 in) 2286 mm (90 in) Clearance circle-rear 1650 mm (64.9 in) 1650 mm (64.9 in) 1650 mm (64.9 in) Operating weight 3435 mm (7,573 lb) 3560 mm (7,848 lb) 3528 kg (7,761 lb)
GENERAL SPECIFICATIONS 01-4C SK1020-5N, SK1020-5NA 12 SPECIFICATIONS Engine Model Komatsu 4D98E-1FD [4SD98E-1FD Optional Turbo] Type Diesel engine 4 cycle Bore and Stroke 98 x 110 (3.85 x 4.334 in) Number of cylinders 4 cylinder Displacement 3.4 L. (203 in3 ) Combustion Direct injection Aspiration Natural or [Turbo charged] Power Rating SAE J1349 52.2 kW (70 hp) [61.9 kW (83 hp) Turbo] @ 2500 rpm 80/1269/EC 52.2 kW (70 hp) [60.0 kW (80 hp) Turbo] @ 2800 rpm Maximum torque 286 N·m (211 lbf ft) @ 1600 rpm Cooling system Antifreeze coolant and distilled water Air filter Dry type with safety element Starting system Electric motor with pre-heating air system for cold weather 0°C (32°F) Transmission Type Hydrostatic Pumps 2 x Variable displacement with 2 stage and APC system Motors 2 x Axial pistons with two speeds Final transmission with heavy duty type roller chains immersed in oil bath connected to the four drive axles Speeds Working: 10.0 kg/h (6.5 mph) Travel: 16.0 km/h (10.0 mph) Sealed wet-disk parking brakes with automatic engagement when operator restraint bar is raised Hydraulic System Type Komatsu CLSS (Closed Load Sensing System) Pump Gear Maximum flow Auxiliary hydraulic: 80.0 L/min (21.0 gal/min) Maximum pressure Auxiliary hydraulic: 210 bar (3,045 psi) Control valve 3 elements fully Servo-controlled High Flow Auxiliary Hydraulic System “SUPER FLOW” (optional) Maximum flow 130 L/min (34 gal/min) Maximum pressure 210 bar (3,045 psi) Control valve 4 elements Loader Performance Without Counterweights Operating load (ISO 5998) 907 kg (2,000 lb) Tipping load (ISO 8313) 1814 kg (4,000 lb) Bucket breakout force (ISO 8313) with short lip bucket 2290 kg (5,038 lb) Bucket breakout force (ISO 8313) with long lip bucket 1940 kg (4,279 lb) Maximum hydraulic lift capacity (ISO 8313) 3082 kg (6,796 lb) Refill Capacities Hydraulic tank 50.0 L (13.0 US gal) Fuel tank 73.0 L (19.0 US gal) Chain case 32.0 L (8.3 US gal) Engine oil 12.5 L (3.2 US gal) Engine coolant 8.0 L (2.0 US gal)
GENERAL SPECIFICATIONS SK1020-5N, SK1020-5NA 01-5 2 Tires 12 - 16.5 10PR heavy duty flotation tires 12 - 16.5 (Airboss) segmented solid tires 33 x 15.5 - 16.5 10PR super wide flotation tires Electrical Rated voltage 12 V Battery 100 Ah Alternator 40A
GENERAL WEIGHT TABLE 01-6C SK1020-5N, SK1020-5NA 12 WEIGHT TABLE Unit: kg (lb) WARNING! This weight table is a guide for use when transporting or handling equipment components Machine Model SK1020-5NA SK1020-5N Engine assembly - Muffler - Exhaust pipe 235 (518) 235 (518) Radiator 35 (77) 38 (84) Hydraulic tank (without oil) 25 (55) 25 (55) Engine hood 18.5 (41) 18.5 (41) Operator compartment (without seat) 215 (474) 215 (474) Seat • Standard • With adjustable suspension 10 (22) 16 (35) 10 (22) 16 (35) Engine-pump group 238-335 (525-739) 238-335 (525-739) Piston pump • Standard • High-flow 91 (201) 98 (216) 91 (201) 98 (216) Wheel assembly (standard only) 52 (115) 52 (115) Control valve • 3-spool (Standard) • 4-spool (High-flow 21 (46) 24 (53) 21 (46) 24 (53) Work equipment • Arm • Work equipment support • Bucket • Tilt back cylinder • Dump cylinder 325 (717) 80 (176) 205 (452) 25 (55) 15 (33) 325 (717) 80 (176) 205 (452) 25 (55) 15 (33)
GENERAL FUEL COOLANT AND LUBRICANTS SK1020-5N, SK1020-5NA 01-7 2 12 FUEL COOLANT AND LUBRICANTS ★ ASTM D975 No. 1 RESERVOIR TYPE OF FLUID AMBIENT TEMPERATURE CAPACITY l (Qts & Gal) -22 -4 14 32 50 68 86 104°F -30 -20 -10 0 10 20 30 40°C First filling Change Engine oil pan 101 l (2.64 US gal) 101 l (2.64 US gal) OIL API CI-4 SAE 10W SAE 30 SAE 40 SAE 10W-30 SAE 5W-30 Hydraulic system and hydrostatic transmission OIL API CI-4 501 l (13.2 US gal) 321 l (8.4 US gal) SAE 10W SAE 5W-30 Final transmission case (each) OIL API CI-4 13.15 l (3.5 US gal) 13.15 l (3.5 US gal) SAE 10W-30 Fuel tank Diesel fuel 721 l (19.0 US gal) ★ ASTM D975 No. 2 Engine cooling system --- 151 l (3.9 US gal) ETHELENE GLYCOL BASE
