CEBM013900

Shop
Manual

SK1020-5N
SK1020-5NA
SKID STEER LOADER

SK1020-5N A70001
SERIAL NUMBERS and UP
SK1020-5NA A60001

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.

Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

October 2004 Copyright 2004 Komatsu

Printed in USA DataKom Publishing Division
SK1020-5N, SK1020-5NA 00-1
FOREWORD CONTENTS
12
CONTENTS 00

01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1

00-2 SK1020-5N, SK1020-5NA

 PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.

Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.

The Publications listed below are available for this particular machine(s).

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

Chassis and Engine (SK1020-5N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB041300
Chassis and Engine (SK1020-5NA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB041200

OPERATION AND MAINTENANCE MANUAL:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM013900

SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM013900
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WEBM4D9801

SAFETY MANUAL

Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SL02-12

Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America Corp. Extranet Literature Ordering System.

If the Extranet Literature Ordering System is not available at the distributor location, then the following
Requisition for Technical Service Publications and Service Forms can be used. Form KDC91E is shown
on the reverse side of this page. Komatsu America Corp. reserves the right to add a surcharge to all fax
orders.

SK1020-5L pubinfok.fm 10/19/04

 REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

COMPLETE FORM DataKom Publications and Training Division

AND RETURN TO 440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887

COMPANY NAME
SHIP TO PURCHASE ORDER NO.

ATTN.

STREET ADDRESS ORDER DATE

TYPE or PRINT
ONLY CITY, STATE, ZIP CODE

COUNTRY

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND
MACHINE SERIAL NUMBER MUST BE SHOWN.

QTY. PUBLICATION FORM NO. PARTS BOOK PUBLICATION MODEL NUMBER SERIAL NUMBER
P-Paper DESCRIPTION
➥

M-Microfiche

KDC91E 071403 CURRENT PRICES WILL BE CHARGED

FOREWORD SAFETY
12
SAFETY 00

SAFETY NOTICE 00

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 symbols are 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.

GENERAL PRECAUTIONS 00 PREPARATIONS FOR WORK 00

Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.

1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not
machine. possible, insert the safety pin or use blocks to prevent
the work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
● Always wear safety glasses when hitting parts with a 3. When disassembling or assembling, support the
hammer. machine with blocks, jacks or stands before starting
● Always wear safety glasses when grinding parts with a work.
grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure PRECAUTIONS DURING WORK 00

before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or
before starting any step of the operation. Before starting hydraulic pressure measuring plugs, loosen them slowly
work, hang UNDER REPAIR signs on the controls in to prevent the oil from spurting out. Before
the operator's compartment. disconnecting or removing components of the oil, water
or air circuits, first remove the pressure completely from
5. Keep all tools in good condition and learn the correct the circuit.
way to use them.
2. The water and oil in the circuits are hot when the engine
6. Decide a place in the repair workshop to keep tools and is stopped, so be careful not to get burned. Wait for the
removed parts. Always keep the tools and parts in their oil and water to cool before carrying out any work on
correct places. Always keep the work area clean and the oil or water circuits.
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke 3. Before starting work, remove the leads from the battery.
while working. ALWAYS remove the lead from the negative (-)
terminal first.

00-3 SK1020-5N, SK1020-5NA

FOREWORD SAFETY
12
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 and always stand clear from what you are raising.

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. Never use flammable liquids to clean parts, always use approved non-flammable solvents to clean parts.

9. Be sure to assemble all parts in their original locations. 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, be sure that they are not twisted. Damaged tubbing dangerous, be extremely careful
when installing tubes for high pressure circuits. Also make sure parts are correctly installed.

11. When assembling or installing parts, always use the specified tightening torques and sequences. When installing
protective parts such as guards, or parts that may vibrate or rotate at high speeds, be particularly careful to check their
installation carefully.

12. When aligning two holes, never insert your fingers or hand. Use appropriate tools to align parts.

13. When measuring hydraulic pressure, be sure the measuring tool is correctly assembled before taking any measurements.

14. Take care when removing or installing the tracks on track-type machines. When removing the track, the track separates
suddenly, never let anyone stand at either end of the track.

15. When making repairs or adjustments on electronically controlled engines, avoid any physical contact with the injection
systems wiring harness while the engine is running. Due to the high voltage and amperage in this system, serious injury
may occur.

16. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

00-4 SK1020-5N, SK1020-5NA

FOREWORD GENERAL
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 AND FUNCTION

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.

TESTING, ADJUSTING AND TROUBLESHOOTING

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 charts correlating “Problems” to “Causes” are also included in this
section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.

MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts.

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.

SK1020-5N, SK1020-5NA 00-5

FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00

VOLUMES 00
Revised pages are shown at the LIST OF REVISED PAGES
between the title page and SAFETY page.
Shop manuals are issued as a guide to carrying out repairs.
They are divided as follows: SYMBOLS 00

Chassis volume: Issued for every machine model So that the shop manual can be of ample practical use,
Engine volume: Issued for each engine series important places for safety and quality are marked with the
following symbols.
Electrical volume: Each issued as one to cover all models
Attachment volume: Each issued as one to cover all models
Symbol Item Remarks
These various volumes are designed to avoid duplication of Special safety precautions are
information. Therefore to deal with all repairs for any model, Safety necessary when performing the
it is necessary that chassis, engine, electrical and attachment work.
be available.
Special technical precautions or
other precautions for preserving
DISTRIBUTION AND UPDATING ★ Caution
00

standards are necessary when

performing the work.
Any additions, amendments or other changes will be sent to
your distributors. Get the most up-to-date information before Weight of parts or systems.
you start any work. Caution necessary when
Weight selecting hoisting wire or when
FILING METHOD 00
working posture is important,
etc.
1. See the page number on the bottom of the page. File the Places that require special
Tightening
pages in correct order. attention for tightening torque
torque
2. Following examples show how to read the page number: during assembly.
Example:
Places to be coated with
Coat
10 - 3 adhesives and lubricants etc.

Places where oil, water or fuel

Item number (10. Structure and Function) Oil, water
must be added, and the capacity.
Consecutive page number for each item Places where oil or water must
Drain be drained, and quantity to be
3. Additional pages: Additional pages are indicated by a drained.
hyphen (-) and numbered after the page number. File as
in the example.
Example:
10-4
10-4-1
Added pages
10-4-2

10-5

REVISED EDITION MARK 00

When a manual is revised, an edition mark (123…) is

recorded on the bottom outside corner of the pages.

REVISIONS 00

00-6 SK1020-5N, SK1020-5NA

FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00

HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc. In
the DISASSEMBLY AND
ASSEMBLY section, every part
weighing 25 kg or more is
indicated clearly with the symbol

● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the 3. Do not sling a heavy load with one rope alone, but sling
relative parts. with two or more ropes symmetrically wound on to the
2. Check for existence of another part causing interface load.
with the part to be removed.
WARNING! Slinging with one rope may
cause turning of the load during
WIRE ROPES 00

hoisting, untwisting of the rope,

or slipping of the rope from its
1. Use adequate ropes depending on the weight of parts to original winding position on the
be hoisted, referring to the table below: load, which can result in a
Wire ropes dangerous accident
(Standard “Z” or “S” twist ropes without galvanizing)
4. Do not sling a heavy load with ropes forming a wide
Rope diameter Allowable load hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
mm kN tons
increase with the hanging angles. The table below
10 9.8 1.0 shows the variation of allowable load (kg) when
hoisting is made with two ropes, each of which is
11.2 13.7 1.4
allowed to sling up to 1000 kg vertically, at various
12.5 15.7 1.6 hanging angles. When two ropes sling a load vertically,
up to 2000 kg of total weight can be suspended. This
14 21.6 2.2
weight becomes 1000 kg when two ropes make a 120°
16 27.5 2.8 hanging angle. On the other hand, two ropes are subject
to an excessive force as large as 4000 kg if they sling a
18 35.3 3.6
2000 kg load at a lifting angle of 150°
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0

★ The allowable load value is estimated to be 1/6 or 1/

7 of the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident

00-7 SK1020-5N, SK1020-5NA

FOREWORD COATING MATERIALS
12
COATING MATERIALS 00

★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and
non-metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant
container
purposes for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives

500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three bond Polyethylene ● Cure time: within 5 sec. to 3 min.
179-129-9140 2g
1735 container ● Used mainly for adhesion of metals,
rubbers, plastics and woods.
● Quick hardening type adhesive.
● Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 50 g 30 minutes).
201 container
● Used mainly for adhesion of rubbers,
plastics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high
648-50 container
temperature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket ● Used as sealant for flange surfaces and bolts
sealant at high temperature locations; used to
LG-3 790-129-9070 1 kg Can prevent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.

00-8 SK1020-5N, SK1020-5NA

FOREWORD COATING MATERIALS

Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
● Used as sealant for mating surfaces of final
drive case, transmission case.
● Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Gasket
● Features: Silicon based, resistant to heat,
sealant
cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case,
etc.
● Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube
● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three bond ● Used as heat-resisting sealant for repairing
790-129-9090 100 g Tube
1211 engines.
● Used as lubricant for sliding parts
LM-G 09940-00051 60 g Can
Molybdenum

(to prevent squeaking).

disulphide
lubricant

● Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load
SYG2-400CA-A
G2-CA Various Various bearing at places in contact with water or
Grease SYG2-160CA
steam.
SYG2-
160CNCA
disulphide lubricant
Molybdenum

400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)

SK1020-5N, SK1020-5NA 00-9

FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE 00

BOLTS AND NUTS STANDARD TIGHTENING TORQUE 00

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.

Thread diameter of bolt Width across flats

mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35

Thread diameter of bolt Width across flats

mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8

00-10 SK1020-5N, SK1020-5NA

FOREWORD STANDARD TIGHTENING TORQUE
12
HOSE NUTS TIGHTENING TORQUE 00

Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5

SPLIT FLANGE BOLTS TIGHTENING TORQUE 00

Use these torques for split flange bolts.

Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3

TIGHTENING TORQUE FOR FLARED NUTS 00

Use these torques for flared part of nut.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm
14 19 24.5 ±4.9 2.5 ±0.5
18 24 49 ±19.6 5 ±2
22 27 78.5 ±19.6 8 ±2
24 32 137.3 ±29.4 14 ±3
30 36 176.5 ±29.4 18 ±3
33 41 196.1 ±49 20 ±5
36 46 245.2 ±49 25 ±5
42 55 294.2 ±49 30 ±5

SK1020-5N, SK1020-5NA 00-11

FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR FLARED NUTS 00

Use these torques for flared part of nut.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm
18 17 23 -25 2.3 - 2.5
16 22 33 - 38 3.4 - 3.9
16 24 51 - 57 5.2 - 5.8
14 30 80 - 90 8.2 -9.2
12 36 120 - 130 12.2 - 13.3
12 41 150 - 170 15.3 - 17.3
12 50 180 - 200 18.4 - 20.4
12 57 200 - 240 20.4 - 24.4

O-RING BOSS PIPING JOINTS TIGHTENING TORQUE 00

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm

02 14 34.3 ± 4.9 3.5 ± 0.5

03, 04 20 93.1 ± 9.8 9.5 ± 1
Varies depending
05, 06 24 on type of 142.1 ± 19.6 14.5 ± 2
connector.
10, 12 33 421.4 ± 58.8 43 ± 6
14 42 877.1 ± 132.3 89.5 ± 13.5

O-RING BOSS PLUGS TIGHTENING TORQUE 00

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
08 08 14 7.35 ± 1.47 0.75 ± 0.15
10 10 17 11.27 ± 1.47 1.15 ± 0.15
12 12 19 17.64 ± 1.96 1.8 ± 0.2
14 14 22 22.54 ± 1.96 2.3 ± 0.2
16 16 24 29.4 ± 4.9 3 ± 0.5
18 18 27 39.2 ± 4.9 4 ± 0.5
20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7±1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 n 127.4 ± 19.6 13 ± 2
36 36 36 151.9 ± 24.5 15.5 ± 2.5
42 42 n 210.7 ± 29.4 21.5 ± 3
52 52 n 323.4 ± 44.1 33 ± 4.5

00-12 SK1020-5N, SK1020-5NA

FOREWORD STANDARD TIGHTENING TORQUE
12
HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) TIGHTENING TORQUE 00

★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal Width across
size of hose flats Nominal thread size
Thread size Root diameter (mm)
Range Target - Threads per inch,
(mm) (Reference)
Thread series
02 19 35-63 {3.5-6.5} 44 {4.5} 14 9/16 - 18UNF 14.3
22 54-93 {5.5-9.5} 74 {4.5} -- 11/16 - 16UN 17.5
03
24 59-98 {6.0-10.0} 78 {8.0} 18 -- --
04 27 84-132 {8.5-13.5} 103 {10.5} 22 13/16 - 16UN 20.7
05 32 128-186 {13.0-19.0} 157 {16.0} 24 1 - 14UNS 25.4
06 36 177-245 {18.0-25.0} 216 {22.0} 30 1 3/16 - 12UNF 30.3
(10) 41 177-245 {18.0-25.0} 216 {22.0} 33 -- --
(12) 46 197-294 {20.0-30.0 245 {25.0} 36 -- --
(14) 55 246-343 {25.0-35.0} 294 {30.0} 42 -- --

SK1020-5N, SK1020-5NA 00-13

FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS 00

Copper wire
Nominal Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
number (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE 00

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Primary

Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary

4 White & Red & Yel- Yellow & Green & Blue &
Color — Black & Red
Blue low Green Yellow Yellow
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue

00-14 SK1020-5N, SK1020-5NA

FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00

METHOD OF USING THE CONVERSION TABLE 00

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.

EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.

B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.

C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it
to 55 mm.

B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.

C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.

2
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

SK1020-5N, SK1020-5NA 00-15

FOREWORD CONVERSION TABLES
12

Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-16 SK1020-5N, SK1020-5NA

FOREWORD CONVERSION TABLES
12

Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

SK1020-5N, SK1020-5NA 00-17

FOREWORD CONVERSION TABLES
12

kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4

00-18 SK1020-5N, SK1020-5NA

FOREWORD CONVERSION TABLES

70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

Temperature

Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees,
consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the
column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

SK1020-5N, SK1020-5NA 00-19

FOREWORD CONVERSION TABLES

°C °F °C °F °C °F °C °F
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

UNITS 00

In this manual, the measuring units are indicated with International System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}

00-20 SK1020-5N, SK1020-5NA

FOREWORD PUSH-PULL TYPE COUPLER
12
PUSH-PULL TYPE COUPLER 00

WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual
pressure from hydraulic tank.

WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected.
Accordingly, prepare an oil receiving
container.

DISCONNECTION

1. Release the residual pressure from the hydraulic tank. For details, see
TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
2. Hold adapter (1) and push hose joint (2) into mating adapter (3). (See
Fig. 1)
★ The adapter can be pushed in about 3.5 mm.
★ Do not hold rubber cap portion (4).
3. After hose joint (2) is pushed into adapter (3), press rubber cap
portion (4) against (3) until it clicks. (See Fig. 2)
4. Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3)
★ Since some hydraulic oil flows out, prepare an oil receiving
container.

CONNECTION

1. Hold hose adapter (1) or hose (5) and insert it in mating adapter (3),
aligning them with each other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2. After inserting the hose in the mating adapter perfectly, pull it back to
check its connecting condition. (See Fig. 5)
★ When the hose is pulled back, the rubber cap portion moves
toward the hose about 3.5 mm. However, this does not indicate
abnormality.

SK1020-5N, SK1020-5NA 00-21

FOREWORD PUSH-PULL TYPE COUPLER
12 Type 2 Type 3
1. Hold the mouthpiece of the tightening portion and push
1. Hold the mouthpiece of the tightening portion and push body (2)
body (2) in straight until sliding prevention ring (1)
in straight until sliding prevention ring (1) contacts surface a of
contacts contact surface a of the hexagonal portion at the
hexagonal portion at the male end.
male end.

2. Hold in the condition in Step 1 and push until cover (3)

contacts contact surface a of the hexagonal portion at the
2. Hold in the condition in Step 1 and turn lever (4) to the right
male end.
(clockwise).
Disassembly

3. Hold in the condition in Steps 1 and 2, and pull out whole body 3. Hold in the condition in Steps 1 and 2, and pull out whole
(2) to disconnect it. body (2) to disconnect it.

• Hold the mouthpiece of the tightening portion and push body (2) • Hold the mouthpiece of the tightening portion and push
in straight until sliding prevention ring (1) contacts contact body (2) in straight until sliding prevention ring (1)
surface a of the hexagonal portion at the male end to connect it. contacts contact surface a of the hexagonal portion at the
male end to connect it.
Connection

00-22 SK1020-5N, SK1020-5NA

 01 GENERAL

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 01-1

GENERAL DIMENSION DRAWINGS
12
DIMENSION DRAWINGS

MACHINE DIMENSIONS

SK1020-5N SK1020-5N
Item Unit
Standard Bucket 1880 mm (74 in) Pallet Forks 1219 mm (48 in)
* * Operating weight kg (lbs) 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)

* 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.

01-2 SK1020-5N, SK1020-5NA

GENERAL DIMENSION DRAWINGS
12
WORKING RANGES

Base Machine with 120 kg (265 lbs)

Base Machine Base Machine with 120 kg (265 lbs)
Bucket weights and 1291 mm (48 in) pallet
with 1880 mm (74 in) bucket weights and 1880 bucket
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
211 kg (465 lbs 211 kg (465 lbs 172 kg (378 lbs)
fork weights
Stacked tipping load 1814 kg (4,000 lbs) 1916 kg (4,400 lbs) 1309 kg (2,880 lbs)
Operating capacity - 50% of tipping
907 kg (2,000 lbs) 998 kg (2,200 lbs) 655 kg (1,440 lbs)
load
Dump clearance, maximum height
2300 mm (90.5 in) 2300 mm (90.5 in) N/A N/A
and 45o dump angle
Height to bucket hinge pin 3100 mm (122 in) 3100 mm (122 in) 3100 mm (122 in)
Reach at maximum height and 45o 690 mm (27.1 in) 690 mm (27.1 in) N/A N/A
dump angle
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 lbs) 3560 mm (7,848 lbs) 3528 kg (7,761 lb)

* 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.