GENERAL SERVICE NOTES 01-8C SK1020-5N, SK1020-5NA 12 SERVICE NOTES • Use only Komatsu genuine parts on this machine • Do not mix different types of oils. • Unless specified otherwise, the oils and the coolant used by Komatsu to fill the tanks before delivery of the machine are as follows: Item Specifications • Engine oil SAE 10W-30 API classification CI-4 • Hydraulic system and hydrostatic transmission oil SAE 10W API classification CI-4 • Final transmission oil SAE 10W-30 API classification CI-4 • Fuel Ambient temperature above - 10°C (14°F) ASTM D975 No. 2 diesel fuel Ambient temperature below - 10°C (14°F) ASTM D975 No. 1 diesel fuel • Radiator Permanent, ethylene glycol-based antifreeze, with corrosion inhibitor for protection up to -36°C (-33°F)
10-1 2 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 1245 WORK EQUIPMENT PIVOT POINT CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 WHEEL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Power Train Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Wheel Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 DRIVE MOTOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Motor Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Motor Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Motor Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 HYDRAULIC PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Drive Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 HST Pump LPV45 + 45 (Standard and High Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Pump Internal View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Operation of Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Suction Safety Valve Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Charge Safety Valve Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 ANTI ENGINE-STALL VALVE (AS VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 AS Valve Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Standard 3-Spool Valve Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Valve-Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 Super High-Flow 4-Spool Valve Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 Valve-Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Control Valve Maintenence Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 Control Valve (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 Control Valve (Super High-Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 CLOSED CENTER LOAD SENSING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 Pressure Compensation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50 System in Series Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 Self Leveling Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 System in Series-Parallel Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 Pressure Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 SK1020-5N, SK1020-5NA
10-2 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TABLE OF CONTENTS Dividing Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 Valve Group ST1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57 PATTERN CHANGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58 Pattern Options Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 Pattern ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 Pattern Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 R.H. PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61 Equipment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61 R.H. PPC Valve Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 R.H. PPC VALVE (PATTERN CHANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64 Equipment and Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64 L.H. PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67 Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69 L.H. PPC VALVE (PATTERN CHANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72 Equipment and Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72 Pattern Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74 CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
SK1020-5N, SK1020-5NA 10-3 2 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PIVOT POINT CLEARANCES WORK EQUIPMENT PIVOT POINT CLEARANCES
10-4 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PIVOT POINT CLEARANCES 12 Unit: mm (in) No. Check Item clearance Criteria Remedy Standard size Tolerance Minimum clearances Clearance limit Replace if damaged or deformed Shaft Hole 1 Between bushing and mounting pin on work equipment 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04) 2 Between bushing and mounting pin on fulcrum arm 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04) 3 Between bushing and mounting pin lift cylinder (top and bottom size) 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04) 4 Between bushing and mounting pin bucket cylinder (top side) 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04) 5 Between bushing and mounting pin bucket cylinder (bottom side) 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04)
SK1020-5N, SK1020-5NA 10-5 2 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WHEEL DRIVE SYSTEM WHEEL DRIVE SYSTEM Power Train Flow 1. Engine 5. High-flow solenoid valve 2. Hydraulic pump 6. L.H. final drive 3. Control valve 7. R.H. final drive 4. Solenoid valve 8. Axle A. Servo control B. Speed increment C. Parking brake
10-6 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WHEEL DRIVE SYSTEM 12 Transmission System 1. L.H. final drive 3. Rear drive chain 2. Front drive chain 4. Master link
SK1020-5N, SK1020-5NA 10-7 2 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WHEEL DRIVE SYSTEM 12 Wheel Axles 1. Front wheel 5. Front drive chain 2. Axle housing 6. Rear wheel 3. Sprocket 7. Rear drive chain 4. Axle shaft
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
10-8 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE MOTOR SYSTEM 12 DRIVE MOTOR SYSTEM Motor Ports L.H. Final Drive R.H. Final Drive a. A Port - To hydraulic pump (PA2 port) a. A Port - To hydraulic pump (PA2 port) b. B Port - To hydraulic pump PB2 port) b. B Port - To hydraulic pump PB2 port) c. PP1 Port - From solenoid valve group ST1 (A Port) (2nd speed) c. PP1 Port - From solenoid valve group ST1 (A Port) (2nd speed) d. PP2 Port - From solenoid valve group ST1 (C Port (parking brake) d. PP2 Port - From solenoid valve group ST1 (C Port (parking brake) e. DR Port - To hydraulic tank e. DR Port - To hydraulic tank
SK1020-5N, SK1020-5NA 10-9 2 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE MOTOR SYSTEM 12 Motor Structure 1. Shaft 10. Brake piston 19. Swash plate 28. Plug 2. Bearing 11. Plate 20. Shaft 29. Spool 3. Bearing 12. Cylinder block 21. Flange 30. Plug 4. Housing body 13. Bearing 22. Flange 31. Spring 5. Pin 14. Spring 23. Collar 6. Gear 15. Brake piston 24. Gasket 7. Pin 16. Brake spring 25. Plug 8. Gear 17. Bushing 26. Spring 9. Shoe 18. Retainer plate 27. Spool
10-10 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE MOTOR SYSTEM 12 Motor Operations Description The drive motor consists of: • 2-speed hydraulic motor • Selector valve • Reduction gearing Motor Function The hydraulic drive motor is an axial piston type motor that converts hydraulic energy supplied by the main hydraulic pump into usable rotary motion. Operation The hydraulic oil arriving from the selector valve is sent on to the valve plate (1). When the oil is sent to port “A” of the valve, it flows into the corresponding port on the cylinder block (2) and presses against the pistons (3). This pressure is converted into rotary motion by a swash plate (4) and transmitted to the shaft (5). The shaft and the cylinder block have been integrated into one piece by means of spined teething. The return oil is sent to the pump through port “B”. Rotation in the opposite direction is achieved by sending the oil to port “B” instead of to port “A”. Varying The Displacement The swash plate (4), which has two surfaces “A” and “B” on the side opposite the sliding side for the shoes (6), is supported by two bearings (7) attached to the body of the motor (8). The position of the bearings is eccentric with respect to the axis of the shaft and when running at a low speed the surface “A” remains in contact with the body of the motor through the pressure exerted by the pistons (3) and by the force of a spring (9) mounted in the cylinder block (2). The angle of the swash plate is α. When an increase in speed is demanded, the oil is sent under pressure to the command piston (10). The command piston (10) moves to the left until the surface “B” makes contact with the housing and the angle of the swash plate becomes β (the displacement of the motor is reduced).