01-3 SK1020-5N, SK1020-5NA

GENERAL SPECIFICATIONS
12
SPECIFICATIONS
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
Engine

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 Nm (211 ft/lbs) @ 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)
Type Hydrostatic
Pumps 2 x Variable displacement with 2 stage and APC system
Transmission

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
Working: 10.0 kg/h (6.5 mph)
Speeds
Travel: 16.0 km/h (10.0 mph)
Sealed wet-disk parking brakes with automatic engagement when operator restraint bar is raised
Type Komatsu CLSS (Closed Load Sensing System)
Pump Gear
Maximum flow Auxiliary hydraulic: 80.0 L/min (21.0 gal/min)
Hydraulic System

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
Performance Without Counterweights
Operating load (ISO 5998) 907 kg (2,000 lbs)
Loader

Tipping load (ISO 8313) 1814 kg (4,000 lbs)

Bucket breakout force (ISO 8313) with short lip bucket 2290 kg (5,038 lbs)
Bucket breakout force (ISO 8313) with long lip bucket 1940 kg (4,279 lbs)
Maximum hydraulic lift capacity (ISO 8313) 3082 kg (6,796 lbs)
Hydraulic tank 50.0 L (13.0 US gal)
Refill Capacities

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)

01-4 SK1020-5N, SK1020-5NA

GENERAL SPECIFICATIONS

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
Rated voltage 12 V
Electrical

Battery 100 Ah
Alternator 40A

SK1020-5N, SK1020-5NA 01-5

GENERAL WEIGHT TABLE
12
WEIGHT TABLE

WARNING! This weight table is a guide for use when transporting or handling equipment components

Unit: kg (lbs)

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 10 (22) 10 (22)
• With adjustable suspension 16 (35) 16 (35)

Engine-pump group 238-335 (525-739) 238-335 (525-739)

Piston pump
• Standard 91 (201) 91 (201)
• High-flow 98 (216) 98 (216)

Wheel assembly (standard only) 52 (115) 52 (115)

Control valve
• 3-spool (Standard) 21 (46) 21 (46)
• 4-spool (High-flow 24 (53) 24 (53)

Work equipment
• Arm 325 (717) 325 (717)
• Work equipment support 80 (176) 80 (176)
• Bucket 205 (452) 205 (452)
• Tilt back cylinder 25 (55) 25 (55)
15 (33) 15 (33)
• Dump cylinder

01-6 SK1020-5N, SK1020-5NA

GENERAL FUEL COOLANT AND LUBRICANTS
12
FUEL COOLANT AND LUBRICANTS
AMBIENT TEMPERATURE CAPACITY (Qts & Gal)
TYPE OF
RESERVOIR
FLUID -22 -4 14 32 50 68 86 104°F
First filling Change
-30 -20 -10 0 10 20 30 40°C

38
SAE 10W (3

SAE 30

OIL 101 L 101 L

Engine oil pan SAE 40
API CD (2.64 US gal) (2.64 US gal)

SAE 10W-30

SAE 5W-30

SAE 10W
Hydraulic system and OIL 501 L 321 L
hydrostatic transmission API CD (13.2 US gal) (8.4 US gal)
SAE 5W-30

Hydraulic system and SEE 501 L 321 L

BIODEGRADABLE OIL
hydrostatic transmission “4.3.1” (13.2 US gal) (8.4 US gal)

Final transmission case OIL 13.15 L 13.15 L

SAE 10W-30
(each) API CD (3.5 US gal) (3.5 US gal)

★
721 L
Fuel tank Diesel fuel
(19.0 US gal)
ASTM D975 No. 2

Engine cooling system --- Antifreeze 151 L (3.9 US gal)

★ ASTM D975 No. 1

SK1020-5N, SK1020-5NA 01-7

GENERAL SERVICE NOTES
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

SAE 10W-30
● Engine oil
API classification CD

SAE 10W
● Hydraulic system and hydrostatic transmission oil
API classification CD

● Biodegradable hydraulic system oil (only for

machines filled with synthetic biodegradable oil Shell Naturelle HFX-32
type HEES not of plant origin)

SAE 10W-30
● Final transmission oil
API classification CD

Ambient temperature above - 10°C (14°F)

ASTM D975 No. 2 diesel fuel
● Fuel
Ambient temperature below - 10°C (14°F)
ASTM D975 No. 1 diesel fuel

Permanent, ethylene glycol-based antifreeze, with

● Radiator
corrosion inhibitor for protection up to -36°C (-33°F)

01-8 SK1020-5N, SK1020-5NA

 10 STRUCTURE AND FUNCTION

12
WHEEL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
POWER TRAIN FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
TRANSMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
WHEEL AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
DRIVE MOTOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
MOTOR PORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
MOTOR STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
MOTOR OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
HYDRAULIC PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
DRIVE DAMPNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
CHARGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
HST PUMP LPV45 + 45 (STANDARD AND HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
PUMP INTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
OPERATION OF MAIN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
SHUTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
SUCTION SAFETY VALVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
CHARGE SAFETY VALVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
ANTI ENGINE-STALL VALVE (AS VALVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
CONTROL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
STANDARD 3-SPOOL VALVE PORT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
VALVE-SECTIONAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
SUPER HIGH-FLOW 4-SPOOL VALVE PORT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
VALVE-SECTIONAL VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
CLOSED CENTER LOAD SENSING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
PRESSURE COMPENSATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
SYSTEM IN SERIES CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
SELF LEVELING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
SYSTEM IN SERIES-PARALLEL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
PRESSURE COMPENSATION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
DIVIDING FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
VALVE GROUP ST1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
VALVE GROUP ST2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
PARTERN CHANGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43
PATTERN OPTIONS ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
PATTERN ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
PATTERN OPTIONAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-45
R.H. PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
EQUIPMENT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
R.H. PPC VALVE (PATTERN CHANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
EQUIPMENT AND TRAVEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
L.H. PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49

SK1020-5N, SK1020-5NA 10-1

STRUCTURE AND FUNCTION TABLE OF CONTENTS
TRAVEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
L.H. PPC VALVE (PATTERN CHANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
EQUIPMENT AND TRAVEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
PATTERN CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-54
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56

10-2 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION WHEEL DRIVE SYSTEM
12
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

SK1020-5N, SK1020-5NA 10-3

STRUCTURE AND FUNCTION WHEEL DRIVE SYSTEM
12
TRANSMISSION SYSTEM

1. L.H. final drive 3. Rear drive chain

2. Front drive chain 4. Master link

10-4 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION 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

SK1020-5N, SK1020-5NA 10-5

STRUCTURE AND FUNCTION 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 c. PP1 Port - From solenoid valve group ST1
(A Port) (2nd speed) (A Port) (2nd speed)
d. PP2 Port - From solenoid valve group ST1 d. PP2 Port - From solenoid valve group ST1
(C Port (parking brake) (C Port (parking brake)
e. DR Port - To hydraulic tank e. DR Port - To hydraulic tank

10-6 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION 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

SK1020-5N, SK1020-5NA 10-7

STRUCTURE AND FUNCTION 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,
(the displacement of the motor is reduced).

Braking Action

10-8 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION DRIVE MOTOR SYSTEM

The hydraulic motor is equipped with a negative brake. When the motor is at a stand still, or when the operator applies the
brake, the braking piston (1) is pushed to the left by the force of the springs (2). The friction disk (3), which has been
integrated with the cylinder block by means of semicircular grooves, is compressed between steel disks (4) and (5), which are
integrated with the housing, and is thus blocked. The drive shaft (6) can therefore no longer turn. When the motor is running
and the operator disengages the brake, oil is sent under pressure to the chamber “A”. The force exerted by the oil is greater
than the force of the springs (2) and the piston (1) is therefore pushed to the right thus releasing the friction disk (3) and
permitting rotation of the cylinder block (7) (and also of the drive shaft)

Flushing Relief Valve

When the oil is sent under pressure to the “A” port, the oil that activated the motor returns to the pump through the “B”
port. The pressurized oil sent to the “A” port is also introduced into the chamber “C”. It now pushes the selector valve (1) to
the right. This opens communication between the “B” port and the oil gallery “D”, which is connected to the overpressure
limitation valve (2). If the pressure present at port “B” exceeds the calibration value of the overpressure limitation valve (2),
this valve will open and discharge the excess oil into the reduction gears. The valve also functions in the same way when the
pressurized oil is sent to the “B” port. The only difference is that the selector valve moves to the left, and the oil gallery “D”
communicates with the “A” port.

Reduction Gearing

SK1020-5N, SK1020-5NA 10-9

STRUCTURE AND FUNCTION DRIVE MOTOR SYSTEM

This final drive motor is equipped with a one-stage elliptical reduction gear that converts the high rotation speed and low
torque of the hydraulic motor into low speed and high torque at the swing pinion.

Operating Principle

The rotary movement of the output shaft of the motor is transmitted to the gear (s1) and hence to the bevel gears (b1) which are
integrated with the planetary gear (1). Since the gear (a1) is fixed with respect to the output shaft of the hydraulic motor, the
planetary gear is obliged to turn, moving with it the output shaft (2) of the reduction gearing (connected to the planetary gear
by means of grooved teething).

The reduction ratio of the rotation speed is described by the formula:

R= Zs1/(Zs1+Za1)
Zs1= number of sun gear teeth
Za1= number of ring gear teeth

10-10 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT

See Section 90

SK1020-5N, SK1020-5NA 10-11

STRUCTURE AND FUNCTION HYDRAULIC PUMPS
12
HYDRAULIC PUMPS

DRIVE DAMPNER

1. Disk 4. Pilot
2. Flywheel 5. Pump
3. Dowel (No.4) 6. Flywheel cover

10-12 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION HYDRAULIC PUMPS
12
CHARGE PUMP
1. Slide plate
2. Coupling
3. Shaft
4. Outer ring
5. Case
6. Inner rotor
7. Outer rotor

Function

HST charge pump is built-in the HST pump and

driven with HST pump at the same time.

Discharged oil is delivered to AS valve and

charge safety valve.

Charge pump draws oil from hydraulic tank.

Specifications

• Type: gerotor pump

• Theological delivery: 25 cm3/rev (1.5 in3/rev)

Charge pump is connected to HST pump shaft by coupling (2), so inner rotor (6) and outer rotor (7) rotate.

When inner rotor (6) and outer rotor (7) rotate, capacity of A increase and oil is drawn in, and capacity of B decrease and oil
discharge.

SK1020-5N, SK1020-5NA 10-13

STRUCTURE AND FUNCTION HYDRAULIC PUMPS
12
HST PUMP LPV45 + 45 (STANDARD AND HIGH FLOW)

Structure

This pump is comprised of a variable swash plate type tandem piston pumps (1), control pistons (2), suction safety valves (3),
charge safety valve (4), charge pump (5), work equipment gear pumps (6), and adjustment screws (7), (8), (9), AS valve (10),
and shuttle valves (11).

1. Piston pump 7. Adjustment screw (Neutral position)

2. Control piston 8. Adjustment screw (Maximum position)
3. Suction safety valve 9. Adjustment screw (Pump power control)
4. Charge safety valve 10. AS Valve
5. Charge pump 11. Shuttle valve
6. Work equipment pump

10-14 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION HYDRAULIC PUMPS

PUMP INTERNAL VIEW

The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged
according to the load. It is possible to change the discharge amount by changing the swash plate angle (plus, zero and minus)

1. Shaft 6. Slider gib 11. Main bearing

2. Case 7. Shoe 12. Spline
3. Bearing cradle 8. Piston 13. Sub bearing
4. Rocker cam 9. Cylinder block 14. Charge pump
5. Control piston 10. Valve plate 15. Work equipment pump

Structure

Cylinder block (9) is supported by shaft (1), spline (12), and shaft (1) is supported by the front and rear bearings (11), (13). The
tip of piston (8) is a concave ball, and shoe (7) is connected to it to form one complete unit. Piston (8) and shoe (7) form a
spherical bearing. Rocker cam (4) has flat surface “A”, and shoe (7) is always pressing against this surface while sliding in a
circular motion. There is a cradle bearing (3) between rocker cam (4) which is secured to the case. Rocker cam (4) sways on
the cradle bearing. Piston (8) carries out relative movement in the axial direction inside each cylinder chamber of
cylinder block (9). The cylinder block seals the pressurized oil to valve plate (10) and carries out the relative rotation. This
surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of
cylinder block (9) is drawn in and discharged through valve plate (10).

SK1020-5N, SK1020-5NA 10-15

STRUCTURE AND FUNCTION HYDRAULIC PUMPS
12
OPERATION OF MAIN PUMP

Cylinder block (9) rotates together with shaft (1), and shoe (7) slides on surface A. When this happens, rocker cam (4) moves
along cylindrical surface B, so angle α between center line X of rocker cam (4) and the axial direction of cylinder
block (9) changes. (Angleα is called the swash plate angle).

• Center line X of rocker cam (4) maintains swash plate angle α in

relation to the axial direction of cylinder block (9), and flat surface
A moves as a cam in relation to shoe (7). In this way, piston (8)
slides on the inside of cylinder block (9), so a difference between
volumes E and F is created inside cylinder block (9). The suction
and discharge is carried out by this difference F-E. In other words,
when cylinder block (9) rotates and the volume of chamber F
becomes smaller, the oil is discharged during that stroke. On the
other hand, the volume of chamber E becomes larger, and as the
volume becomes bigger, the oil is drawn in (Fig. 1).

• If center line X of rocker cam (4) is in line with the axial direction
of cylinder block (9) (swash plate angle = 0), the difference
between volumes E and F inside cylinder block (9) becomes 0, so
the pump does not carry out any suction or discharge of oil (Fig. 2).

• Center line X of rocker cam (4) maintains swash plate angle α in

relation to the axial direction of cylinder block (9), and flat surface
A moves as a cam in relation to shoe (7). In this way, piston (8)
slides on the inside of cylinder block (9), so a difference between
volumes E and F is created inside cylinder block (9). The suction
and discharge is carried out by this difference E-F. In other words,
when cylinder block (9) rotates and the volume of chamber E
becomes smaller, the oil is discharged during that stroke. On the
other hand, the volume of chamber F becomes larger, and as the
volume becomes bigger, the oil is sucked in. If the direction of
swash plate angle is changed, the relation between discharge and
suction of port PA, PB reverse (Fig. 3).

10-16 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION HYDRAULIC PUMPS
12
Control Of Fluid Flow

• If swash plate angle α becomes larger, the difference between

volumes E and F becomes larger and discharge amount Q
increases.
• Swash plate angle α is changed by control piston (5).
• Control piston (5) moves in a reciprocal movement according to the
signal pressure from pilot line (PPC and AS valves). This straight
line movement is transmitted through slider (6) to rocker cam (4),
which is supported by the cylindrical surface to cradle, slides in a
rotating movement in direction.

• On this pump, maximum swash plate angle is ±15.8o.

• Screw A restricts to the maximum stroke of control piston (i.e.

maximum displacement of each pump). When screw A is tightened,
maximum displacement decreases, and when screw A is loosened,
maximum displacement increase. This screw should be adjusted
when the machine does not travel straight or machine maximum
speed is little bit wrong.
• Screw B is the fine adjuster of neutral position of control piston (5).
That adjust prevent machine from creep.

Piston Control (on non-induction of pilot signal)

• If there is no pressure control piston (5) does not move and main
pump to a neutral condition.

SK1020-5N, SK1020-5NA 10-17

STRUCTURE AND FUNCTION HYDRAULIC PUMPS
12
• When pressurized oil which has the pressure PPA, PPB (PPA>PPB)
is led from pilot line (PPC or AS valve), control piston (5) moves
the (>) direction. Control piston (5) moves the balanced position by
spring force and pressure PPA, PPB.

• If the relation of pressure dimension of PPA, PPB is reversed (i.e.

PPA<PPB), control piston moves reversal direction.

AS valve is installed and lower pressure between AS valve output

pressure and PPC pressure is selected by shuttle valve and inducted
to control piston (see topic shuttle valve).

SHUTTLE VALVE

1. Valve
2. Plug
3. Cover

Function

The shuttle valves are installed in the covers of pump and are part of the
swash plate control pistons. They select the lower pressure either travel
PPC pressure or AS valve pressure, and supply the pump swash plate with control pressure.

10-18 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION SAFETY VALVES
12
SAFETY VALVES

SUCTION SAFETY VALVE ACTION

1. Charge pump
2. Charge safety valve
3. Suction safety valve
3A: Valve
3B: Rod
3C: Sleeve
3D: Spring
3E: Spring
3F: Plug
4. Piston pump
5. Travel motor

Functions

There are two suction safety valves installed to each HST pump, and
they have the following functions:
★ High pressure safety valve

The valve restricts the maximum pressure inside the HST circuit in
order to protect the HST circuit.
★ Suction safety valve

The valve ensures the flow of the charge oil to the closed HST circuit
and prevents the charge oil from flowing into the pump high pressure
side (delivery side).

SK1020-5N, SK1020-5NA 10-19

STRUCTURE AND FUNCTION SAFETY VALVES
12
Acting As High Pressure Relief Valve

★ Valve at piston pump delivery side

Port A is connected to the piston pump circuit and port B is
connected to the charge circuit. The pressurized oil fills port C
through drill hole a of piston (3A). The pressurized oil at high
pressure port A fills port D through groove b between body and
valve. Poppet (3A) is in tight contact with valve seat (3C).

If abnormal pressure is generated in the circuit and the oil pressure

at ports A and D reaches to the pressure set by spring (3D), poppet
(3A) is pushed to > direction, and oil at port A is relieved to port B
to reduce the oil pressure at port A.

Acting As Suction Safety Valve

★ When HST pump delivery is 0.

The HST circuit is closed, and the charge oil does
not flow into the HST circuit. Therefore the
charge pressurized oil from the charge pump (1)
all passes the charge safety valve (2) and is
drained to the pump case.

10-20 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION SAFETY VALVES
12
When HST Pump Discharges From Port PA

★ Valve at the piston pump delivery side.

When the pressure oil is discharged from port PA of the HST pump (4),
port PA becomes the high pressure side. This pressure oil at port PA
flow into port D through the groove b. When this happen, sleeve (3C) is
pushed < to direction, because of the difference in area (A1>A2).
Therefore the pressure oil from charge pump is prevented from flowing
into HST pump.

★ Valve at piston pump suction side

Port PB is at low pressure because port PB is suction side. And sleeve
(3C) is pushed to > direction to open body seat portion because of the
difference in area (A1>A2). In this way, the charge pressure oil at port B
flows into port PB through this clearance to charge to the HST circuit.

SK1020-5N, SK1020-5NA 10-21

STRUCTURE AND FUNCTION SAFETY VALVES
12
CHARGE SAFETY VALVE ACTION

1. Charge pump
2. Charge safety valve
2A: Valve
2B: Spring
2C: Valve seat
2D: Poppet
2E: Spring
2F: Adjustment screw
3. Piston pump

Function

There is the charge safety valve installed to the HST pump. The charge
safety valve restricts the maximum pressure inside the charge circuit in
order to protect the charge circuit.

Port A is connected to the charge circuit. Port B is connected to the tank

drain circuit. The pressurized oil fills port C through orifice a in valve
(2A). Poppet (2D) is in tight contact with valve seat (2C)

10-22 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION SAFETY VALVES
If abnormal pressure is generated in the circuit or the shuttle valve of
HST motor is at neutral and the oil pressure at ports A and C reaches
the pressure set by spring (2E), poppet (2D) is pushed to > direction,
and oil at C is relieved to port B and pressure of the oil at C reduce.

When the pressure of the oil at port C goes down, a differential pressure
is occurred between ports A and C because of orifice a in valve (2A).
Valve (2A) is pushed to > direction by oil pressure at port A, and oil at
port A is relieved to port B. In this way, the pressure in the charge circuit
is prevented from going any higher.

SK1020-5N, SK1020-5NA 10-23

STRUCTURE AND FUNCTION ANTI ENGINE-STALL VALVE (AS VALVE)
12
ANTI ENGINE-STALL VALVE (AS VALVE)

1. AS valve 2. Charge pump

1A: Nut 3. Orifice
1B: Screw 4. Charge safety valve
1C: Spring 5. Engine
1D: Spring
1E: Spring
1F: Valve
1G: Valve
1H: Nut
1L: Screw

Function

The AS valve is attached on the main piston pump. It reduces pressure for pump swash plate control from charge circuit. The
AS valve outputs pressure correspond with engine revolutions.

10-24 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION ANTI ENGINE-STALL VALVE (AS VALVE)
12
Operation

• The oil from the charge pump (2) flows through a orifice (3) installed in the main piston pump. Oil always flows to pump
charge circuit.
• Charge pump (2) is a fixed capacity pump, so that discharge flow is proportionate to engine speed. When oil from the
charge pump (2) passes through the orifice, differential pressure is generated at port A and port B. This differential
pressure actuates the differential pressure sensing valve (1G) and produces hydraulic force F.
• Because of the hydraulic force F, the differential pressure sensing valve (1G) is moved > direction. That causes a change
in spring (1D) load. In port C, the AS valve output pressure that is balanced with spring (1C) and (1D) load is generated
by reducing charge pressure from port G. So the AS valve output pressure corresponds with charge flow that changes with
engine (5) revolution.