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Komatsu sk1020 5 n skid steer loader service repair manual sn a70001 and up

  • 1. CEBM013902 Shop Manual SK1020-5N SK1020-5NA SKID STEER LOADER SERIAL NUMBERS SK1020-5N A70001 and up SK1020-5NA A60001 and up ENGINE S4D98E-2 ® www.KomatsuAmerica.com
  • 2. FOREWORD CONTENTS 00-2 c SK1020-5N, SK1020-5NA 12 CONTENTS 00 01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . 10-1 20 STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1 30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1 90 DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
  • 3. FOREWORD SAFETY SK1020-5N, SK1020-5NA 00-3 c 12 SAFETY 00 SAFETY NOTICE 00 GENERAL PRECAUTIONS 00 Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • Always wear safety glasses when hitting parts with a hammer. • Always wear safety glasses when grinding parts with a grinder, etc. 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. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang "UNDER REPAIR" signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 00 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. 2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. IMPORTANT SAFETY NOTICE 00 Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. WARNING! Never modify, weld, cut, or drill on any part of a ROPS structure. Doing so may weaken the structure which could lead to possible failure in a rollover situation
  • 4. FOREWORD SAFETY 00-4 c SK1020-5N, SK1020-5NA 4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad- ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 00 1. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 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. 3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 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. 6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 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. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents. 9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 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. 11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 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. 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.
  • 5. FOREWORD GENERAL SK1020-5N, SK1020-5NA 00-5 c 12 GENERAL 00 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 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. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
  • 6. FOREWORD HOW TO READ THE SHOP MANUAL 00-6 c SK1020-5N, SK1020-5NA 12 HOW TO READ THE SHOP MANUAL 00 Volumes 00 Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment be available. Distribution and Updating 00 Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. Filing Method 00 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number: Example: 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example: Revised Edition Mark 00 When a manual is revised, an edition mark (bcd…) is recorded on the bottom outside corner of the pages. Revisions 00 Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page. Symbols 00 So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. 10-4 10-4-1 Added pages 10-4-2 10-5 Symbol Item Remarks Safety Special safety precautions are necessary when performing the work. ★ Caution Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc. Tightening torque Places that require special attention for tightening torque during assembly. Coat Places to be coated with adhesives and lubricants etc. Oil, water Places where oil, water or fuel must be added, and the capacity. Drain Places where oil or water must be drained, and quantity to be drained.
  • 7. 01 GENERAL 01-1C DIMENSION DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2 Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4 WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6 FUEL COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7 SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8 SK1020-5N, SK1020-5NA
  • 8. GENERAL DIMENSION DRAWINGS 01-2 2 SK1020-5N, SK1020-5NA 12 DIMENSION DRAWINGS Machine Dimensions * Weights, lengths and widths will vary depending on the attachment used on the machine. * * With standard bucket, full fuel tank and 80 kg (176 lb) operator. Item Unit SK1020-5N Standard Bucket 1880 mm (74 in) SK1020-5N Pallet Forks 1219 mm (48 in) * * Operating weight kg (lb) 3435 (7,573) 3435 (7,573) Bucket capacity (standard SAE rated) m3 (yd3 ) 0.47 (0.61) N/A Diesel engine --- KOMATSU 4D98E-1FD [4SD98E-1FD Optional Turbo] Engine horsepower kW @ rpm 52.2 @ 2800 [60.0 @ 2800] A * Overall length mm (in) 3547 (140) 3547 (140) B * Overall width mm (in) 1880 (75) 1880 (75) C Overall height mm (in) 2230 (88) 2230 (88) D Cab height mm (in) 2050 (81) 2050 (81) E Ground clearance (chassis) mm (in) 237 (9.3) 237 (9.3) F Ground clearance (drive motor) mm (in) 190 (7.5) 190 (7.5) G Axle width (no tires) mm (in) 1504 (59.2) 1504 (59.2) H Axle length (center to center) mm (in) 1162 (46) 1162 (46) I Front axle center to bucket cutting edge mm (in) 1358 (53.5) 1358 (53.5) J Rear axle center to counter weight face mm (in) 1027 (40.4) 1027 (40.4)
  • 9. GENERAL DIMENSION DRAWINGS SK1020-5N, SK1020-5NA 01-3 2 12 Working Ranges * All dimensions, weights and performance values based on SAE J72c and J742b standards. Static tipping load and operating weight shown include 12.00 X 16.5 8PR tires, lubricant, coolant, full fuel tank, ROPS canopy and operator. Machine stabil- ity and operating weight are affected by counterweight, tire size and other attachments. Bucket Base Machine with 1880 mm (74 in) bucket Base Machine with 120 kg (265 lb) weights and 1880 bucket Base Machine with 120 kg (265 lb) weights and 1291 mm (48 in) pallet forks Bucket capacity (SAE rated) 0.47m3 (0.61 yd3 ) 0.47m3 (0.61 yd3 ) N/A N/A Bucket width 1880 mm (74 in) 1880 mm (74 in) N/A N/A Bucket weight 1219 mm (48 in) pallet fork weights 211 kg (465 lb 211 kg (465 lb 172 kg (378 lb) Stacked tipping load 1814 kg (4,000 lb) 1916 kg (4,400 lb) 1309 kg (2,880 lb) Operating capacity - 50% of tipping load 907 kg (2,000 lb) 998 kg (2,200 lb) 655 kg (1,440 lb) Dump clearance, maximum height and 45o dump angle 2300 mm (90.5 in) 2300 mm (90.5 in) N/A N/A Height to bucket hinge pin 3100 mm (122 in) 3100 mm (122 in) 3100 mm (122 in) Reach at maximum height and 45o dump angle 690 mm (27.1 in) 690 mm (27.1 in) N/A N/A Operating height (fully raised) 4100 mm (161 in) 4100 mm (161 in) N/A N/A Clearance circle-front 2265 mm (89.2 in) 2265 mm (89.2 in) 2286 mm (90 in) Clearance circle-rear 1650 mm (64.9 in) 1650 mm (64.9 in) 1650 mm (64.9 in) Operating weight 3435 mm (7,573 lb) 3560 mm (7,848 lb) 3528 kg (7,761 lb)
  • 10. GENERAL SPECIFICATIONS 01-4C SK1020-5N, SK1020-5NA 12 SPECIFICATIONS Engine Model Komatsu 4D98E-1FD [4SD98E-1FD Optional Turbo] Type Diesel engine 4 cycle Bore and Stroke 98 x 110 (3.85 x 4.334 in) Number of cylinders 4 cylinder Displacement 3.4 L. (203 in3 ) Combustion Direct injection Aspiration Natural or [Turbo charged] Power Rating SAE J1349 52.2 kW (70 hp) [61.9 kW (83 hp) Turbo] @ 2500 rpm 80/1269/EC 52.2 kW (70 hp) [60.0 kW (80 hp) Turbo] @ 2800 rpm Maximum torque 286 N·m (211 lbf ft) @ 1600 rpm Cooling system Antifreeze coolant and distilled water Air filter Dry type with safety element Starting system Electric motor with pre-heating air system for cold weather 0°C (32°F) Transmission Type Hydrostatic Pumps 2 x Variable displacement with 2 stage and APC system Motors 2 x Axial pistons with two speeds Final transmission with heavy duty type roller chains immersed in oil bath connected to the four drive axles Speeds Working: 10.0 kg/h (6.5 mph) Travel: 16.0 km/h (10.0 mph) Sealed wet-disk parking brakes with automatic engagement when operator restraint