SK1020-5N, SK1020-5NA 10-25

STRUCTURE AND FUNCTION CONTROL VALVES
12
CONTROL VALVES

STANDARD 3-SPOOL VALVE PORT LOCATION

P1: From gear pump A3: To attachment port

T: To tank B1: To lift arm cylinder (bottom side)
Ts: To tank B2: To bucket cylinder (bottom side)
A1: To lift arm cylinder (top side) B3: To attachment port
A2: To bucket cylinder (top side)

10-26 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION CONTROL VALVES
12
VALVE-SECTIONAL VIEWS

1. Main relief valve 8. Spool (bucket)

2. Stop plug (lift arm bottom side) 9. Spool (attachment)
3. Suction valve (bucket bottom side) 10. Flow divider
4. Plug 11. Check valve (circulating circuit)
5. Plug 12. Combination circulating valve
6. Series-parallel circuit switching valve 13. Leveling circulating valve
7. Spool (lift arm)

SK1020-5N, SK1020-5NA 10-27

STRUCTURE AND FUNCTION CONTROL VALVES
12

1. Unload valve 9. Suction valve

2. Pressure compensation valve F (lift arm) 10. Shuttle valve
3. Pressure compensation valve F (bucket) 11. Spool (bucket)
4. Pressure compensation valve F (attachment) 12. Suction valve
5. Pressure compensation valve R (attachment) 13. Shuttle valve
6. Pressure compensation valve R (bucket) 14. Spool (attachment)
7. Pressure compensation valve R (lift arm) 15. Stop plug for individual relief valve
8. Spool (lift arm)

★ F: Flow control valve

R: Pressure reducing valve

10-28 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION CONTROL VALVES
12
SUPER HIGH-FLOW 4-SPOOL VALVE PORT LOCATION

P1: From gear pump A3: To attachment port

P2: From gear pump A4: To High-Flow port
T: To tank B1: To lift arm cylinder (bottom side)
Ts: To tank B2: To bucket cylinder (bottom side)
Pi2: From solenoid valve group ST2 (S port) B3: To attachment port
A1: To lift arm cylinder (top side) B4: To High-Flow attachment port
A2: To bucket cylinder (top side)

SK1020-5N, SK1020-5NA 10-29

STRUCTURE AND FUNCTION CONTROL VALVES

VALVE-SECTIONAL VIEWS

1. Main relief valve 6. Series-parallel circuit switching valve

2. Stop plug (lift arm bottom side) 7. Spool (lift arm)
3. Suction valve (bucket bottom side) 8. Spool (bucket)
4. Stop plug for individual relief valve 9. Spool (attachment)
5. Float valve 10. Spool (High-Flow)

10-30 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION CONTROL VALVES
12

1. Unload valve 8. Pressure compensation valve R (attachment)

2. Pressure compensation valve F (lift arm) 9. Pressure compensation valve R (bucket)
3. Pressure compensation valve F (bucket) 10. Pressure compensation valve R (lift arm)
4. Pressure compensation valve F (attachment) 11. Combination circulating valve
5. Pressure compensation valve F (High-Flow) 12. Leveling circulating valve
6. Check valve (for High-Flow joining circuit) 13. Flow divider
7. Pressure compensation valve R (High-Flow) 14. Check valve (circulating circuit)

★ F: Flow control valve

R: Pressure reducing valve

SK1020-5N, SK1020-5NA 10-31

STRUCTURE AND FUNCTION CONTROL VALVES
12

1. Pressure compensation valve F (lift arm) 12. Pressure compensation valve R (bucket)
2. Spool (lift arm) 13. Shuttle valve
3. Stop plug 14. Pressure compensation valve F (attachment)
4. Float valve 15. Spool (attachment)
5. On-Off solenoid 16. Stop plug for individual relief valve
6. Spool (float) 17. Pressure compensation valve R (attachment)
7. Pressure compensation valve F (lift arm) 18. Pressure compensation valve F (High-Flow)
8. Shuttle valve 19. Spool (High-Flow)
9. Pressure compensation valve R (bucket) 20. Pressure compensation valve R (High-Flow)
10. Spool (bucket) 21. Check valve (High-Flow joining circuit)
11. Suction valve 22. Spool (High-Flow joining)

10-32 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION CLOSED CENTER LOAD SENSING SYSTEM

CLOSED CENTER LOAD SENSING SYSTEM

Outline

CLSS stands for Closed center Load Sensing System, and has the followings characteristics.

A. Control ability, not influenced by load.

B. Controllable digging force at a fine control range.

C. Easy simultaneous operation by spool opening proportional flow dividing function.

PRESSURE COMPENSATION CONTROL

A valve (pressure compensation valve) is installed to the inlet port side of the control valve to balance the load. When there is
compound operation of the equipment, this valve acts to make pressure difference ▲P constant for the upstream flow (inlet
port) and downstream flow (outlet port) of each spool. In this way, the flow of oil from the pump is divided in proportion to
area of opening S1 and S2 of each valve.

SK1020-5N, SK1020-5NA 10-33

STRUCTURE AND FUNCTION CLOSED CENTER LOAD SENSING SYSTEM
12
Features

• The small capacity gear pump provides high flow movement because lift arm and the bucket circuit are connected in a
series circuit.
• The control valve has built in self leveling function.
• If loading pressure on the bucket goes beyond a certain value, the lift arm and the bucket circuits automatically change to
a parallel circuit to provide a strong digging force.
• The lift arm, attachment and High-flow section are connected in a parallel circuit and are provided with a pressure
compensational function in each section.
• During individual operations, attachment High-flow keeps individual demand flow rate normal. However during
compound operations, they are divided in a proportion of 1 to 9 flow rate.

HYDRAULIC CIRCUIT DIAGRAM

1. Unloader valve 8. Leveling circulating valve

2. Main relief valve 9. Combination circulating valve
3. Pressure compensation valve (lift arm) 10. Flow divider
4. Pressure compensation valve (bucket) 11. Shuttle valve
5. Pressure compensation valve (attachment) 12. Check valve (circulating circuit)
6. Pressure compensation valve (High-Flow) 13. High-Flow Joining spool
7. Float valve

10-34 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION CLOSED CENTER LOAD SENSING SYSTEM
12
SYSTEM IN SERIES CIRCUIT OPERATION

Function

Return flow rate from the lift arm is recirculated to the bucket.

Operation

When (lift arm raise) and (bucket dump) are operated at the same time.
• The lift arm spool (1) is at full stroke and the bucket spool (2) is at half stroke.
• When this happens, notch (a) does not open, so all flow from pump supplies to the (lift arm raise).
• The lift arm and the bucket PPC pressure are sent through passage E and F. Then the leveling circulating valve (3) and the
combination circulating valve (4) are at full stroke.
• Return flow rate from the lift arm cylinder passes through passage A. Then it is divided and sent to passage B and C, by
the leveling circulating valve (4) and the combination circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passage B and C in
proportion to the area of opening of notch (b) and (c) as below expression. Q1:Q2= (notch (b) + notch (d)): notch (C)
Q1= flow rate flows to B, Q2= flow rate flows to C
• Q1 passes through the check valve (6) and then supplies to the bucket cylinder.

SK1020-5N, SK1020-5NA 10-35

STRUCTURE AND FUNCTION CLOSED CENTER LOAD SENSING SYSTEM
12
SELF LEVELING FUNCTION

Function

When the only lever of the lift arm raise is operated, the lift arm raise and the bucket dump are worked. When this happens, the
work equipment can raise with constant bucket bottom angle. (Only the lift arm raise).

Operation

• When the lift arm raise is operated individually.

• The lift arm spool (1) is at a full stroke position and the bucket spool is at a half stroke position.
• When this happens, notch (a) does not open, so all flow rate from pump is supplied to the (lift arm raise).
• The lift arm raise PPC pressure is then sent through passage E. When this happens the leveling circulating valve is at a
full stroke position.
• Return flow rate from the lift arm cylinder passes through passage A. Then it is divided into passage B and C, by the
leveling circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to B and C in proportion
to the area of opening of notch (b) and (c) as below expression. Q1:Q2= notch (b):notch (C)
• Q1 passes through the check valve (6) and then supplies to the bucket cylinder.

10-36 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION CLOSED CENTER LOAD SENSING SYSTEM
12
SYSTEM IN SERIES-PARALLEL CIRCUIT OPERATION

Function

• (1) Low bucket load: Series circuit

• (2) High bucket load: Parallel circuit
• Depending on bucket load, a circuit can change automatically as above.

Operation

When the (lift arm raise) and (bucket digging) are operated at the same time.
• The lift arm spool (1) and the bucket spool (2) are at full stroke.
• When this happens, the bucket digging PPC pressure is sent through passage H. Then the combination circulating valve
(3) fully strokes to the right and the lift arm raise PPC pressure is sent through passage E. Then the leveling circulating
valve (4) is at full stroke to the left.

SK1020-5N, SK1020-5NA 10-37

STRUCTURE AND FUNCTION CLOSED CENTER LOAD SENSING SYSTEM
• Return flow rate from the lift arm cylinder passes through passage A. Then it is divided and sent to passage B and C, by
the leveling circulating valve (4) and the combination circulating valve (3).
• When this happens, the flow divider (5) is operated as P1=P2, so flow rate (Q1, Q2) is divided to passage B and C in
proportion to the area of opening as below expression. Q1:Q2= (notch (b) + notch (d)): notch (C) Q1= flow rate flows to
B Q2=flow rate flows to C
• If the bucket load goes beyond a certain load, the series-parallel switching valve (7) strokes to the right. Then it passes
thorough passage G by opening notch (e). And then the spring chamber of flow divider (5) is connected to tank.
• As a result, flow divider strokes fully to the right, and P2=T Return flow rate from the lift arm is connected with tank
totally, and Q1=0L/min.
• When this happens, notch (f) of the lift arm spool and notch (a) of the bucket spool open, so the lift arm and the bucket
become parallel circuit (CLSS). And flow rate of the lift arm raise (Q3) and then bucket digging flow rate are divided as
below expression. Q3:Q4= notch (f): notch (a)

PRESSURE COMPENSATION VALVE

Function

During compound operations, if the load pressure becomes lower than the other actuator and the oil flow tries to increase,
compensation is received. (When this happens, the other actuator being used for compound operation (right side) is at a higher
load than the actuator on this side (left side).

Operation

• If the load pressure of the other actuator (right side) becomes higher during compound operations, the oil flow in actuator
circuit A on this side (left side) tries to increase.
• If this happens, the LS pressure PLS of the other actuator acts on spring chamber PLS1, and reducing valve (1) and flow
control valve (2) are pushed to the left in the direction of the arrow ➮.
• Flow control valve (2) throttles the area of opening between pump circuit PP and spool upstream PPA, and pressure loss
is generated between PP and PPA.

10-38 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION CLOSED CENTER LOAD SENSING SYSTEM
• Flow control valve (2) and reducing valve (1) are balanced in position where the difference in pressure between PLS and
PA acting on both ends of reducing valve (2) and the pressure loss between PP and PPA on both sides of flow control
valve (2) are the same.
• In this way, the pressure difference between upstream pressure PPA and down stream pressure PA of both spools used
during compound operations is the same, so the pump flow is divided in proportion to the area of opening of notch (a) of
each spool.

DIVIDING FUNCTION

When each section is operated individually

• Attachment: 60L/min (16 gal/min)
• High-Flow attachment: 100L/min (26 gal/min)
When standard attachment and high flow attachment are operated at the same time 1:9=attachment: High-Flow

Operation

• When each section is operated individually

• Attachment spool (1) and High-Flow spool (3) stroke fully and individually, therefore they keep demand flow rate
individually.
• Attachment: 60L/min (16 gal/min)
• High-Flow: 100L/min (16 gal/min)
• When attachment and High-Flow are operated at the same time.
• High-Flow attachment PPC pressure passes through passage A, is sent to retainer (2) and makes retainer (2) stroke to the
left.
• When this happens, attachment spool (1) can stroke by half.
• As a result, flow rate of attachment and High-Flow are divided as below expression. Attachment: High-Flow= 1:9
• Therefore flow rate of high flow is kept.

SK1020-5N, SK1020-5NA 10-39

STRUCTURE AND FUNCTION SOLENOID VALVE
12
SOLENOID VALVE

VALVE GROUP ST1

Servo control - Parking Brake - 2nd. Speed

Function

1. 2nd. speed A Port - To travel motors (PP1 port)

2. Servo control B Port - To PPC valve
3. Parking brake C Port - To travel motors (PP2 port)
P Port - From hydraulic pump (E1 port)
T Port - To hydraulic tank
S Port - To accumulator

10-40 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION SOLENOID VALVE
12
VALVE GROUP ST2
High-Flow Control

T Port - To hydraulic tank

P1 Port - From control valve (PA3 port)
P2 Port - From control valve (PB3 port)
S Port - To control valve (Pi2 port)

SK1020-5N, SK1020-5NA 10-41

STRUCTURE AND FUNCTION ACCUMULATOR
12
ACCUMULATOR

Technical Data

Servo control
• Nominal volume: 0.35 L (21.4 in3)
• Pre-loading: 8 bar (116 psi)
• Working pressure: 25 - 27 bar (363 - 392 psi)

Function

An elastic rubber bag (1) containing nitrogen is fitted inside the accumulator to maintain oil pressure in the circuit to which the
accumulator is connected.

Operation

• When the engine is running the chamber A bag (1) (containing nitrogen) is compressed by oil under pressure coming from
line B.
• If the oil under line B falls below the maximum calibration pressure (even after intensive use), the rubber bag (1) will
expand due to pressure from the nitrogen.

10-42 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION PARTERN CHANGE VALVE
12
PARTERN CHANGE VALVE

P in 1. - From L.H. PPC valve (P4 port) P out 1. - To hydraulic pump (DA1 port)
P in 2. - From L.H. PPC valve (P1 port) P out 2. - To hydraulic pump (DA2 port)
P in 3. - From L.H. PPC valve (P3 port) P out 3. - To hydraulic pump (DB1 port)
P in 4. - From L.H. PPC valve (P2 port) P out 4. - To hydraulic pump (DB2 port)
P in 5. - From R.H. PPC valve (P1 port) P out 5. - To control valve (PA1 port)
P in 6. - From R.H. PPC valve (P2 port) P out 6. - To control valve (PB1 port)

SK1020-5N, SK1020-5NA 10-43

STRUCTURE AND FUNCTION PARTERN CHANGE VALVE
12

1. Lever 3. Valve seat 5. Upper cover 7. Pin lock

2. Rotor 4. Ball 6. Lower cover

10-44 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION PARTERN CHANGE VALVE

PATTERN OPTIONS ARRANGEMENT

PATTERN ISO

PATTERN OPTIONAL

SK1020-5N, SK1020-5NA 10-45

STRUCTURE AND FUNCTION R.H. PPC VALVE (STANDARD)
12
R.H. PPC VALVE (STANDARD)

EQUIPMENT CONTROL

P1 port - To control valve (PA1 port) Function

P2 port - To control valve (PB1 port) P1 Lower arm
P3 port - To control valve (PA2 port) P2 Raise arm
P4 port - To control valve (PB2 port) P3 Curl bucket
P port - From solenoid valve group ST1 (B port) P4 Dump bucket
T port - To hydraulic tank

10-46 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE)
12
R.H. PPC VALVE (PATTERN CHANGE)

EQUIPMENT AND TRAVEL CONTROL

Supply P1 - To pattern change valve (Pin 5 port) Function

Supply P2 - To pattern change valve (Pin 6 port) ISO Pattern P1 Lower arm
P3 port - To control valve (PA2 port) P2 Raise arm
P4 port - To control valve (PB2 port) P3 Curl bucket
P port - From solenoid valve group ST1 (B port) P4 Bucket dump
T port - To hydraulic tank Optional Pattern P1 R.H. Travel forward
P2 R.H. Travel reverse
P3 Curl bucket
P4 Dump bucket

SK1020-5N, SK1020-5NA 10-47

STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE)
12

1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body

10-48 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE)
Function

★ Neutral
Ports P1 and P2 of the PPC valve are connected to drain chamber D
through fine control hole f in spool (Fig. 1)

★ During Fine Control (Neutral ➬ Fine Control)

When piston (4) starts to be pushed by disc (5), retainer (9) is pushed;
spool (1) is also pushed by metering spring (2), and moves down. When
this happens, fine control hole f is shut off from drain chamber D, and at
almost the same time, it is connected to pump pressure chamber PP, so
pilot pressure oil from the control pump passes through fine control hole
f and goes to port P1. When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f is shut off from pump
pressure chamber PP.

At almost the same time, it is connected to drain chamber D to release

the pressure at port P1. When this happens, spool (1) moves up or down
so that the force of metering spring (2) is balanced with the pressure at
port P1. The relationship in the position of spool (1) and body (10) (fine
control hole f is at a point midway between drain hole D and pump
pressure chamber PP) does not change even if the pressure at port P1
becomes max. Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the control lever, so the
pressure at port P1 also rises in proportion to the travel of the control
lever. (Fig. 2)

★ During Fine Control (When The Lever Is Returned)

★ (fine control ➬ neutral)

When disc (5) starts to be returned, spool (1) is pushed up by the force
of centering spring (3) and the pressure at port P1. When this happens,
fine control hole f is connected to drain chamber D and the pressure oil
at port P1 is released. If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine control hole f is shut off
from drain chamber D. At almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is supplied until the
pressure at port P1 recovers to a pressure that corresponds to the lever
position. (Fig. 3).

SK1020-5N, SK1020-5NA 10-49

STRUCTURE AND FUNCTION L.H. PPC VALVE (STANDARD)
12
L.H. PPC VALVE (STANDARD)

TRAVEL CONTROL

P1 port - To control valve (DA2 port) Function

P2 port - To control valve (DB2 port) P1 Travel forward
P3 port - To control valve (DA1 port) P2 Travel reverse
P4 port - To control valve (DB1 port) P3 R.H. Travel forward
P port - From solenoid valve group ST1 P4 R.H. Travel reverse
T port - To hydraulic tank

★ When acting control lever, two ports are pressurized contemporarily (i.e.: travel forward pressurize P1 and P3 ports).

10-50 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION L.H. PPC VALVE (PATTERN CHANGE)
12
L.H. PPC VALVE (PATTERN CHANGE)

EQUIPMENT AND TRAVEL CONTROL

P1 port - To pattern change valve (Pin 1 port) Function

P2 port - To pattern change valve (Pin 2 port) ISO Pattern P1 Travel forward
P3 port - To pattern change valve (Pin 3 port) P2 Travel reverse
P4 port - To pattern change valve (Pin 4 port) P3 L.H. Travel
P port - From solenoid valve group ST1 P4 R.H. Travel
T port - To hydraulic tank Optional Pattern P1 L.H. Travel forward
P2 L.H. Travel reverse
P3 Raise arm
P4 Lower arm

SK1020-5N, SK1020-5NA 10-51

STRUCTURE AND FUNCTION L.H. PPC VALVE (PATTERN CHANGE)

STANDARD

1. Spool 8. Cover
2. Metering spring 9. Stopper
3. Centering spring 10. Body
4. Piston 11. Plug
5. Disc 12. Ball
6. Nut 13. Seat
7. Joint 14. Body (for shuttle valve)

10-52 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION L.H. PPC VALVE (PATTERN CHANGE)
12
Function

★ Neutral
Ports P1 and P2 of the PPC valve are connected to drain chamber D
through fine control hole f in spool (Fig. 1)

★ During Fine Control (Neutral ➬ Fine Control)

When piston (4) starts to be pushed by disc (5), retainer (9) is pushed;
spool (1) is also pushed by metering spring (2), and moves down. When
this happens, fine control hole f is shut off from drain chamber D, and at
almost the same time, it is connected to pump pressure chamber PP, so
pilot pressure oil from the control pump passes through fine control hole
f and goes to port P1. When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f is shut off from pump
pressure chamber PP.

At almost the same time, it is connected to drain chamber D to release

the pressure at port P1. When this happens, spool (1) moves up or down
so that the force of metering spring (2) is balanced with the pressure at
port P1. The relationship in the position of spool (1) and body (10) (fine
control hole f is at a point midway between drain hole D and pump
pressure chamber PP) does not change even if the pressure at port P1
becomes max. Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the control lever, so the
pressure at port P1 also rises in proportion to the travel of the control
lever. (Fig. 2)

★ During Fine Control (When The Lever Is Returned)

★ (fine control ➬ neutral)

When disc (5) starts to be returned, spool (1) is pushed up by the force
of centering spring (3) and the pressure at port P1. When this happens,
fine control hole f is connected to drain chamber D and the pressure oil
at port P1 is released. If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine control hole f is shut off
from drain chamber D. At almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is supplied until the
pressure at port P1 recovers to a pressure that corresponds to the lever
position. (Fig. 3).

SK1020-5N, SK1020-5NA 10-53

STRUCTURE AND FUNCTION L.H. PPC VALVE (PATTERN CHANGE)
12
PATTERN CHANGE

1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body

10-54 SK1020-5N, SK1020-5NA

STRUCTURE AND FUNCTION L.H. PPC VALVE (PATTERN CHANGE)
12
Function

★ Neutral
Ports P1 and P2 of the PPC valve are connected to drain chamber D
through fine control hole f in spool (Fig. 1)

★ During Fine Control (Neutral ➬ Fine Control)

When piston (4) starts to be pushed by disc (5), retainer (9) is pushed;
spool (1) is also pushed by metering spring (2), and moves down. When
this happens, fine control hole f is shut off from drain chamber D, and at
almost the same time, it is connected to pump pressure chamber PP, so
pilot pressure oil from the control pump passes through fine control hole
f and goes to port P1. When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f is shut off from pump
pressure chamber PP.

At almost the same time, it is connected to drain chamber D to release

the pressure at port P1. When this happens, spool (1) moves up or down
so that the force of metering spring (2) is balanced with the pressure at
port P1. The relationship in the position of spool (1) and body (10) (fine
control hole f is at a point midway between drain hole D and pump
pressure chamber PP) does not change even if the pressure at port P1
becomes max. Therefore, metering spring (2) is compressed
proportionally to the amount of movement of the control lever, so the
pressure at port P1 also rises in proportion to the travel of the control
lever. (Fig. 2)

★ During Fine Control (When The Lever Is Returned)

★ (fine control ➬ neutral)

When disc (5) starts to be returned, spool (1) is pushed up by the force
of centering spring (3) and the pressure at port P1. When this happens,
fine control hole f is connected to drain chamber D and the pressure oil
at port P1 is released. If the pressure at port P1 drops too far, spool (1) is
pushed down by metering spring (2), and fine control hole f is shut off
from drain chamber D. At almost the same time, it is connected to pump
pressure chamber PP, and the pump pressure is supplied until the
pressure at port P1 recovers to a pressure that corresponds to the lever
position. (Fig. 3).

SK1020-5N, SK1020-5NA 10-55

STRUCTURE AND FUNCTION CYLINDERS
12
CYLINDERS

BOOM

BUCKET

Unit: mm (in)

Cylinder Rod Piston Stroke Cylinder length Max. Cylinder length Min. Key size
Boom 40 (1.6) 65 (2.5) 690 (27.2) 1634 (64.3) 944 (37.2) 41 (1.6)
Bucket 35 (1.4) 65 (2.5) 423 (16.6) 1110 (43.7) 687 (27.0) 41 (1.6)

1. Bushing 4. O-ring 7. Bushing ring 10. Piston 13. Gland nut

2. Dust seal 5. Rod 8. Bushing 11. Cylinder
3. O-ring 6. Seal 9. Nut 12. Seal

10-56 SK1020-5N, SK1020-5NA

 20 TESTING, ADJUSTING AND
TROUBLESHOOTING

STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8
T-ADAPTER PROCEDURES AND KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
MEASURING EXHAUST SMOKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
MEASURING EXHAUST TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
MEASURING CRANCASE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
MEASURING ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
MEASURING BOOST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
MEASURING FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
ADJUSTING ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
BLEEDING AIR FROM FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
ADJUSTING ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
ADJUSTING PPC VALVE PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
PPC VALVE REBUILD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
R.H. PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
LH PPC VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
L.H. PPC VALVE (PATTERN CHANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
ADJUSTING PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-17
ADJUSTING SERVO-CONTROL SAFETY SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
CHAIN TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
TESTING AND ADJUSTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
RELEAVING HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
BLEEDING HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
CALIBRATING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
TRAVEL DEVIATION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
SERVO-CONTROL POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
CONTROL VALVE REBUILD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31
CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
CONTROL VALVE (SUPER HIGH-FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
WORK EQUIPMENT PIVOT POINT CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39

SK1020-5N, SK1020-5NA 20-1

TESTING AND ADJUSTING
12
★ Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.

1. The standard value for a new machine given in the table is the value used when shipping the machine from the factory and
is given for reference. It is used as a guideline for judging the progress of wear after the machine has been operated, and as
a reference value when carrying out repairs.

2. The service limit value given in the tables is the estimated value for the shipped machine based on the results of various
tests. It is used for reference together with the state of repair and the history of operation to judge if there is a failure.

3. These standard values are not the standards used in dealing with claims

WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on
level ground, insert the safety pins, and use blocks to prevent the machine from
moving.

WARNING! When carrying out work together with other workers, always use signals and do
not let unauthorized people near the machine.

WARNING! When checking the coolant level, always wait for the coolant to cool down. If the
radiator cap is removed when the coolant is still hot, the coolant will spurt out and
cause burns.

WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.

WARNING! Be careful the hydraulic tank on this machine is pressurized, always relieve tank
pressure before removing any hydraulic components.

20-2 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING STANDARD VALUE TABLE

STANDARD VALUE TABLE

ENGINE
Machine Model SK1020-5N and SK1020-5NA

Engine 4D98E-2NFE (natural aspirated and turbo)

Item Measurement Conditions Unit Standard Value For Service Limit Value
New Machine

High idling 2700 2675 - 2725

Revolving Speed rpm
Low idling 1000 975 - 1025
At sudden acceleration
Exhaust gas color Bosch index -- --
At high idling
Air intake valve 5.08 (0.20)
mm 3.8 - 6.4 (0.15 - 0.25)
Valve clearance Exhaust valve 5.08 (0.20)
(in)
(Normal temperature) 20°C (68°F) 20°C (68°F)
Oil temperature: 40 - 60°C (104 - 140°F) MPa 28±1
Compression {kg/cm2} 35±1
pressure (SAE 30 oil) (lbf/in2) (498) (398)
[250] [250]
(Engine speed) [rpm]

At high idling KPa

{mmH2O}
Crankcase pressure (coolant temperature: Min. 70°C {158°F}) -- --
(SAE15W-40 oil) (lbf/ft2)
(Oil temperature: Min. 80°C {176°F})
kPa
Oil pressure At high idling (SAE15W-40) {kg/cm2} 3.0 - 4.0 (43 - 57) ---
> 0.6 (> 8.5)
(lbf/in2)
At low idling (SAE15W-40)
Oil temperature All revolution range (Inside oil pan) °C (°F) 120 (248) 120 (248)
Fuel injection timing Before compression top dead center °(deg.) --- ---
Fan belt tension - -
Air conditioner
compressor belt Deflection made by finger pressure of about mm 10 (22) 10 - 15 (0.4 - 1.0)
98.1N {about 10kg} (22 lbf) (in)
tension

SK1020-5N, SK1020-5NA 20-3

TESTING AND ADJUSTING STANDARD VALUE TABLE

CHASSIS
Machine model SK1020-5N and SK1020-5NA
Category Item Measurement Conditions Unit Standard Value Service Limit Value
Travel forward ● Engine stopped Neutral Forward 65 (2.5) 58.5-71.5 (2.3-2.8)
● At center of lever knob
Travel in reverse Neutral Reverse 65 (2.5) 58.5-71.5 (2.3-2.8)
● Reading at end of travel
R.H. travel ● Equipment on ground Neutral Right 65 (2.5) 58.5-71.5 (2.3-2.8)
Stroke of levers and pedals

L.H. travel Neutral Left 65 (2.5) 58.5-71.5 (2.3-2.8)

Raise arm Neutral Raise 65 (2.5) 58.5-71.5 (2.3-2.8)

Lower arm Neutral Lower mm 65 (2.5) 58.5-71.5 (2.3-2.8)

(in)
Dump bucket Neutral Dump 65 (2.5) 58.5-71.5 (2.3-2.8)

Curl bucket back Neutral Curled 65 (2.5) 58.5-71.5 (2.3-2.8)

Neutral Right 20 (1.0) 15-25 (0.5-1)

Attachment pedal
Neutral Left 20 (1.0) 15-25 (0.5-1)

Travel speed Min. Max. 105 (4.1) 100-110 (3.9-4.3)

Accelerator pedal Min. Max. 40 (1.6) 30-50 (1.2-1.7)

Travel forward 2.0 (70.5) 1.8-2.2 (63-78)

operating force for control levers and pedals

Travel in reverse ● Engine speed: Minimum speed 2.0 (70.5) 1.8-2.2 (63-78)

R.H. travel ● Oil temperature 45-55°C (113-131°F) 2.0 (70.5) 1.8-2.2 (63-78)

L.H. travel ● Instrument coupling at center of control lever knob 2.0 (70.5) 1.8-2.2 (63-78)

Raise arm ● Instrument coupling on outside edge (for control 1.8 (63) 1.5-2.1 (53-74)
Lower arm pedal) kg
1.8 (63) 1.5-2.1 (53-74)
(oz)
Dump bucket 1.8 (63) 1.5-2.1 (53-74)
Curl bucket back 1.8 (63) 1.5-2.1 (53-74)

Right 5.0 (176) 4.0-6.0 (141-212)

Attachment pedal
Left 5.0 (176) 4.0-6.0 (141-212)

Travel speed 7.5 (265) 5-10 (176-353)

● Engine speed: 1800 ± 50 rpm 196-211

Control valve 206 (2988)
● Oil temperature: 45-55°C (113-131°F) (2843-3060)
Hydraulic pressure

290-350
Travel motor 343 (4975)
● Engine speed: 1800 ± 50 rpm (4206-5076)
● Oil temperature: 45-55°C (113-131°F) 25-29
Servo control bar 26.5 (384)
(psi) (363-421)

Low idle --- ---

AS valve ● Travel levers: neutral
Set speed --- ---

Unloading valve --- ---

20-4 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING STANDARD VALUE TABLE

Machine model SK1020-5N and SK1020-5NA

Category Item Measurement Conditions Unit Standard Value Service Limit Value
Pilot system travel 5.5 (80)
forward (start-up) * 4.0-7.0 (58-111)

Pilot system travel

Pilot and secondary circuit pressure

14.5 (210) 14-15 (203-218)

(maximum)
Pilot system travel
5.5 (80) 4.0-7.0 (58-111)
reverse (start-up) *
Pilot system travel ● Engine speed: 2800 ± 10 rpm
14.5 (210) 14-15 (203-218)
(maximum) ● Oil temperature: 45-55°C (113-131°F) bar
Pilot system travel ● Machine raised from the ground (psi)
to right or left ● * Pressure of wheels at start of rotation 5.5 (80) 4.0-7.0 (58-111)
(start-up) *
Pilot system travel
to right or left 14.5 (210) 14-15 (203-218)
(maximum)
Pilot system with
parking brake 5.5 (80) min. 22 (319)
disengaged
● Engine speed: Maximum
● Oil temperature: 45-55°C (113-131°F)
Engine speed (with load)

With travel pump ● 2nd. speed 2600 2500-2700

● Travel lever: At full stroke
● Parking brake: Applied

● Engine speed: Maximum rpm

● Oil temperature: 45-55°C (113-131°F)
With travel and ● 2nd. speed
2300 2200-2500
equipment pump ● Travel lever: At full stroke
● Parking brake: Applied
● Raise: At end of stroke

Total work
equipment
(Downward
movement of
bucket teeth)
Max. 250 Max. 275
(9.8) (10.8)
Hydraulic drift of the work equipment

Rasing
cylinder
Front bucket

(Retraction)
mm Max 20 Max. 30
(in)
(1.0) (1.2)
● In this position, measure extension or retraction of
each cylinder, and any leakages occurring when a
load is applied to the tips of the bucket teeth.
● Horizontal and level ground
Bucket
cylinder ● Engine: Switched off
(retraction) ● Oil temperature: 45-55°C (113-131°F)
● Take measurements as soon as the engine stops Max.13 Max. 20
● Measure the variations every 5 minutes and check
(0.5) (1.0)
the total variation after 15 mins.

SK1020-5N, SK1020-5NA 20-5

TESTING AND ADJUSTING STANDARD VALUE TABLE

Machine model SK1020-5N and SK1020-5NA

Category Item Measurement Conditions Unit Standard Value Service Limit Value

★ Arm Raise Raise

3.6 3.2-4.0
Arm on
ground

Lower Lower
Cylinder fully
extended 3.0 2.7-3.3
●
Standard

Engine speed: Maximum

● Oil temperature: 45-55°C (113-131°F) sec.

★ Bucket Dump Dump

2.1 1.9-2.3
Cylinder fully
extended
Work equipment speeds

Cylinder fully Curl Curl

retracted
● Engine speed: Maximum 2.2 2.0-2.4
● Oil temperature: 45-55°C (113-131°F)

★ Arm Raise Raise

3.6 3.2-4.0
Arm on
ground

Lower Lower
Pattern change version

Cylinder fully
extended 3.0 2.7-3.3
● Engine speed: Maximum
● Oil temperature: 45-55°C (113-131°F) sec.

★ Bucket Dump Dump

2.1 1.9-2.3
Cylinder fully
extended

Cylinder fully Curl Curl

retracted
● Engine speed: Maximum 2.2 2.0-2.4
● Oil temperature: 45-55°C (113-131°F)

20-6 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING STANDARD VALUE TABLE

Machine model SK1020-5N and SK1020-5NA

Category Item Measurement Conditions Unit Standard Value Service Limit Value
Normal Normal

68.6 57-75

Wheel rotation
(without load) rpm
With With increment
increment

113 102-124
● Engine speed: Maximum
● Oil temperature: 45-55°C (113-131°F)
● Machine raised from ground

Normal Normal

9.0 8.1-9.9

(5.5 (5.0-6.2)

sec.
Travel

Travel speed km/h With

(mph) increment With increment

14.4 13.0-15.8
(9.1)
(8.0-10.0)
● Travel for 25 meters (27 yards) and then check on
the time needed for distance traveled

Max. 250 Max. 325

(9.8) (13)

mm
Travel deviation
(in)
Value with
speed Value with speed
● Engine speed: Maximum increment increment
● Oil temperature: 45-55°C (113-131°F) Max.280 Max.375
● Travel 20 meters (21 yards) on flat ground and then (11) (14.7)
check the deviation
● Check all direction

SK1020-5N, SK1020-5NA 20-7

TESTING AND ADJUSTING SPECIAL TOOLS

SPECIAL TOOLS
Check or
Symbol Part number Part Name Qty Remarks
measurement item

Commercially
1 Multi-scale tachometer 1 20 to 4000 rpm
available
Engine speed A
Commercially
2 Stroboscope tachometer 1 6 to 30000 rpm
available

Commercially
Valve clearance B 1 Feeler gauge 1
available

1 Gauge set 1 Kit Yanmar

Compression gauge C
2 Adapter 1 TOL-97190080

Commercially
1 Pressure adapter 1 Thread 1/8 in.
available
Engine oil pressure D
Commercially
2 Pressure gauge 1 Scale 10 bar (145 psi)
available

Commercially
1 Pressure gauge 2 Scale 60 bar (870 psi)
available

Commercially
2 Pressure gauge 1 Scale 10 bar (145 psi)
available

Commercially
Hydraulic pressure E 3 Pressure gauge 1 Scale 400 bar (5802 psi)
available

Commercially Servo control kit

4 1 0 to 1000 bar (0 to 14504)
available (differential pressure)

Commercially
5 Pressure adapter 1 Thread M10
available

20-8 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING T-ADAPTER PROCEDURES AND KITS
12
T-ADAPTER PROCEDURES AND KITS
★ For machines equipped with the weather sealing connectors these procedures must be followed in order to prevent dam-
age to the connector then testing a circuit for an open or a short.
★ The following KOMATSU Harness Checker Kits are available
Special Tools Required

Symbol Part No. Part Name

1 799-601-9000A Kit
U
2 799-601-7500 Kit

1. For testing circuits the T-adapters listed for the circuit should be
used.

2. When using the T-adapters it may be necessary to use the break-out

box in the kit. This allows you to check several circuits.

Remark
For testing the RC connectors, a Bosch Rexroth MA-RC1-1/10
must be used.

★ For T-adapter listing see TROUBLESHOOTING (GENERAL)

SK1020-5N, SK1020-5NA 20-9

TESTING AND ADJUSTING ENGINE COMPONENTS

ENGINE COMPONENTS
Remark
To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL for tools and
proper procedures.

MEASURING EXHAUST SMOKE

MEASURING EXHAUST TEMPERATURE

ADJUSTING VALVE CLEARANCE

MEASURING COMPRESSION PRESSURE

MEASURING CRANKCASE PRESSURE

MEASURING ENGINE OIL PRESSURE

MEASURING BOOST PRESSURE

MEASURING FUEL PRESSURE

ADJUSTING ENGINE SPEED SENSOR

BLEEDING AIR FROM FUEL SYSTEM

ADJUSTING ENGINE STOP SOLENOID

20-10 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ENGINE COMPONENTS

ADJUSTING ENGINE SPEED

WARNING! Before proceeding with any adjustments,

be sure all work equipment is on the
ground and there controls neutralized. Be
sure the parking brake is set and the
machine is on a flat level surface. Be sure
the engine is in the OFF position.

★ Conditions for the adjustment:

● Working equipment: Resting on the ground
● Cab: Raised
● If the cables or there components need to be replaced, place the throttle
lever (or pedal) in an intermediate position before carrying out the
adjustment.

1. With cables removed, start the engine and set engine speed to the
proper low idle position using adjustment screw (3). Check the travel
movement of linkage (5) to be sure there is no binding.
● Low idle: 1000±25 rpm

2. Once the engine speed is set, stop the engine and install the throttle
linkage.

3. Place lever (1) in low idle position.

4. Temporarily adjust the cable (2) to an intermediate position and loosen

retainer lock (3). Then set retainer lock (3) at approx. 1 mm (0.04 in)
from the injection pump lever (4).

5. Set the throttle lever (1) at a high idle position.

6. Adjust nuts (7) and (8) to reset the position of the injection pump lever
(5) to approx. 0.5 mm (0.02 in) from the high idling adjustment screw
(6).

7. Bring the throttle lever back to the low idle position and check to be
sure the retainer (3) has sufficient clearance.

● Repeat the same procedure for the accelerator pedal cable.

SK1020-5N, SK1020-5NA 20-11

TESTING AND ADJUSTING ADJUSTING PPC VALVE PRESSURES
12
ADJUSTING PPC VALVE PRESSURES

WARNING! Before removing the valve assembly be sure to relive all hydraulic system pressure.

Disassembly and Adjustment

1. Remove the complete PPC VALVE.

● (For details refer to section 30 REMOVAL OF PPC VALVES).

2. Lift the boot (1) and mark the position of the lever (2) in relation to the
PPC valve housing (3).

3. Loosen screw (4), remove the washer (5) and pull out the complete
handle (6).

4. Remove the joint (7) and retainer plate (8).

5. Remove the boot (9) and remove the O-ring (10).

20-12 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ADJUSTING PPC VALVE PRESSURES
12
6. Loosen the 4 retaining screws (11) from the plate (12) and remove the
plate.

7. Remove the stopper (13) and seals.

● Use a soft tool to remove.