bar is raised Hydraulic System Type Komatsu CLSS (Closed Load Sensing System) Pump Gear Maximum flow Auxiliary hydraulic: 80.0 L/min (21.0 gal/min) Maximum pressure Auxiliary hydraulic: 210 bar (3,045 psi) Control valve 3 elements fully Servo-controlled High Flow Auxiliary Hydraulic System “SUPER FLOW” (optional) Maximum flow 130 L/min (34 gal/min) Maximum pressure 210 bar (3,045 psi) Control valve 4 elements Loader Performance Without Counterweights Operating load (ISO 5998) 907 kg (2,000 lb) Tipping load (ISO 8313) 1814 kg (4,000 lb) Bucket breakout force (ISO 8313) with short lip bucket 2290 kg (5,038 lb) Bucket breakout force (ISO 8313) with long lip bucket 1940 kg (4,279 lb) Maximum hydraulic lift capacity (ISO 8313) 3082 kg (6,796 lb) Refill Capacities Hydraulic tank 50.0 L (13.0 US gal) Fuel tank 73.0 L (19.0 US gal) Chain case 32.0 L (8.3 US gal) Engine oil 12.5 L (3.2 US gal) Engine coolant 8.0 L (2.0 US gal)
  • 11. GENERAL SPECIFICATIONS SK1020-5N, SK1020-5NA 01-5 2 Tires 12 - 16.5 10PR heavy duty flotation tires 12 - 16.5 (Airboss) segmented solid tires 33 x 15.5 - 16.5 10PR super wide flotation tires Electrical Rated voltage 12 V Battery 100 Ah Alternator 40A
  • 12. GENERAL WEIGHT TABLE 01-6C SK1020-5N, SK1020-5NA 12 WEIGHT TABLE Unit: kg (lb) WARNING! This weight table is a guide for use when transporting or handling equipment components Machine Model SK1020-5NA SK1020-5N Engine assembly - Muffler - Exhaust pipe 235 (518) 235 (518) Radiator 35 (77) 38 (84) Hydraulic tank (without oil) 25 (55) 25 (55) Engine hood 18.5 (41) 18.5 (41) Operator compartment (without seat) 215 (474) 215 (474) Seat • Standard • With adjustable suspension 10 (22) 16 (35) 10 (22) 16 (35) Engine-pump group 238-335 (525-739) 238-335 (525-739) Piston pump • Standard • High-flow 91 (201) 98 (216) 91 (201) 98 (216) Wheel assembly (standard only) 52 (115) 52 (115) Control valve • 3-spool (Standard) • 4-spool (High-flow 21 (46) 24 (53) 21 (46) 24 (53) Work equipment • Arm • Work equipment support • Bucket • Tilt back cylinder • Dump cylinder 325 (717) 80 (176) 205 (452) 25 (55) 15 (33) 325 (717) 80 (176) 205 (452) 25 (55) 15 (33)
  • 13. GENERAL FUEL COOLANT AND LUBRICANTS SK1020-5N, SK1020-5NA 01-7 2 12 FUEL COOLANT AND LUBRICANTS ★ ASTM D975 No. 1 RESERVOIR TYPE OF FLUID AMBIENT TEMPERATURE CAPACITY l (Qts & Gal) -22 -4 14 32 50 68 86 104°F -30 -20 -10 0 10 20 30 40°C First filling Change Engine oil pan 101 l (2.64 US gal) 101 l (2.64 US gal) OIL API CI-4 SAE 10W SAE 30 SAE 40 SAE 10W-30 SAE 5W-30 Hydraulic system and hydrostatic transmission OIL API CI-4 501 l (13.2 US gal) 321 l (8.4 US gal) SAE 10W SAE 5W-30 Final transmission case (each) OIL API CI-4 13.15 l (3.5 US gal) 13.15 l (3.5 US gal) SAE 10W-30 Fuel tank Diesel fuel 721 l (19.0 US gal) ★ ASTM D975 No. 2 Engine cooling system --- 151 l (3.9 US gal) ETHELENE GLYCOL BASE
  • 14. GENERAL SERVICE NOTES 01-8C SK1020-5N, SK1020-5NA 12 SERVICE NOTES • Use only Komatsu genuine parts on this machine • Do not mix different types of oils. • Unless specified otherwise, the oils and the coolant used by Komatsu to fill the tanks before delivery of the machine are as follows: Item Specifications • Engine oil SAE 10W-30 API classification CI-4 • Hydraulic system and hydrostatic transmission oil SAE 10W API classification CI-4 • Final transmission oil SAE 10W-30 API classification CI-4 • Fuel Ambient temperature above - 10°C (14°F) ASTM D975 No. 2 diesel fuel Ambient temperature below - 10°C (14°F) ASTM D975 No. 1 diesel fuel • Radiator Permanent, ethylene glycol-based antifreeze, with corrosion inhibitor for protection up to -36°C (-33°F)