8. Remove the complete spool (14).

9. Remove the retainer (15), spring (16) and shims (17) from the spool
(14).

Assembly

1. Add shims until you reach calibration value; bear in mind that 0.3 mm
thickness corresponds to a variation in pressure of about 0.6 bar. (For
details, please refer to TECHNICAL DATA).

● To assemble, perform the disassembly procedure in the reverse order.

● Thoroughly clean all parts.

Cleaner: Loctite 20162

Screw: 64 to 74 Nm (47.2 to 55 ft/lbs)

● Press down on the stoppers (13) to ease setting into place; tighten the retainer plate (8) until it is properly seated and adjust
clearance. (For details, see “ADJUSTING PPC VALVE”).

Joint: 112.8 ± 14.7 Nm (83 ± 10 ft/lbs)

Screws: 13.2 ± 1.5 Nm (10 ± 1.1 ft/lbs)

● Lubricate the stoppers (13).

SK1020-5N, SK1020-5NA 20-13

TESTING AND ADJUSTING PPC VALVE REBUILD SPECIFICATIONS

PPC VALVE REBUILD SPECIFICATIONS

R.H. PPC VALVE

Unit: mm (in)

Criteria Remedy
Standard Size Repair Limit
No. Check Item
Free Installed Installed Free Installed
Length Length Load Length Load
Center spring 42.4 x 15.5 9.8 N 9.2 N
1 34 (1.3) -- Replace
(P3 and P4) (2.1 x 1.0) (2.2 lbf) (2.1 lbf)
springs if
Center spring 36.6 x 15.5 17.6 N 16.5 N damaged or
2 34 (1.3) --
(P1 and P2) (1.4 x 1.0) (3.9 lbf) (3.7 lbf) deformed
Metering spring 32.7 x 8.2 40.8 N 39.4 N
3 25.6 (1.0) --
(P3 and P4) (1.3 x 0.3) (9.2 lbf) (8.8 lbf)
Metering spring 26.2 x 8.2 5.3 N 4.3 N
4 25.3 (0.9) --
(P1 and P2) (1.0 x 0.3) (1.2 lbf) (1.0 lbf)

SK1020-5N, SK1020-5NA 20-14

TESTING AND ADJUSTING PPC VALVE REBUILD SPECIFICATIONS

LH PPC VALVE (STANDARD)

Unit: mm (in)

Criteria Remedy
Standard Size Repair Limit
No. Check Item
Free Installed Installed Free Installed
Length Length Load Length Load
Replace
Center spring 35.5 x 15.5 9.8 N 9.2 N
1 34 (1.3) -- springs if
(P-out 3 and P-out 4) (1.4 x 1.0) (2.2 lbf) (2.1 lbf)
damaged or
Center spring 26.6 x 15.5 17.6 N 16.5 N deformed
2 34 (1.3) --
(P-out 1 and P-out 2) (1.1 x 1.0) (3.9 lbf) (3.7 lbf)
Metering spring 32.7 x 8.2 5.3 N 52.4 N
3 25.3 (0.9) --
(P3 and P4) (1.3 x 0.3) (1.2 lbf) (11.7 lbf)

20-15 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING PPC VALVE REBUILD SPECIFICATIONS

L.H. PPC VALVE (PATTERN CHANGE)

Unit: mm (in)

Criteria Remedy
Standard Size Repair Limit
No. Check Item
Free Installed Installed Free Installed
Length Length Load Length Load
Replace
Center spring 35.5 x 15.5 9.8 N 9.2 N
1 34 (1.3) -- springs if
(P-out 3 and P-out 4) (1.4 x 1.0) (2.2 lbf) (2.1 lbf)
damaged or
Center spring 36.6 x 15.5 17.6 N 16.5 N deformed
2 34 (1.3) --
(P-out 1 and P-out 2) (1.4 x 1.0) (3.9 lbf) (3.7 lbf)
Metering spring 26.6 x 15.5 5.3 N 52.4 N
3 25.3 (0.9) --
(P3 and P4) (1.1 x 1.0) (1.2 lbf) (11.7 lbf)

SK1020-5N, SK1020-5NA 20-16

TESTING AND ADJUSTING PPC VALVE REBUILD SPECIFICATIONS
12
ADJUSTING PPC VALVE

WARNING! Before proceeding with any adjustments, be sure all work equipment is on the ground and
there controls neutralized. Be sure the parking brake is set and the machine is on a flat
level surface. Be sure the engine is in the OFF position.

● The clearance on the PPC valve (hand and foot) levers are adjusted as follows:

1. Slowly loosen the oil-tank cap to eliminate any residual pressure.

2. Remove cap (1).

3. Loosen the nut (2) that retains the disc (3).

4. Tighten disc (3) until it makes light contact with the 4

push-rods (4).
★ During this adjustment, take care not to activate any of the
push-rods (4) individually.

5. Secure this position by tightening the retaining nut (2) to the

specific torque.

Retaining nut: 113 ± 15 Nm (83 ± 11 ft/lbs)

20-17 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ADJUSTING SERVO-CONTROL SAFETY SENSOR
12
ADJUSTING SERVO-CONTROL SAFETY SENSOR

WARNING! Before proceeding with any adjustments, be sure all work equipment is on the ground and
there controls neutralized. Be sure the parking brake is set and the machine is on a flat
level surface. Be sure the engine is in the OFF position.

1. Lower the LH safety bar (1) and adjust the position of the sensor (2)
by loosening then tightening the adjustment nuts (3).

★ Distance between safety bar and sensor: 1 mm (0.04 in)

SK1020-5N, SK1020-5NA 20-18

TESTING AND ADJUSTING CHAIN TENSION
12
CHAIN TENSION

TEST
★ Test conditions:
● Machine: Raised from the ground and level
● Work equipment: In road-driving position
★ Check all the wheels.

1. Position an appropriate indicator and check the wheel rotation

diameter at 630 mm (25 in). Make a notch “A” close to the
indicator.

2. Rotate the tire by hand in both directions and check the total
displacement of the notch. See if it remains within the permissible
limits.
★ Standard displacement: 2-6 mm (0.08-0.2 in)

ADJUSTMENT
★ For greater clarity, the illustration shows the adjustment operations
with the tire removed. It is not necessary to remove the tires for this
adjustment.

1. Adjust screw “A” (M10x50, fully threaded) in until it makes

contact with the wheel hub.

2. Loosen the retaining screws (1) on the wheel hub until it can move.

3. Gradually tighten the screw “A” until correct tension has been
restored to the chain.

4. Tighten the nuts (1).

Nuts: 200 Nm (148 ft/lbs)

20-19 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING TESTING AND ADJUSTING THE HYDRAULIC SYSTEM
12
TESTING AND ADJUSTING THE HYDRAULIC SYSTEM

Test conditions

● Engine: At working temperature.

● MIN and MAX. engine speeds: Within permissible limits.
● Oil temperature: 45-55 °C. (113-131 °F)
● Before removing the plugs, release the residual pressures in the circuits and place the safety engagement levers into their
locked positions.
● After having connected the pressure gauges, pressurize the tank.

Command Ports
Arm (Lower - Raise) A1 - B1
Bucket (Dump - Curled) A2 - B2
Equipment (R.H. - L.H.) A3 - B3

SK1020-5N, SK1020-5NA 20-20

TESTING AND ADJUSTING TESTING AND ADJUSTING THE HYDRAULIC SYSTEM
12
RELEAVING HYDRAULIC PRESSURE

WARNING! Before any work is to be performed on the hydraulic system it is important to remember to
lower all work equipment to the ground, neutralize and lock the controls and relieve any
hydraulic pressure in the hydraulic tank. Be sure all work is performed on a flat level
surface and the parking brake is set.

Elimination Of Pressures In The Hydraulic Circuits.

1. Rest the working equipment on the ground and stop the engine.

2. Turn the ignition key to the position “I” and, with safety bars lower, move the control lever in all directions to release all
pressure in the main hydraulic circuits and servo-controls.

3. Return the ignition key to the position “O” (OFF) and remove the key.

4. Place a (Do Not Operate) tag on the ignition switch.

Elimination Of Pressure In The Tank

1. The hydraulic oil tank is sealed and pressurized.

2. When hydraulic lines are to be removed or disconnected for repairs,

or when caps are removed, tank pressure must be relieved using the
following procedures:

3. Rest the working equipment on the ground and stop the engine.

4. Slowly loosen the hydraulic oil-refill cap (1) in order to release the
residual pressure.

Elimination Of Pressure

1. This operation should be performed every time the hydraulic tank

cap is removed for installation of equipment or hydraulic lines are
removed.

2. Start the engine and position the machine as in the figure.

3. Stop the engine, loosen the tank cap (1) and then close it again.
★ This operation lets air into the tank when the level of the
remaining oil is at minimum.

4. Start the engine and lower the working equipment to the ground.

20-21 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING TESTING AND ADJUSTING THE HYDRAULIC SYSTEM
12
BLEEDING HYDRAULIC CIRCUITS

Bleeding Air From The Pump

1. Loosen and remove the cap (1) from the pump body (2).

2. Pour hydraulic oil through the hole until the entire casing is full.

3. Replace the cap (1).

★ After filling the casing, start the engine and allow it to run at
low idling for about 10 minutes before proceeding to bleed the
air from the circuits.

Bleeding Air From The Cylinders

1. Start the engine and let it run at low idle for about 5 minutes.

2. Lower and raise the boom 4 to 5 times.

● Lower and raise the piston of the boom up to about the end of
its stroke. Care must be taken to avoid pressurizing the circuits.

3. Bring the engine up to high idle and repeat the operations described
in procedure 2. Return the engine to low idle and operate the piston
through its entire stroke until it reaches max. pressure in both
directions.

Bleeding Air From Any Optional Equipment

1. This method must be used for all the optional equipment, unless
otherwise indicated.
★ Each time optional equipment is installed, operate the
equipment repeatedly, with the engine at low idle, until all air
has been completely eliminated from the system.

Procedures for bleeding air from hydraulic circuits

1 2 3 4 5
Starting Pressurized Starting
Pumps Cylinders
engine tank tasks
● Replacing hydraulic oil ❍ ❍ ❍ ❍ ❍
● Replacing or cleaning filters ❍ ❍ ❍ ❍
● Repairs to any pumps ❍ ❍ ❍ ❍ ❍
● Repair of control valve ❍ ❍ ❍ ❍
● Repair of hydraulic cylinders
❍ ❍ ❍ ❍
● Replacing hydraulic cylinders
● Repair of travel motor
❍ ❍ ❍ ❍ ❍
● Removal of any hydraulic lines

20-22 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING HYDRAULIC PUMP
12
HYDRAULIC PUMP

Checking Working Pressure Of Travel HST Charge Valve

★ Test conditions:
● Engine: High idle
● Hydraulic Oil temperature: 45-55 °C. (113-131 °F)
● Safety bar: Raised

WARNING! Do not activate the travel lever.

1. Remove plugs (1) and (2) and install the two pressure adapters E5.

2. Connect pressure gauges E1 60 bar (870 psi), start the engine and
accelerate to high idle.

3. Check to see if the pressure is within permissible limits.

● Use the lower of the two pressure values taken.
● Normal pressure: 25-29 bar (363-421 psi)

4. Remove the pressure adapters and install the plugs (1) and (2).

Plugs: 19.6-27.4 Nm (173-243 in/lbs)

Checking Working Pressure Of The AS Valve

★ Test conditions:
● Engine: High idle
● Hydraulic oil temperature: 45-55 °C. (113-131 °F)
● Safety bar: Lowered
● Machine: Raised from the ground

1. Remove plug (1) and install pressure adapter E5.

2. Connect pressure gauge E1 60 bar (870 psi) and start the engine.
Allow engine to idle at (1100 rpm).

3. Push the travel lever full stroke forward and read the pressure.

4. Repeat the readings with the engine at a working speed of (2800 ± 30 rpm).

5. Remove the pressure adapter and install plug (1).

Plugs: 19.6-27.4 Nm (173-243 in/lbs)

SK1020-5N, SK1020-5NA 20-23

TESTING AND ADJUSTING HYDRAULIC PUMP
12
CALIBRATING VALVE

HST Valve Calibration

1. Loosen nut (1), be careful not to move adjustment screw (2).

2. Adjust the working pressure of the HST valve as follows:

● To INCREASE pressure, turn the screw (2) in a
CLOCKWISE direction.
● To REDUCE pressure, turn the screw (2) in a
COUNTER-CLOCKWISE direction.

★ One complete turn of the screw (2) varies the pressure by

15.5 bar (225 psi).

3. Tighten nut (1) and check to see if the working pressure remains
within permissible limits.

Nut: 58.8-78.5 Nm (44-58 ft/lbs)

AS Valve Calibration

★ Pressure adjustment made at low idle

1. Loosen nut (1), and adjust the working pressure of the AS valve
(with the engine at low idle), proceed as follows:
● To INCREASE pressure, turn the screw (2) in a
CLOCKWISE direction.
● To REDUCE pressure, turn the screw (2) in a
COUNTER-CLOCKWISE direction.

★ One complete turn of the screw (2) varies the pressure by

3.37 bar (49 psi)

2. Tighten nut (1) and check to be sure the working pressure remains
within permissible limits.

Nut: 34.3-58.8 Nm (25-43 ft/lbs)

20-24 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING HYDRAULIC PUMP
12
Rebuild Specifications For AS Valve

Unit: mm (in)

Criteria Remedy
Standard Size Repair Limit
No. Check Item
Free Installed Free
Installed Load Installed Load
Length Length Length
Replace
1 Spring 38.1 (1.5) 30 (1.2) 52 N (12 lbs) -- 41.1 N (9.2 lbs)
2 Spring 25.9 (1.0) 23 (1.0) 16.7 N (4 lbs) -- 13.7 N (3.1 lbs)
3 Spring 38.5 (1.5) 34.5 (1.4) 98 N (22 lbs) -- 78.4 N (18 lbs)

Pressure Adjustment At Working Pressure

1. Loosen nut (3),. and adjust the working pressure of the AS valve
(with the engine at working pressure), proceeding as follows:
● To INCREASE pressure, turn the screw (4) in a
CLOCKWISE direction.
● To REDUCE pressure, turn the screw (4) in a
COUNTER-CLOCKWISE direction.
★ One complete turn of the screw (4) varies the pressure by
1.96 bar (28.4 psi).

2. Tighten nut (3) and check to see if the working pressure remains
within permissible limits.

Nut: 34.3-58.8 Nm (25-43 ft/lbs)

SK1020-5N, SK1020-5NA 20-25

TESTING AND ADJUSTING HYDRAULIC PUMP

TRAVEL DEVIATION CHECK

★ Test conditions:
● Engine: At working temperature
● Hydraulic oil temperature: 45-55 °C. (113-131 °F)
★ Drive the machine onto solid, level ground.
Checking The Deviation

1. Position the boom and bucket in their travelling positions.

2. Boom lowered and bucket fully curled.

3. Bring the engine up to maximum rpm.

4. Push the travel lever to full stroke forward

5. Travel for 10 metres, then measure the deviation of the machine over the next 20 metres (22 yds).

6. Check the deviation also in reverse gear and while accelerating in both directions.

20-26 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING HYDRAULIC PUMP
12
Adjusting The Deviation

1. Select the adjustment screw to be re-set:

Travel Deviation Screw

Forwards Left A1
Forwards Right A2
Reverse Left B1
Reverse Right B2

2. Loosen the nut (1) and tighten the screw (2).

● A 60o turn of the screw (2) will reduce the deviation by about
500 mm (20 in).

3. Tighten the nut (1).

Nut: 26.5-32.4 Nm (20-24 ft/lbs)

SK1020-5N, SK1020-5NA 20-27

TESTING AND ADJUSTING CONTROL VALVE
12
CONTROL VALVE

Operating Pressure (Unloading Valve)

1. Remove plug (1) and install a pressure adapter.

2. Connect the pressure gauge E3 10 bar (145 psi).

3. Start the engine and bring it up to a high idle with all levers in
neutral position.

4. Check the pressure.

● Normal pressure: 4.8 bar (70 psi)

WARNING! Take care do not operate the equipment levers. The unloading valve cannot be
re-adjusted. If the pressure differs from the normal value the valve must be replaced.

Operating pressures of the working equipment

1. Remove plug (1) and install a pressure adapter.

2. Connect a pressure gauge E2 400 bar or 600 bar (5802 or 8702 psi).

3. Start the engine and bring it up to high idle.

4.Check the pressure for each movement of the lever at the end of its
stroke and with the pressure stabilized.
★ To check the pressure of the working equipment, push the piston to
the end of its stroke.

Valve Adjustment

★ The unloading valve cannot be re-adjusted, only replaced.

Adjustment Of Main Relief Valve

1.If the pressures measured for the working equipment and machine
travel do not fall within normal values, adjust the main relief valve
(1) as follows:
★ Loosen lock nut (2) and rotate the adjusting screw (3).
● To INCREASE pressure, turn in a CLOCKWISE direction.
● To DECREASE pressure, turn in a
COUNTERCLOCKWISE direction.
★ Each turn of the adjusting screw (3) varies the pressure by about 55
bar. (798 psi)

2. Lock the nut (2).

Nut: 69 ± 10 Nm (51 ± 7 ft/lbs)

★ After adjustment, check the adjustment of the main relief valve

with the same procedures as used for the measurements.

20-28 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING CONTROL VALVE
12
SERVO-CONTROL POWER SUPPLY

★ Test conditions:
● Engine: At working temperature.
● Oil temperature: 45-55 °C. (113-131 °F)

WARNING! Before removing the cap to measure the pressure, release the residual pressures from
the circuits. Put the safety device engagement levers into their locked position. After
connecting the pressure gauge, pressurize the tank. For details see RELIEVING
HYDRAULIC PRESSURE page 20-21

Checking The Pressure Of The Servo-controls

1. Disconnect the delivery line (1) and install a tee and a adapter;
reconnect the line (1).

2. Connect pressure gauge E1 60 bar (870 psi)

3. Start the engine and bring it up to 2800 rpm with all levers in a
neutral position.

4. Lower the safety bars and check the pressure.

● Normal pressure: 25-29 bar (363-421 psi)

Test The Pressure Of The Travel Pilot System

★ Test conditions:
● Machine raised from the ground.

1.Disconnect the line (1) of the actuator to be tested, install a union

tee and a pressure adapter, and then reconnect the line (1).
★ During travel in one direction, two actuators are nevertheless
activated.

Always check both pressures:

Action involved
Action
A1 A2 B1 B2
FORWARD ❍ ❍
REVERSE ❍ ❍
RIGHT ❍ ❍
LEFT ❍ ❍

SK1020-5N, SK1020-5NA 20-29

TESTING AND ADJUSTING CONTROL VALVE
12
2. Connect pressure gauge E1 60 bar (870 psi).

3. Lower the cab and sit in the driving seat.

4. Start the engine and bring it up to working speed of about 2800 rpm
with all the levers in a neutral position.

5.Lower the safety bar, slowly activate the travel lever in the direction
of the test to be performed, then check the following conditions:
★ Pressure as the wheels start to turn
★ Pressure with the levers at full stroke
● Normal pressures:
● When the wheels start to turn: 4.0-7.0 bar (58-102 psi)
● With levers at full stroke: 14-15 bar (203-218 psi)

Parking Brake System Pressure Check

1. Disconnect the brake control hose (1); connect a “T” fitting and a
pressure tap and reconnect the hose.

2. Connect a manometer E1 60 bar (870 psi).

3. Lower the cab and sit down in the drivers seat.

4. Start the engine and bring it up to operating speed (2800 rpm) with
all the levers in neutral position.

5. Lower the safety bars; operate the parking brake control and check
the pressure.
★ Parking brake pressure: Minimum. 22 bar (319 psi)

20-30 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING CONTROL VALVE
12
CONTROL VALVE REBUILD SPECIFICATIONS

Unit: mm (in)

Criteria Remedy
Standard Size Repair Limit
No. Check Item
Free Installed Free
Installed Load Installed Load
Height Length Height
28.8x17.1 30.6N
Replace if damaged or deformed
1 Spool return spring (lift arm) 26.8 (1.1) 38.2N (8.6lbs) ---
(1.1x0.7) (6.8lbs)
26.3x17.7 176.5N 141.1N
2 Spool return spring (bucket) 18.5 (0.7) ---
(1.0x0.7) (40lbs) (31.7lbs)
21.6x14.8 38.7N 31.0N
3 Spool return spring (bucket) 10 (0.4) ---
(0.9x0.6) (8.7lbs) (6.9lbs)
28x11.5 137.3N 109.8N
4 Spool return spring (ATT) 24.5 (1.0) ---
(1.0x0.5) (31.1lbs) (24.6lbs)
29x17.6 131.4N 105.1N
5 Spool return spring (High-flow) 25.5 (1.0) ---
(1.1x0.6) (30lbs) (23.6lbs)
14.7x4.4 4.9N 3.9N
6 Spool return spring (lift arm) 9.5 (0.4) ---
(0.6x0.2) (1.1lbs) (0.8lbs)
Spring for series-parallel 38.3x15.2 161.8N 129.5N
7 24 (1.0) ---
circuit switching valve (1.5x0.6) (39.4lbs) (29.1lbs)

SK1020-5N, SK1020-5NA 20-31

TESTING AND ADJUSTING CONTROL VALVE

Unit: mm (in)

Criteria Remedy
Standard Size Repair Limit
No. Check Item
Free Installed Free
Installed Load Installed Load
Height Length Height
32.9x18.2 74.0N 59.2N
1 Spring/unloader valve 18 (0.7) ---
(1.3x0.7) (16.7lbs) (13.3lbs)
Replace if damaged or deformed
18.7x9.3 3.4N 2.7N
2 Spring/unloader valve 16 (0.6) ---
(0.7x0.4) (0.7lbs) (0.6lbs)
Spring/pressure 15.4x6 2.5N 2.0N
3 13 (0.5) ---
compensation valve (0.6x0.2) (0.6lbs) (0.4lbs)
Spring/pressure 20x8.4 6.9N 5.5N
4 12 (0.4) ---
compensation valve (0.8x0.3) (1.6lbs) (1.2lbs)
Spring/combination 37.5x16.6 177.5N 142.0N
5 22.5 (0.8) ---
circulating valve (1.5x0.7) (40lbs) (32lbs)
37.5x15.4 66.7N 53.4N
6 Spring/leveling circulating valve 22.5 (0.8) ---
(1.5x0.6) (15lbs) (12lbs)
30.2x9.4 2.9N 2.4N
7 Spring/flow divider 23 (0.9) ---
(1.2x0.4) (0.7lbs) (0.5lbs)
18.5x3.8 1.1N 0.9N
8 Spring/check valve 15.5 (0.6)
(0.7x0.1) (0.2lbs) (0.2lbs)

20-32 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING CONTROL VALVE

Unit: mm (in)

Criteria Remedy
Standard Size Repair Limit

damaged or deformed
No. Check Item
Free Installed Free
Installed Load Installed Load
Replace if
Height Length Height
13x6.5 2.0N 1.6N
1 Spring/unloader valve 9.5 (0.4) ---
(0.5x0.2) (0.4lbs) (0.4lbs)
25.7x11.1 66.7N 53.4N
2 Spring/unloader valve 22 (1.0) ---
(1.0x0.4) (15lbs) (12lbs)

20-33 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING CONTROL VALVE
12

Unit: mm (in)

Criteria Remedy
Standard Size Repair Limit
No. Check Item
Free Installed Free
Installed Load Installed Load
Height Length Height
28.8x17.1 30.6N
1 Spool return spring (lift arm) 26.8 (1.1) 38.2N (8.6lbs) ---
(1.1x0.7) (6.8lbs)
26.3x17.7 176.5N 141.1N
2 Spool return spring (bucket)
(1.0x0.7)
18.5 (0.7)
(40lbs)
---
(31.7lbs) Replace if damaged or deformed
21.6x14.8 38.7N 31.0N
3 Spool return spring (bucket) 10 (0.4) ---
(0.9x0.6) (8.7lbs) (6.9lbs)
29x17.5 180N 144.4N
4 Spool return spring (ATT) 25 (1.0) ---
(1.1x0.6) (40.4lbs) (32.4lbs)
Spring for series-parallel 38.3x15.2 161.8N 129.5N
5 24 (1.0) ---
circuit switching valve (1.5x0.6) (39.4lbs) (29.1lbs)
32.9x18.2 74.0N 59.2N
6 Spring/unloader valve 18 (0.7) ---
(1.3x0.7) (16.7lbs) (13.3lbs)
18.7x9.3 3.4N 2.7N
7 Spring/unloader valve 16 (0.6) ---
(0.7x0.4) (0.7lbs) (0.6lbs)
Spring/pressure 15.4x6 2.5N 2.0N
8 13 (0.5) ---
compensation valve (0.6x0.2) (0.6lbs) (0.4lbs)
Spring/pressure 20x8.4 6.9N 5.5N
9 12 (0.4) ---
compensation valve (0.8x0.3) (1.6lbs) (1.2lbs)

SK1020-5N, SK1020-5NA 20-34

TESTING AND ADJUSTING CONTROL VALVE

CONTROL VALVE (STANDARD)

20-35 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING CONTROL VALVE
12
CONTROL VALVE (SUPER HIGH-FLOW)

SK1020-5N, SK1020-5NA 20-36

TESTING AND ADJUSTING WORK EQUIPMENT PIVOT POINT CLEARANCES

WORK EQUIPMENT PIVIT POINT CLEARANCES

20-37 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING WORK EQUIPMENT PIVOT POINT CLEARANCES
12

Unit: mm (in)

Criteria Remedy
No. Check Item clearance Standard Tolerance Minimum Clearance
size Shaft Hole clearances limit
Between bushing and
-0.01 (0.0004) +0.072 (0.003) 0.082 (0.003)
1 mounting pin on work 35 (1.4) 1.0 (0.04)
-0.05 (0.002) +0.134 (0.005) 0.184 (0.007)
equipment

2
Between bushing and
35 (1.4)
-0.01 (0.0004) +0.072 (0.003) 0.082 (0.003)
1.0 (0.04) Replace if damaged
or deformed

mounting pin on fulcrum arm -0.05 (0.002) +0.134 (0.005) 0.184 (0.007)
Between bushing and
-0.01 (0.0004) +0.072 (0.003) 0.082 (0.003)
3 mounting pin lift cylinder (top 35 (1.4) 1.0 (0.04)
-0.05 (0.002) +0.134 (0.005) 0.184 (0.007)
and bottom size)
Between bushing and
-0.01 (0.0004) +0.072 (0.003) 0.082 (0.003)
4 mounting pin bucket cylinder 35 (1.4) 1.0 (0.04)
-0.05 (0.002) +0.134 (0.005) 0.184 (0.007)
(top side)
Between bushing and
-0.01 (0.0004) +0.072 (0.003) 0.082 (0.003)
5 mounting pin bucket cylinder 35 (1.4) 1.0 (0.04)
-0.05 (0.002) +0.134 (0.005) 0.184 (0.007)
(bottom side)

SK1020-5N, SK1020-5NA 20-38

TESTING AND ADJUSTING WORK EQUIPMENT PIVOT POINT CLEARANCES
12
CYLINDERS

Unit: mm (in)

Criteria Remedy
No. Check Item (tolerance) Cylinder Standard Tolerance Minimum
Limit
size Shaft Hole clearances
Bucket -0.01 (0.0004) +0.072 (0.003) 0.082 (0.003) 1.0
Replace bushing

35 (1.4)
Between bushing and lift -0.05 (0.002) +0.134 (0.005) 0.184 (0.007) (0.04)
1
piston mounting pin Bucket -0.01 (0.0004) +0.072 (0.003) 0.082 (0.003) 1.0
35 (1.4)
tilt -0.05 (0.002) +0.134 (0.005) 0.184 (0.007) (0.04)
Bucket -0.01 (0.0004) +0.072 (0.003) 0.082 (0.003) 1.0
35 (1.4)
Between bushing and lift -0.05 (0.002) +0.134 (0.005) 0.184 (0.007) (0.04)
2
cylinder mounting pin Bucket -0.01 (0.0004) +0.072 (0.003) 0.082 (0.003) 1.0
35 (1.4)
tilt -0.05 (0.002) +0.134 (0.005) 0.184 (0.007) (0.04)
Bucket -0.025 (0.001) +0.039 (0.002) 0.025 (0.001) 0.426
40 (1.5) Replace
Between piston rod and lift -0.087 (0.003) +0 0.126 (0.005) (0.017)
3 gland
gland nut Bucket -0.025 (0.001) +0.039 (0.002) 0.025 (0.001) 0.426
35 (1.4) nut
tilt -0.087 (0.003 +0 0.126 (0.005) (0.017)

SK1020-5N, SK1020-5NA 20-39

TESTING AND ADJUSTING WORK EQUIPMENT PIVOT POINT CLEARANCES
12

MEMORANDUM

20-40 SK1020-5N, SK1020-5NA

 TROUBLESHOOTING (GENERAL)

POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
HANDLING CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS . . . . . . . . . . . . . 20-111
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-112
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
T-ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140
INFORMATION CONTAINED IN TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-143
ENGINE COOLANT TEMPERATURE SENSOR FAILURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-145
ABNORMAL ENGINE OIL PRESSURE INDICATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-146
AIR CLEANER CLOG INDICATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-147
ENGINE PREHEAT SYSTEM INOPERABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-148
FUEL LEVEL INDICATION IS INCORRECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150
FUEL PUMP MOTOR INOPERATIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-151
ENGINE DOES NOT SHUT DOWN OR WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-152
ALTERNATOR NOT CHARGING BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-154
ENGINE WILL NOT CRANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-156
BACK-UP ALARM WILL NOT FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-158
HYDRAULIC FILTER SENSOR WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160
PPC SYSTEM ELECTRICAL MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-161
SEAT SAFETY SWITCH MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-163
SAFETY BAR SWITCH MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-164
TRAVEL SPEEDS CANNOT BE CHANGED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-165
FLOAT CONTROL MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-167
PARKING BRAKE SYSTEM MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-169
PATTERN CHANGE MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171
STABALIZER SYSTEM MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-173
LOW OR WEEK TRAVEL WEEK BRAKE-OUT FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-176
WEAK TRAVEL WEAK BREAK-OUT FORCE IN REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-178
ROTATING BEACON INOPERABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180
REAR WORK LIGHTS WILL NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-182
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-184
POSSIBLE DEFECTIVE SAFETY RELAY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-186

SK1020-5N, SK1020-5NA 20-101

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.

WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.

WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.

WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.

WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However,
a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the
failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
● Parts that have no connection with the failure or other unnecessary parts will be disassembled.
● It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.

2. Points to ask the user or operator.

A. Have any other problems occurred apart from the problem that has been reported?

B. Was there anything strange about the machine before the failure occurred?

C. Did the failure occur suddenly, or were there problems with the machine condition before this?

D. Under what conditions did the failure occur?

E. Had any repairs been carried out before the failure? When were these repairs carried out?

F. Has the same kind of failure occurred before?

20-102 SK1020-5N, SK1020-5NA

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
3. Check before troubleshooting.

A. Check the oil level.

B. Check for any external leakage of oil from the piping or hydraulic equipment.

C. Check the travel of the control levers.

D. Check the stroke of the control valve spool.

E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.

4. Confirming the failure.

A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.

5. Troubleshooting

A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.

B. The basic procedure for troubleshooting is as follows.

i. Start from the simple points.

ii. Start from the most likely points.

iii. Investigate other related parts or information.

6. Measures to remove root cause of failure.

A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.

B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

SK1020-5N, SK1020-5NA 20-103

TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

20-104 SK1020-5N, SK1020-5NA

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur,
correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly
with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives
sections on 'Handling electric equipment' and 'Handling hydraulic equipment' (particularly hydraulic oil).

PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT

1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting one component to
another component, connectors used for connecting and
disconnecting one wire from another wire, and protector or tubes
used for protecting the wiring. Compared with other electrical
components fitted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain, water, heat, or
vibration. Furthermore, during inspection and repair operations
they are frequently removed and installed again, so they are likely
to suffer deformation or damage. For this reason, it is necessary to
be extremely careful when handling wiring harnesses.

2. Main failures occurring in wiring harness

A. Faulty contact of connectors

(faulty contact between male and female).
Problems with faulty contact are likely to occur because the
male connector is not properly inserted into the female
connector, or because one or both of the connectors is
deformed or the position is not correctly aligned, or because
there is corrosion or oxidation of the contact surfaces.

B. Defective compression or soldering of connectors

The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.

SK1020-5N, SK1020-5NA 20-105

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
C. Disconnections in wiring
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring
still connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.

D. High pressure water entering a connector

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter the connector
depending on the direction of the water jet.
The connector is designed to prevent water from entering, but
if water does enter, it is difficult for it to be drained. Therefore,
if water should get into the connector, the pins will be
short-circuited by the water, so if any water gets in,
immediately dry the connector or take other appropriate action
before passing electricity through it.

E. Oil, grease or dirt stuck to connector

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female
pins, the oil will not let the electricity pass, and this will cause
a defective contact.
If there is oil or grease or dirt stuck to the connector, wipe it off
with a dry cloth or blow dry with air, and spray it with a
contact restorer.
★ When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
★ If there is water or oil present, it will increase the
contamination of the points, so clean with air until all
water and oil has been removed.

20-106 SK1020-5N, SK1020-5NA

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
3. Removing, installing, and drying connectors and wiring harnesses.

A. Disconnecting connectors

i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors
and not the wires. For connectors held by a screw, loosen
the screw fully, then hold the male and female connectors
in each hand and pull apart. For connectors which have a
lock stopper, press down the stopper with your thumb and
pull the connectors apart.
★ Never try to pull apart with one hand

ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.

iii. When disconnecting male and female connectors, release

the lock and pull in parallel with both hands.
★ Never try to pull apart with one hand.

iv. Action to take after removing connectors.

After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.

SK1020-5N, SK1020-5NA 20-107

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
B. Connecting connectors

i. Check the connector visually.

● Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
● Check that there is no deformation, faulty contact,
corrosion, or damage to the connector pins.
● Check that there is no damage or breakage to the
outside of the connector.
★ If there is any oil, water, or dirt stuck to the connector,
wipe it off with a dry cloth. If any water has gotten
inside the connector, warm the inside of the wiring
with a dryer, but be careful not to make it too hot as
this will cause short circuits.
★ If there is any damage or breakage, replace the
connector.

ii. Assemble the connector securely.

Align the position of the connector correctly, then insert it
securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks into position.

iii. Correct any protrusion of the boot and any misalignment

of the wiring harness.
For connectors fitted with boots, correct any protrusion or
the boot. In addition, if the wiring harness is misaligned,
or the clamp is out of position, adjust it to its correct
position.
★ When blowing with dry air, there is danger that the oil
in the air may cause improper contact, so clean with
properly filtered air.

iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.

C. Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors have two
latches respectively, push them in until they click 2 times.
● Male connector (1), Female connector (2).
● Normal locking state (Horizontal): a, b, d
● Incomplete locking state (Diagonal): c

20-108 SK1020-5N, SK1020-5NA

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
D. Drying wiring harness
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:

i. Disconnect the connector and wipe off the water with a

dry cloth.
★ If the connector is blown dry with air, there is the risk
that oil in the air may cause a faulty contact, so avoid
blowing with air.

ii. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to dry the
connector.
★ Hot air from the dryer can be used, but be careful not
to make the connector or related parts too hot, as this
will cause deformation or damage to the connector.

iii. Carry out a continuity test on the connector.

After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, spray it with
contact restorer and reassemble.

SK1020-5N, SK1020-5NA 20-109

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

HANDLING CONTROL BOX

1. The control box contains a microcomputer and electronic control
circuits.
★ This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control box.

2. Do not open the cover of the control box unless necessary.

3. Do not place objects on top of the control box.

4. Cover the control connectors with tape or a vinyl bag.

5. Do not leave the control box in a place where it is exposed to rain.

6. Do not place the control box on oil, water, or soil, or in any hot
place, even for a short time.
★ Place it on a suitable dry stand.

7. Precautions when carrying out arc welding.

★ When carrying out arc welding on the body, disconnect all
wiring harness connectors connected to the control box. Fit an
arc welding ground close to the welding point.

20-110 SK1020-5N, SK1020-5NA

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIR-

CUITS
1. Always turn power OFF before disconnecting or connecting connectors.

2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.

3. Always connect any disconnected connectors before going on to the next step.
★ If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.

4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.

5. When checking a single diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.

6. When checking a dual diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.

7. Always be aware of what you are measuring. Voltage, Ohms or

Amps. Always use caution when measuring a circuit.
★ When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are
measuring.
★ When measuring ohms, be sure the circuit is dead and has (no
voltage) in it before you take any readings. Be sure the meter is
set in the proper ohms range.
★ When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage your equipment or possibly cause
injury. Always study the operators manuel for the meter you
will be using.

SK1020-5N, SK1020-5NA 20-111

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.

1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot
of dust.

2. Disassembly and maintenance work in the field.

If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the
equipment. It is also difficult to confirm the performance after
repairs, so it is desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be carried out in a
specially prepared dust proof workshop, and the performance
should be confirmed with special test equipment.

3. Seal or cover all openings of disconnected piping.

After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag,
this could cause particles or dirt to get into the system. Drain all oil
into a container and not unto the ground and be sure to follow the
proper environmental regulation for any disposal of oil.

4. Do not let any dirt, or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt that has collected
during storage, so this is an even more effective method.

20-112 SK1020-5N, SK1020-5NA

TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.

6. Flushing operations.
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil, and secondary
flushing is carried out with the specified hydraulic oil.

7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.

SK1020-5N, SK1020-5NA 20-113

TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

Item Judgement Value Action
1. Check fuel level - Add fuel
Lubricating oil, coolant

2. Check for impurities in fuel - Drain

3. Check oil level in hydraulic oil tank - Add oil
4. Check oil filter (Hydraulic, HST) - Replace
5. Check brake oil level - Add oil
6. Check engine oil level inside oil pan - Add oil
7. Check coolant level - Add coolant
8. Check dust indicator for clogging - Clean or replace
9. Check play of steering wheel Max. 80 mm (3.1 in) Adjust
10. Check emergency steering - Repair
Air, Hydraulic, Mechanical equipment

11. Check tire inflation pressure and damage - Air charge or replace
Before Starting Checking Item

Tightening torque (See DISASSENBLY

12. Check loosening of hub nut AND ASSEMBLY) Tighten

13. Check effect of foot brake - Adjust

14. Check effect of parking brake - Adjust or repair
15. Check effect of emergency brake - Adjust or repair
16. Check operation of steering - Adjust or repair
17. Check direction of rear view mirror and under mirror - Adjust
18. Check effect of exhaust gas color and sound - Adjust or repair
19. Check effect retarder brake - Adjust or repair
20. Check effect body mounting rubber - Replace
21. Check sound of horn - Repair
22. Check flashing of lamps - Repair or replace
Electrical equipment

23. Check operation of gauge when during operation - Adjust or repair

24. Check operation of monitor panel - Adjust or repair
25. Check operation of machine monitor system - Adjust or repair
26. Check for missing central warning lamps - Repair or replace
27. Check for looseness, corrosion of battery terminal, wiring - Tighten or clean
28. Check for looseness, corrosion of alternator terminal, wiring - Tighten or clean
29. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or clean
30. Check for abnormal noise, smell - Repair
31. Check for oil leakage - Repair
32. Carry out air bleeding - Bleed air
33. Check battery voltage (Engine stopped) 24 V Charge or replace
Others Checking Item

34. Check battery electrolyte level - Add

35. Check for discolored, burnt, exposed wiring - Replace
36. Check for missing wiring clamps, hanging wire - Repair
37. Check for water leakage on wiring (Pay particular attention to water
leaking on connectors or terminals) - Dry

38. Check for blown, corroded fuses - Replace

After running for several minutes:
39. Check alternator voltage (Engine running at 1/2 throttle or above) 28.5 - 29.5V Replace

40. Check sound of actuation of battery relay (When starting switch is - Replace
turned ON, OFF)

20-114 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

USING TROUBLESHOOTING CHARTS

1. Categories of troubleshooting codes
★ If the machine monitor displays a failure code, the name of the controller is also displayed at the same time, so the
troubleshooting codes are categorized according to the name of each controller. (This may also includes some failure
codes for the electrical system that are not displayed)
★ Failures of the hydraulic and mechanical system that the machine monitor cannot display are categorized as H mode.
Failure code System for troubleshooting
HST Troubleshooting of HST controller system
MON Troubleshooting of machine monitor system
E Troubleshooting of electrical system
H Troubleshooting of hydraulic, mechanical system
Engine Troubleshooting of engine (see 102 Series engine shop manual)

2. Procedure for troubleshooting

★ If a problem occurs on the machine, or if any problem is felt, carry out troubleshooting as follows.