  • 15. 10-1 2 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 1245 WORK EQUIPMENT PIVOT POINT CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 WHEEL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Power Train Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Transmission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6 Wheel Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7 DRIVE MOTOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Motor Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8 Motor Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9 Motor Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10 HYDRAULIC PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Drive Dampener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13 Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14 HST Pump LPV45 + 45 (Standard and High Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15 Pump Internal View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17 Operation of Main Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18 Shuttle Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Suction Safety Valve Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21 Charge Safety Valve Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24 ANTI ENGINE-STALL VALVE (AS VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26 AS Valve Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28 CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Standard 3-Spool Valve Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29 Valve-Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30 Super High-Flow 4-Spool Valve Port Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32 Valve-Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33 Control Valve Maintenence Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 Control Valve (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 Control Valve (Super High-Flow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 CLOSED CENTER LOAD SENSING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 Pressure Compensation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48 Hydraulic Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50 System in Series Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51 Self Leveling Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 System in Series-Parallel Circuit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53 Pressure Compensation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54 SK1020-5N, SK1020-5NA
  • 16. 10-2 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TABLE OF CONTENTS Dividing Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55 SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 Valve Group ST1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57 PATTERN CHANGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58 Pattern Options Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 Pattern ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 Pattern Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60 R.H. PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61 Equipment Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61 R.H. PPC Valve Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 R.H. PPC VALVE (PATTERN CHANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64 Equipment and Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64 L.H. PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67 Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-69 L.H. PPC VALVE (PATTERN CHANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72 Equipment and Travel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72 Pattern Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-73 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74 CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 Maintenance Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
  • 17. SK1020-5N, SK1020-5NA 10-3 2 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PIVOT POINT CLEARANCES WORK EQUIPMENT PIVOT POINT CLEARANCES
  • 18. 10-4 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PIVOT POINT CLEARANCES 12 Unit: mm (in) No. Check Item clearance Criteria Remedy Standard size Tolerance Minimum clearances Clearance limit Replace if damaged or deformed Shaft Hole 1 Between bushing and mounting pin on work equipment 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04) 2 Between bushing and mounting pin on fulcrum arm 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04) 3 Between bushing and mounting pin lift cylinder (top and bottom size) 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04) 4 Between bushing and mounting pin bucket cylinder (top side) 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04) 5 Between bushing and mounting pin bucket cylinder (bottom side) 35 (1.4) -0.01 (0.0004) -0.05 (0.002) +0.072 (0.003) +0.134 (0.005) 0.082 (0.003) 0.184 (0.007) 1.0 (0.04)
  • 19. SK1020-5N, SK1020-5NA 10-5 2 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WHEEL DRIVE SYSTEM WHEEL DRIVE SYSTEM Power Train Flow 1. Engine 5. High-flow solenoid valve 2. Hydraulic pump 6. L.H. final drive 3. Control valve 7. R.H. final drive 4. Solenoid valve 8. Axle A. Servo control B. Speed increment C. Parking brake
  • 20. 10-6 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WHEEL DRIVE SYSTEM 12 Transmission System 1. L.H. final drive 3. Rear drive chain 2. Front drive chain 4. Master link
  • 21. SK1020-5N, SK1020-5NA 10-7 2 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WHEEL DRIVE SYSTEM 12 Wheel Axles 1. Front wheel 5. Front drive chain 2. Axle housing 6. Rear wheel 3. Sprocket 7. Rear drive chain 4. Axle shaft
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  • 23. 10-8 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE MOTOR SYSTEM 12 DRIVE MOTOR SYSTEM Motor Ports L.H. Final Drive R.H. Final Drive a. A Port - To hydraulic pump (PA2 port) a. A Port - To hydraulic pump (PA2 port) b. B Port - To hydraulic pump PB2 port) b. B Port - To hydraulic pump PB2 port) c. PP1 Port - From solenoid valve group ST1 (A Port) (2nd speed) c. PP1 Port - From solenoid valve group ST1 (A Port) (2nd speed) d. PP2 Port - From solenoid valve group ST1 (C Port (parking brake) d. PP2 Port - From solenoid valve group ST1 (C Port (parking brake) e. DR Port - To hydraulic tank e. DR Port - To hydraulic tank
  • 24. SK1020-5N, SK1020-5NA 10-9 2 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE MOTOR SYSTEM 12 Motor Structure 1. Shaft 10. Brake piston 19. Swash plate 28. Plug 2. Bearing 11. Plate 20. Shaft 29. Spool 3. Bearing 12. Cylinder block 21. Flange 30. Plug 4. Housing body 13. Bearing 22. Flange 31. Spring 5. Pin 14. Spring 23. Collar 6. Gear 15. Brake piston 24. Gasket 7. Pin 16. Brake spring 25. Plug 8. Gear 17. Bushing 26. Spring 9. Shoe 18. Retainer plate 27. Spool
  • 25. 10-10 2 SK1020-5N, SK1020-5NA STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE MOTOR SYSTEM 12 Motor Operations Description The drive motor consists of: • 2-speed hydraulic motor • Selector valve • Reduction gearing Motor Function The hydraulic drive motor is an axial piston type motor that converts hydraulic energy supplied by the main hydraulic pump into usable rotary motion. Operation The hydraulic oil arriving from the selector valve is sent on to the valve plate (1). When the oil is sent to port “A” of the valve, it flows into the corresponding port on the cylinder block (2) and presses against the pistons (3). This pressure is converted into rotary motion by a swash plate (4) and transmitted to the shaft (5). The shaft and the cylinder block have been integrated into one piece by means of spined teething. The return oil is sent to the pump through port “B”. Rotation in the opposite direction is achieved by sending the oil to port “B” instead of to port “A”. Varying The Displacement The swash plate (4), which has two surfaces “A” and “B” on the side opposite the sliding side for the shoes (6), is supported by two bearings (7) attached to the body of the motor (8). The position of the bearings is eccentric with respect to the axis of the shaft and when running at a low speed the surface “A” remains in contact with the body of the motor through the pressure exerted by the pistons (3) and by the force of a spring (9) mounted in the cylinder block (2). The angle of the swash plate is α. When an increase in speed is demanded, the oil is sent under pressure to the command piston (10). The command piston (10) moves to the left until the surface “B” makes contact with the housing and the angle of the swash plate becomes β (the displacement of the motor is reduced).