A. When failure code is displayed on machine monitor.

If a failure code is displayed on the machine monitor at the same time as the problem occurs, check the content of the
display, then go to the applicable troubleshooting for the failure code.

B. If no failure code is displayed on the machine monitor but the failure is recorded in memory.
If it is impossible to check the failure code display on the machine monitor when a problem occurs, use the
troubleshooting history display function in the service mode of the machine monitor to check if there is a failure code.
If a failure code is recorded, it is probable that it is the cause, so go to the applicable troubleshooting for the failure
code.

C. If no failure code is displayed and no failure history is recorded.

If it is impossible to check the failure display on the machine monitor when a problem occurs, and there is also no
failure code recorded in the troubleshooting history display function in the service mode of the machine monitor, it is
probable that are problem has occurred in the hydraulic or mechanical system or in the electrical system that the
controller cannot detect. In such a case, check the condition of the failure carefully, then go to the applicable
troubleshooting for the failure.

SK1020-5N, SK1020-5NA 20-115

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
★ Deuscht connector has marks of pin numbers on the wiring harness side.

X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010

2 799-601-7020

Part number: 08055-00282 Part number: 08055-00292

3 799-601-7030

Part number: 08055-00381 Part number: 08055-00391

4 799-601-7040

Part number: 08055-00481 Part number: 08055-00491

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
• Wire size: 2.0 • Wire size: 2.0
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: red • Grommet: red

20-116 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

6 799-601-7050

Part number: 08055-10681 Part number: 08055-10691

8 799-601-7060

Part number: 08055-10881 Part number: 08055-10891

12 799-601-7310

Part number: 08055-11281 Part number: 08055-11291

14 799-601-7070

Part number: 08055-11481 Part number: 08055-11491

SK1020-5N, SK1020-5NA 20-117

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

SWP Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

16 799-601-7320

Part number: 08055-11681 Part number: 08055-11691

Terminal part number: Terminal part number:
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
• Wire size: 1.25 • Wire size: 1.25
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: red • Grommet: red

20-118 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

M Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080

2 799-601-7090

Part number: 08056-00271 Part number: 08056-00281

3 799-601-7110

Part number: 08056-00371 Part number: 08056-00381

4 799-601-7120

Part number: 08056-00471 Part number: 08056-00481

6 799-601-7130

Part number: 08056-00671 Part number: 08056-00681

SK1020-5N, SK1020-5NA 20-119

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

8 799-601-7340

Part number: 08056-00871 Part number: 08056-00881

20-120 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

8 799-601-7140

Part number: 08056-10871 Part number: 08056-10881

10 (white) 799-601-7150

Part number: 08056-11071 Part number: 08056-11081

12 (white) 799-601-7350

Part number: 08056-11271 Part number: 08056-11281

16 (white) 799-601-7330

Part number: 08056-11671 Part number: 08056-11681

SK1020-5N, SK1020-5NA 20-121

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

S Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

10 (blue) —

— —

12 (blue) 799-601-7160

Part number: 08056-11272 Part number: 08056-11282

16 (blue) 799-601-7170

Part number: 08056-11672 Part number: 08056-11682

20-122 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 —
(Quantity: 5 pieces) (Quantity: 5 pieces)
Body part number: 79A-222-2680 Body part number: 79A-222-2670
11 (Quantity: 5 pieces) (Quantity: 5 pieces) —

5 799-601-2710

Body part number: 79A-222-2620 Body part number: 79A-222-2610

(Quantity: 5 pieces) (Quantity: 5 pieces)

9 799-601-2950

Body part number: 79A-222-2660 Body part number: 79A-222-2650

(Quantity: 5 pieces) (Quantity: 5 pieces)

13 799-601-2720

Body part number: 79A-222-2710 Body part number: 79A-222-2690

(Quantity: 2 pieces) (Quantity: 2 pieces)

SK1020-5N, SK1020-5NA 20-123

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

MIC Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

17 799-601-2730

Body part number: 79A-222-2730 Body part number: 79A-222-2720

(Quantity: 2 pieces) (Quantity: 2 pieces)

21 799-601-2740

Body part number: 79A-222-2750 Body part number: 79A-222-2740

(Quantity: 2 pieces) (Quantity: 2 pieces)
Body part number: 79A-222-2770 Body part number: 79A-222-2760
— —
(Quantity: 50 pieces) (Quantity: 50 pieces)

20-124 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP040 Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

8 799-601-7180

Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)

12 799-601-7190

— Housing part number: 79A-222-3440

(Quantity: 5 pieces)

16 799-601-7210

Housing part number: 79A-222-3450

—
(Quantity: 5 pieces)

20 799-601-7220

— Housing part number: 79A-222-3460

(Quantity: 5 pieces)

★ Terminal part number: 79A-222-3470 (for all numbers of pins).

SK1020-5N, SK1020-5NA 20-125

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

AMP070 Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

10 799-601-7510

— Part number: 08195-10210

12 799-601-7520

— Part number: 08195-12210

14 799-601-7530

— Part number: 08195-14210

18 799-601-7540

— Part number: 08195-18210

20-126 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

20 799-601-7550

— Part number: 08195-20210

L Type Connector
Number of
Pins T-adapter Part
Male (Female housing) Female (Male housing) Number

2 —

— —

PA Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

9 —

— —

SK1020-5N, SK1020-5NA 20-127

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

BENDIX (MS) Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

10 799-601-3460

— —

20-128 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES1 Automobile Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

2 —

Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)

3 —

Part number: 08027-10310 Part number: 08027-10360

4 —

Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)

6 —

Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)

SK1020-5N, SK1020-5NA 20-129

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

KES1 Automobile Type Connector

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

8 —

Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)

20-130 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Connector for relay (Socket)

Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number

5 799-601-7360

— —

6 799-601-7370

— —

Type F Type Connector

(shell size T-adapter Part
code) Pin (Male terminal) Body (Female terminal)
Number

4 —

— —

SK1020-5N, SK1020-5NA 20-131

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9210

Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)

799-601-9210

Part number: 08191-11201, 08191-12202 Part number: 08191-13101, 08191-13102

08191-11205, 08191-12206 08191-13105, 08191-13106
Pin (male terminal) Pin (female terminal)

799-601-9220

Part number: 08191-21201, 08191-12202 Part number: 08191-24101, 08191-24102

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
(2) Pin (female terminal) Pin (male terminal)

799-601-9220

Part number: 08191-22201, 08191-22202 Part number: 08191-23101, 08191-23102

08191-22205, 08191-22206 08191-23105, 08191-23106

20-132 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9230

18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

(3) Pin (female terminal) Pin (male terminal)

799-601-9230

Part number: 08191-32201, 08191-32202 Part number: 08191-33101, 08191-33102

Pin (male terminal) Pin (female terminal)

799-601-9240

18-21 Part number: 08191-41201, 08191-42202 Part number: 08191-44101, 08191-44102

(4) Pin (female terminal) Pin (male terminal)

799-601-9240

Part number: 08191-42201, 08191-42202 Part number: 08191-43101, 08191-43102

SK1020-5N, SK1020-5NA 20-133

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9250

24-9 Part number: 08191-51201, 08191-51202 Part number: 08191-54101, 08191-54102

(5) Pin (female terminal) Pin (male terminal)

799-601-9250

Part number: 08191-52201, 08191-52202 Part number: 08191-53101, 08191-53102

Pin (male terminal) Pin (female terminal)

799-601-9260

Part number: 08191-61201, 08191-62202 Part number: 08191-64101, 08191-64102

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
(6) Pin (female terminal) Pin (male terminal)

799-601-9260

Part number: 08191-62201, 08191-62202 Part number: 08191-63101, 08191-63102

08191-62205, 08191-62206 08191-63105, 08191-63106

20-134 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9270

Part number: 08191-71201, 08191-71202 Part number: 08191-74101, 08191-74102

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
(7) Pin (female terminal) Pin (male terminal)

799-601-9270

Part number: 08191-72201, 08191-72202 Part number: 08191-73102, 08191-73102

08191-72205, 08191-72206 08191-73105, 08191-73106
Pin (male terminal) Pin (female terminal)

799-601-9280

Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
(8) Pin (female terminal) Pin (male terminal)

799-601-9280

Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106

SK1020-5N, SK1020-5NA 20-135

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The pin No. is also marked on the connector (electric wire insertion end)

Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)

799-601-9290

Part number: 08191-91203, 08191-91204 Part number: 08191-94103, 08191-94104

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
(9) Pin (female terminal) Pin (male terminal)

799-601-9290

Part number: 08191-92203, 08191-92204 Part number: 08191-93103, 08191-93104

08191-92205, 08191-92206 08191-93105, 08191-93106

20-136 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins Body (plug) Body (receptacle) T-adapter Part
Number

2 799-601-9020

Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)

3 799-601-9030

Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)

4 799-601-9040

Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)

6 799-601-9050

Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)

SK1020-5N, SK1020-5NA 20-137

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number

8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080

Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)

12GR: 799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR: 799-601-9140

Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)

20-138 SK1020-5N, SK1020-5NA

TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The pin No. is also marked on the connector (electric wire insertion end)
DTM Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number

2 799-601-9010

Part number: 08192-02200 Part number: 08192-02100

DTHD Series connector

Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number

1 —

Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)

SK1020-5N, SK1020-5NA 20-139

TROUBLESHOOTING T-ADAPTER TABLE

T-ADAPTER TABLE
★ The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring harness checker
assemblies are shown in the lines.
KIT No.

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.

799-601-2600 For measuring box Econo-21P O O O O O O

799-601-3100 For measuring box MS-37P O
799-601-3200 For measuring box MS-37P O
799-601-3300 For measuring box Econo-24P O
799-601-3360 Plate For MS box
799-601-3370 Plate For MS box
799-601-3380 Plate For MS box
799-601-3410 BENDIX(MS) 24P O O
799-601-3420 BENDIX(MS) 24P O O
799-601-3430 BENDIX(MS) 17P O O
799-601-3440 BENDIX(MS) 17P O O
799-601-3450 BENDIX(MS) 5P O O
799-601-3460 BENDIX(MS) 10P O O
799-601-3510 BENDIX(MS) 5P O O
799-601-3520 BENDIX(MS) 14P O O
799-601-3530 BENDIX(MS) 19P O O
799-601-2910 BENDIX(MS) 14P O O
799-601-3470 CASE O
799-601-2710 MIC 5P O O O O
799-601-2720 MIC 13P O O O O
799-601-2730 MIC 17P O O O O O O O
799-601-2740 MIC 21P O O O O O O O
799-601-2950 MIC 9P O O O O
799-601-2750 ECONO 2P O O
799-601-2760 ECONO 3P O O
799-601-2770 ECONO 4P O O
799-601-2780 ECONO 8P O O
799-601-2790 ECONO 12P O O
799-601-2810 DLI 8P O O
799-601-2820 DLI 12P O O
799-601-2830 DLI 16P O O
799-601-2840 Extension cable O O O
799-601-2850 CASE O
799-601-7010 X 1P O O
799-601-7020 X 2P O O O O
799-601-7030 X 3P O O O O
799-601-7040 X 4P O O O O
799-601-7050 SWP 6P O O O
799-601-7060 SWP 8P O O O
799-601-7310 SWP 12P O

20-140 SK1020-5N, SK1020-5NA

TROUBLESHOOTING T-ADAPTER TABLE

KIT No.

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.

799-601-7070 SWP 14P O O

799-601-7320 SWP 16P O
799-601-7080 M 1P O O
799-601-7090 M 2P O O O O
799-601-7110 M 3P O O O O
799-601-7120 M 4P O O O O
799-601-7130 M 6P O O O O
799-601-7340 M 8P O
799-601-7140 S 8P O O O O
799-601-7150 S 10P-White O O O O
799-601-7160 S 12P-Blue O O O
799-601-7170 S 16P-Blue O O O O
799-601-7330 S 16P-White O
799-601-7350 S 12P-White O
799-601-7180 AMP040 8P O
799-601-7190 AMP040 12P O O
799-601-7210 AMP040 16P O O O O
799-601-7220 AMP040 20P O O O O
799-601-7230 Short connector X-2 O O O O
799-601-7240 Case O O
799-601-7270 Case O
799-601-7510 070 10P O
799-601-7520 070 12P O
799-601-7530 070 14P O
799-601-7540 070 18P O
799-601-7550 070 20P O
799-601-7360 Relay connector 5P O
799-601-7370 Relay connector 6P O
799-601-7380 JFC connector 2P O
799-601-9010 DTM 2P O O
799-601-9020 DT 2P O O
799-601-9030 DT 3P O O
799-601-9040 DT 4P O O
799-601-9050 DT 6P O O
799-601-9060 DT 8P-Gray O O
799-601-9070 DT 8P-Black O O
799-601-9080 DT 8P-Green O O
799-601-9090 DT 8P-Blown O O
799-601-9110 DT 12P-Gray O O
799-601-9120 DT 12P-Black O O
799-601-9130 DT 12P-Green O O
799-601-9140 DT 12P-Blown O O
799-601-9210 HD30 18-8 O O
799-601-9220 HD30 18-14 O O

SK1020-5N, SK1020-5NA 20-141

TROUBLESHOOTING T-ADAPTER TABLE

KIT No.

799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.

799-601-9230 HD30 18-20 O O

799-601-9240 HD30 18-21 O O
799-601-9250 HD24 24-9 O O
799-601-9260 HD30 2-16 O O
799-601-9270 HD30 24-21 O O
799-601-9280 HD30 24-23 O O
799-601-9290 HD30 24-31 O O
799-601-9310 Plate For HD30 O O O
799-601-9320 For measuring box For DT, HD O O O
799-601-9330 Case O
799-601-9340 Case O
799-601-9350 DEUTSCH 40P O
799-601-9360 DEUTSCH 24P O
799-601-9410 For NE, G sensor 2P O
799-601-9420 For boost pressure, fuel 3P O
799-601-9430 PVC socket 2P O
AMP 2-963215-1
799-601-9710 AMP 2-963217-1 16P O
for HST controller
AMP 2-963215-1
799-601-9720 AMP 2-963217-1 16P O
for HST controller
AMP 2-1437285-2
799-601-9730 AMP 2-1437285-8 26P O
for HST controller

20-142 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING INFORMATION CONTAINED IN TESTING PROCEDURES

INFORMATION CONTAINED IN TESTING PROCEDURES

★ The testing table and the related circuit diagrams contain the following information. Read all information and each step
carefully, if necessary, repeat each step in a test procedure to confirm the fault. The idea behind these procedures is to
isolate each part of the circuit.

• Failure.
Contents Of Trouble • Failure code displayed.
• Additional information.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures For Service Code Specifications No. Readings

1. Sensor or Actuator
• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)

Your
Test procedure for component only. readings 1
Resistance Ω information
A. What you are testing
or Voltage
Your
Test procedure for component only. readings 2
information

2. Diode Test
• With ignition switch in the “OFF” position. (The importance of these tests are to isolate each component for testing separately)
• When checking a diode always isolate the circuit. Check diode continuity in both directions reversing meter leads each time to confirm
electrical flow. Electrical flow should be one way only. (See section 20-111 for detail).

At a diode, between point (x) and (x) Continuity one

A. Diode test Resistance Ω 3 Yes or No
reverse meter lead polarity each time to check diode. way only?

3. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)

Your
Test procedure for harness. (connector) to (connector) readings 4
information
A. Open or high Resistance Ω
resistance or Voltage
Your
Test procedure for harness. (connector) to (connector) readings 5
information

Your
Test procedure for harness. (connector) to (connector) readings 6
B. Short to chassis information
Resistance Ω
ground or within
or Voltage Your
harness
Test procedure for harness. (connector) to (connector) readings 7
information

4. Additional Components To Be Tested

• With ignition switch in the “OFF” position. (no voltage should be in the system you are testing unless called for indicated with a symbol ✸)
• Disconnect components and isolate them for testing. (The importance of these tests are to isolate each component for testing separately)
• Zero meter leads for proper Ω readings. (remove resistance from your meter leads before taking reading. See DVOM meter operators manual)

Resistance Ω Your
A. What you are testing Test procedure for any additional components. readings 8
or Voltage information

SK1020-5N, SK1020-5NA 20-143

TESTING AND ADJUSTING INFORMATION CONTAINED IN TESTING PROCEDURES
Electrical Circuit Diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred.

● Connector No.: Indicates (Type - numbers of a pin) (color)

● Arrow: Roughly indicates the location in the machine where it is installed.

20-144 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ENGINE COOLANT TEMPERATURE SENSOR FAILURE
12
ENGINE COOLANT TEMPERATURE SENSOR FAILURE
• The engine coolant is indicating an incorrect condition.
Contents Of Trouble
• Engine coolant temperature indication overheat or no heat condition.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

1. Coolant Temperature Sensor Unit

• With ignition switch in the “OFF” position.
• Disconnect (X18) connector from temperature sensor and isolate sensor.
• Zero meter leads for proper Ω readings.

At sensor X18, between (1) and (2)

9.2 to 3.4Ω 1
temperature from 10 to 100° C (50 to 212° F)
A. Sensor test Resistance Ω
At sensor X18, between (1) or (2) and chassis ground. (OL) open 2

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X18) connector from temperature sensor.
• Disconnect (X80) connector from monitor panel and install T-adapter on (X80) wiring harness connector only.
• * Ignition switch must be on for this test

Voltage * Between connector X80, (4) and chassis ground. 12 to 15V 3

A. Open or high Between connectors X80, (3) and X81, (1) 0.0 to 1.0Ω 4
resistance
Resistance Ω Between connector X81, (2) and chassis ground. 0.0 to 1.0Ω 5

Between connector X80, (6) and chassis ground. 0.0 to 1.0Ω 6

B. Short to chassis At connector X81, between (1) and chassis ground. (OL) open 7
ground or within Resistance Ω
harness At connector X81, between (1) and (2) (OL) open 8

Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-145

TESTING AND ADJUSTING ABNORMAL ENGINE OIL PRESSURE INDICATED
12
ABNORMAL ENGINE OIL PRESSURE INDICATED
• Abnormal engine oil pressure indicated.
Contents Of Trouble
• Shut engine down immediately.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

Check engine oil pressure with mechanical gauge first See Engine
A. Live pressure test — 1 —
before checking electrical system. Shop Manual

1. Defective Oil Pressure Sensor

• With ignition switch in the “OFF” position.
• Disconnect (S31) connector from indicator sensor and isolate sensor.
• Zero meter leads for proper Ω readings.
• Start the engine.

At sensor S31, between (1) and chassis ground,

2.9 to 4.0Ω 2
engine at low idle slowly increasing RPM to mid point.
A. Sensor test Resistance Ω
At sensor X28, between (1) and chassis ground,
0.0 to 0.2Ω 3
engine off.

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X28) connector from sensor.
• Disconnect (X80) connector from monitor panel and install T-adapter on (X80) wiring harness connector only.

A. Short to
chassis ground Resistance Ω At connector X28, between (1) and chassis ground. (OL) open 4
or within harness

B. Open or high
Resistance Ω Between connectors X28, (1) and X80, (16) 0.0 to 1.0Ω 5
resistance

Related Circuit Diagram

20-146 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING AIR CLEANER CLOG INDICATED
12
AIR CLEANER CLOG INDICATED
• Air cleaner clog indicated.
Contents Of Trouble
• Shut engine down immediately.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

Check condition of air cleaner first before checking See Operators

A. Visual test — 1 —
electrical system. Manual

1. Defective Vacuum Sensor

• With ignition switch in the “OFF” position.
• Disconnect (S25) connector from vacuum sensor and isolate sensor.
• Zero meter leads for proper Ω readings.

At sensor S25, between (1) and (2), engine at low idle

A. Sensor test Resistance Ω (OL) open 2
slowly increasing RPM to mid point.

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X16) connector from sensor.
• Disconnect (X80) connector from monitor panel and install T-adapter on (X80) wiring harness connector only.

A. Short to
chassis ground Resistance Ω At connector X16, between (1) and chassis ground. (OL) open 3
or within harness

B. Open or high
Resistance Ω Between connectors X16, (1) and X80, (14) 0.0 to 1.0Ω 4
resistance

Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-147

TESTING AND ADJUSTING ENGINE PREHEAT SYSTEM INOPERABLE
12
ENGINE PREHEAT SYSTEM INOPERABLE
• Preheat system not working properly.
Contents Of Trouble
• Hard starting engine in cold weather
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

1. Defective Heater Coil

• With ignition switch in the “OFF” position.
• Disconnect (X15) connector from heater coil.
• Zero meter leads for proper Ω readings.
• * Ignition switch must be in the “ON” position for this test.

Resistance Ω At heater coil R1, between (1) and chassis ground. 0.0 to 1.0Ω 1

A. Heater test At connector X15, between (1) and chassis ground with
Voltage the ignition switch in the PRE-HEAT position and 12 to 15V 2
ambient temperature 4.4°C (40°F)

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X15) connector from heater coil.
• Disconnect (S10) connector from the ignition switch.
• Disconnect (X80) connector from control panel and install T-adapter on (X80) wiring harness connector only.
• Disconnect (X50) connector from electronic unit and install T-adapter on (X50) wiring harness connector only.

A. Short to
chassis ground Resistance Ω At connector X15, between (1) and chassis ground. (OL) open 4
or within harness

Between connectors X15, (1) and X80, (4) 0.0 to 1.0Ω 5

B. Open or high
Resistance Ω Between connectors X15, (1) and X50, (6) 0.0 to 1.0Ω 6
resistance
Between connectors X15, (1) and ignition switch 0.0 to 1.0Ω 7

20-148 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ENGINE PREHEAT SYSTEM INOPERABLE
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-149

TESTING AND ADJUSTING FUEL LEVEL INDICATION IS INCORRECT
12
FUEL LEVEL INDICATION IS INCORRECT
• Fuel level indicator not showing proper fuel level.
Contents Of Trouble
• Low fuel indicator may show full or empty.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

1. Fuel Level Sensor Unit

• With ignition switch in the "OFF" position.
• Disconnect (X17) connector from level sensor.
• Zero meter leads for proper Ω readings.

At sensor X17, between (1) and chassis ground,

10.6 ≈ 37.2Ω 1
fuel tank near full to half full.
A. Sensor test Resistance Ω
At sensor X17, between (1) and chassis ground,
37.2 ≈ 90.6Ω 2
fuel tank near half full to empty.

2. Wiring Harness Assembly Test

• With ignition switch in the "OFF" position.
• Disconnect (X17) connector from sensor.
• Disconnect (X80) connector from monitor panel and install T-adapter on (X80) wiring harness connector only

A. Open or high
Resistance Ω Between connectors X80, (2) and X17, (1) 0.0 to 1.0Ω 3
resistance

B. Short to chassis
ground or within Resistance Ω At connector X17, between (1) and chassis ground. (OL) open 4
harness

Related Circuit Diagram

20-150 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING FUEL PUMP MOTOR INOPRTATIVE
12
FUEL PUMP MOTOR INOPRTATIVE
Contents Of Trouble • Engine will not start or runs out of fuel when operating machine with a full fuel tank.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU10 Fuse good? 1 Yes or No

1. Defective Motor
• With ignition switch in the “OFF” position.
• Disconnect (X14) connector from motor.
• Turn ignition switch to the “ON” position

Voltage Between connector X14, (1) and chassis ground. 12 to 15V 2

A. Motor test
Resistance Ω Between motor M, and chassis ground. 0.0 to 1.0Ω 3

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X14) connector from motor.
• Disconnect (FU10) fuse and remove fuse.

A. Short to
chassis ground Resistance Ω At connector X14, between (1) and chassis ground. (OL) open 4
or within harness

B. Open or high
Resistance Ω Between connectors X14, (1) and fuse, (FU10) 0.0 to 1.0Ω 5
resistance

Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-151

TESTING AND ADJUSTING ENGINE DOES NOT SHUT DOWN OR WILL NOT START
12
ENGINE DOES NOT SHUT DOWN OR WILL NOT START
• Engine starter switch will not shut the system down or it will not start.
Contents Of Trouble • Engine keeps running or will not start.
• See: ENGINE SHOP MANUAL
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

1. Fuel Cut Solenoid

• With the engine running at a low idle.
• Turn ignition switch in the "OFF" position.
• Zero meter leads for proper Ω readings.
★ (No) If the engine does not shut down after performing this procedure. Do not continue with electrical testing.
(See ENGINE SHOP MANUAL) for further testing or repair procedures on the fuel cut solenoid component.

Fuel cut solenoid check —

★ Disconnect connector (X13) from fuel cut Did engine shut
1 Yes or No
solenoid and observe any system changes down?

A. Fuse — Check condition of fuse FU08 and FU11 Fuse good? 2 Yes or No

2. Fuel Solenoid, Fuel Pull Relay and Timer

• With ignition switch in the "OFF" position.
• Disconnect (X13) connector from fuel cut solenoid.
• Disconnect (X07) connector from timer and install T-adapter between (X07) connector and timer.

Cut solenoid connector X13, (2) and (3) key “OFF” 0V 3

Cut solenoid connector X13, (1) and (3) key “OFF” 0V 4

Cut solenoid connector X13, (2) and (3) key held in the
12 to 15V 5
“START” position.

Cut solenoid connector X13, (1) and (3) key in the “ON”
A. Timer and 12 to 15V 6
position.
solenoid
Voltage
and relay At fuel pull relay X03, between (85) and (86), key
0V 7
test “OFF”

At fuel pull relay X03, between (85) and (86), key “ON” 12 to 15V 8

At fuel pull relay X03, between (30) and chassis ground,

12 to 15V 9
key “ON”

At fuel pull relay X03, between (87) and chassis ground,

12 to 15V 10
key “ON”

20-152 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ENGINE DOES NOT SHUT DOWN OR WILL NOT START
12
3. Wiring Harness Assembly Test
• With ignition switch in the "OFF" position.
• Disconnect (X13) connector from fuel cut solenoid.
• Disconnect (X50) connector from electronic unit and install T-adapter on (X50) wiring harness connector only
• * For this test the ignition key must be in the “ON” position

Between connectors X50, (16) and X13, (2) 0.0 to 1.0Ω 11

A. Open or high Resistance Ω Between connector X50, (8) and chassis ground. 0.0 to 1.0Ω 12
resistance
At connector X13, (3) and chassis ground. 0.0 to 1.0Ω 13

Voltage * At connector X50, (18) and chassis ground. 12 to 15V 14

At connector X13, between (2) and chassis ground. (OL) open 15

B. Short to chassis
ground or within Resistance Ω At connector X13, between (1) and chassis ground. (OL) open 16
harness
At connector X50, between (18) and chassis ground. (OL) open 17
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-153

TESTING AND ADJUSTING ALTERNATOR NOT CHARGING BATTERY
12
ALTERNATOR NOT CHARGING BATTERY
Contents Of Trouble • Charging system not working properly.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU09 Fuse good? 1 Yes or No

1. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X11, X09) connector from alternator.
• Disconnect (X80) from control panel.
• Disconnect (X08) from safety relay.
• Zero meter leads for proper Ω readings.
• * For this test the ignition switch must be in the “ON” position.

At connector X11, between (1) and chassis ground. (OL) open 2

At connector X09, between (1) and chassis ground,

(OL) open 3
A. Short to fuse removed.
chassis ground Resistance Ω
or within harness At connector X11, between (2) and chassis ground. (OL) open 4

At connector X11, between (3) and chassis ground,

(OL) open 5
battery disconnected.

Between connectors X11, (1) and X08, (1) 0.0 to 1.0Ω 6

Resistance Ω Between connectors X11, (2) and X80, (15) 0.0 to 1.0Ω 7

B. Open or high Between connectors X11, (3) and X08, (6) 0.0 to 1.0Ω 8
resistance
* At connector X09, (1) ignition switch in the “ON”
12 to 15 V 9
position.
Voltage
* At connector X11, (1) ignition switch ON. 12 to 15 V 10

20-154 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ALTERNATOR NOT CHARGING BATTERY
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-155

TESTING AND ADJUSTING ENGINE WILL NOT CRANK
12
ENGINE WILL NOT CRANK
Contents Of Trouble • Ignition key held in the “START” position and the engine will not crank.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

Check condition of fuse (FU10) in fuse panel and fuse

A. Fuse — Fuses good? 1 Yes or No
link (FG1)

1. Starter Check
• With ignition switch in the “OFF” position.
• Disconnect (XB, XM) connections from the starter motor.

At connection XB, (1) to chassis ground. 12 to 15V 2

A. Starter motor Voltage
Between connections XM, (1) to terminal XB, (1) with
12 to 15V 3
key held in the “START” position.

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (SX1, X07) connector from safety relay.
• Zero meter leads for proper Ω readings.
• * For this test the ignition switch must be in the “ON” position.

Between connectors SX1, (A) and XB, (1) 0.0 to 1.0Ω 4

Resistance Ω Between connectors SX1, (B) and XM, (1) 0.0 to 1.0Ω 5

A. Open or high At connection X08, (5) and chassis ground. 0.0 to 1.0Ω 6
resistance
Between connection X08, (3) and chassis ground,
12 to 15 V 7
ignition key held in the “START” position.
Voltage
At connector X08, (1) and chassis ground. 12 to 15 V 8

20-156 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ENGINE WILL NOT CRANK
12
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-157

TESTING AND ADJUSTING BACK-UP ALARM WILL NOT FUNCTION
12
BACK-UP ALARM WILL NOT FUNCTION
Contents Of Trouble • Back-up alarm will not function
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

★ For this procedure the machine must be placed on secure stands with all four wheels off the ground. (see section “20 TESTING ADJUSTING AND
TROUBLESHOOTING). An operator must be on the machine in order to perform these tests.

1. Back-up Alarm Check

• With ignition switch in the “OFF” position.
• Disconnect (X29) connections from the back-up alarm.
• Have the operator start the engine and allow it to idle at a low RPM

At connection X29, between (1) and (2) with the

12 to 15V 1
machine operating in a full reverse direction.
A. Back-up alarm Voltage
At connection X29, between (1) and (2) with the
0V 2
machine operating in a full forward direction.

2. Back-up Alarm Switches Test

• With ignition switch in the “OFF” position.
• Disconnect (X23) connections from and install T-adapter between switch and harness connector.
• Disconnect (X21) connections from and install T-adapter between switch and harness connector.
• Have the operator start the engine and allow it to idle at a low RPM

At switch X23, (2) and X22, (1) operating in reverse. 0.0 to 1.0Ω 3
A. Switch test Resistance Ω
At switch X23, (2) and X22, (1) operating in forward. (OL) open 4

3. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X23 and X22) connector from pressure switches.
• Zero meter leads for proper Ω readings.
• * For this test the ignition switch must be in the “ON” position.

Voltage * At connector X22, (1) and chassis ground. 12 to 15V 5

Between connectors X23, (2) and X29, (1) 0.0 to 1.0Ω 6

A. Open or high
resistance
Resistance Ω Between connectors X23, (1) and X22, (2) 0.0 to 1.0Ω 7

Between connectors X29, (2) and chassis ground. 0.0 to 1.0Ω 8

20-158 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING BACK-UP ALARM WILL NOT FUNCTION
12
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-159

TESTING AND ADJUSTING HYDRAULIC FILTER SENSOR WARNING
12
HYDRAULIC FILTER SENSOR WARNING
• The hydraulic filter sensor is indicating a blockage.
Contents Of Trouble • The hydraulic filter has been replaced and a blockage is still being indicated.
• No sensor warning is indicated at all.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

Replace hydraulic filter with a new and check the fluid System
Filter and system check — 1 Yes or No
level. Start the engine and operate work equipment normal?

1. Hydraulic Filter Sensor Unit

• With ignition switch in the “OFF” position.
• Disconnect (X19) connector from pressure sensor and isolate sensor.
• Zero meter leads for proper Ω readings.

At sensor X19, between (1) and chassis ground, engine

(OL) open 2
OFF
A. Sensor test Resistance Ω
At sensor X19, between (1) and chassis ground, new
(OL) open 3
filter installed and engine running.

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X19) connector from pressure sensor.
• Disconnect (X80) connector from control panel and install T-adapter on (X80) wiring harness connector only.
• * Ignition switch must be on for this test

* Jumper wire between control panel connection X80, Warning light

Voltage 4 Yes or No
A. Open or high (11) and chassis ground. ON?
resistance
Resistance Ω Between connectors X80, (11) and X19, (1) 0.0 to 1.0Ω 5

B. Short to chassis
ground or within Resistance Ω At connector X80, between (11) and chassis ground. (OL) open 6
harness

Related Circuit Diagram

20-160 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING PPC SYSTEM ELECTRICAL MALFUNCTION
12
PPC SYSTEM ELECTRICAL MALFUNCTION
• Warning light is illuminated and machine will not move.
Contents Of Trouble
• Warning light is on and work equipment will not operate.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

1. PPC Safety Switch

• With ignition switch in the “OFF” position.
• Disconnect (X32) and (X32A) connector from safety switch.
• Zero meter leads for proper Ω readings.

At switch X32, between (1) and (2), engine at low idle. 0.1Ω 1
A. Sensor test Resistance Ω At switch X32, between (1) or (2) and chassis ground,
(OL) open 2
engine at low idle.

2. PPC Safety Valve

• With ignition switch in the “OFF” position.
• Disconnect (X33) connector from safety valve and isolate valve.
• Zero meter leads for proper Ω readings.
• * Ignition switch must be on for this test

A. Valve test Resistance Ω At valve X33, between (1) and (2). 7.4Ω 3

3. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X32) and (X32A) connectors from PPC safety switch.
• Disconnect (X33) connector from PPC safety valve.
• Disconnect (X50) connector from electronic unit and install T-adapter on (X50) wiring harness connector only.
• * Ignition switch must be on for this test

Voltage * At connector X32 (1) and chassis ground. 12 to15V 5

Between connectors X50, (3) and X32A, (2) 0.0 to 1.0Ω 6

A. Open or high
resistance Resistance Ω Between connectors X50, (2) and X33, (1) 0.0 to 1.0Ω 7

Between connector X33, (2) and chassis ground. 0.0 to 1.0Ω 8

B. Short to chassis At connector X50, between (3) and chassis ground. (OL) open 9
ground or within Resistance Ω
harness At connector X50, between (2) and chassis ground. (OL) open 10

SK1020-5N, SK1020-5NA 20-161

TESTING AND ADJUSTING PPC SYSTEM ELECTRICAL MALFUNCTION
12
Related Circuit Diagram

20-162 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING SEAT SAFETY SWITCH MALFUNCTION
12
SEAT SAFETY SWITCH MALFUNCTION
• When ignition key is turned to the START position warning lights come on but engine will not crank.
Contents Of Trouble • Engine stops during operation occasionally.
• Machine can be started from a standing position.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU08 Fuse good? 1 Yes or No

1. Seat Safety Switch

• With ignition switch in the “OFF” position.
• Disconnect (X55) connector from seat safety switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X55, between (1) and (2), operator seated. 0.0 to 1.0Ω 2
A. Switch test Resistance Ω
At switch X55, between (1) and (2) no operator. (OL) open 3

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X55) connector from seat safety switch and isolate connector.
• Disconnect (X50) connector from electronic unit and install T-adapter on (X50) wiring harness connector only.
• * Ignition switch must be on for this test.

A. Open or high Voltage * At connector X55, (1) and chassis ground. 12 to15V 4
resistance
Resistance Ω Between connectors X55, (2) and X50 (19) 0.0 to 1.0Ω 5

B. Short to chassis
ground or within Resistance Ω At connector X50, between (19) and chassis ground. (OL) open 6
harness

Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-163

TESTING AND ADJUSTING SAFETY BAR SWITCH MALFUNCTION
12
SAFETY BAR SWITCH MALFUNCTION
• With operator seated and safety bar in the operation position machine cannot be started.
Contents Of Trouble
• Machine can be started with bar in non-operational position
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU08 Fuse good? 1 Yes or No

1. Safety Bar Switch

• With ignition switch in the “OFF” position.
• Disconnect (X54) connector from safety bar switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X54, between (C) and (B), bar in operating

0.0 to 1.0Ω 2
position.
A. Switch test Resistance Ω
At switch X54, between (C) and (B), bar in non
(OL) open 3
operating position. (UP)

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X54) connector from bar safety switch and isolate connector.
• Disconnect (X50) connector from electronic unit and install T-adapter on (X50) wiring harness connector only.
• * Ignition switch must be on for this test.

Voltage * At connector X54, (B) and chassis ground. 12 to15V 4

A. Open or high
Between connectors X54, (C) and X50 (20) 0.0 to 1.0Ω 5
resistance Resistance Ω
Between connector X54, (A) and chassis ground. 0.0 to 1.0Ω 6

B. Short to chassis
ground or within Resistance Ω At connector X50, between (20) and chassis ground. (OL) open 7
harness

Related Circuit Diagram

20-164 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING TRAVEL SPEEDS CANNOT BE CHANGED
12
TRAVEL SPEEDS CANNOT BE CHANGED
Contents Of Trouble • Travel speed cannot be changed.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU06 Fuse good? 1 Yes or No

1. Second Speed Switch

• With ignition switch in the “OFF” position.
• Disconnect (X83) connector from second speed switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X83, between (1) and (3), button pressed. 0.0 to 1.0Ω 2
A. Switch test Resistance Ω
At switch X83, between (1) and (3), button released. (OL) open 3

2. Second Speed Valve

• With ignition switch in the “OFF” position.
• Disconnect (X36) connector from second speed valve and isolate valve.
• Zero meter leads for proper Ω readings.

At valve X36, between (1) and (2) 7.4Ω 4

A. Valve test Resistance Ω
At valve X36, between (1) or (2) and chassis ground. (OL) open 5

3. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X36) connector from second speed valve and isolate connector.
• Disconnect (X83) connector from second speed switch and isolate connector.
• Disconnect (X50) connector from electronic unit and install T-adapter on (X50) wiring harness connector only.
• Disconnect (X81) connector from control panel and install T-adapter on (X50) wiring harness connector only.
• * Ignition switch must be on for this test.

Voltage * At connector X83, (1) and chassis ground. 12 to15V 6

Between connectors X83, (3) and X50 (22) 0.0 to 1.0Ω 7

A. Open or high
Between connector X36, (2) and chassis ground. 0.0 to 1.0Ω 8
resistance
Resistance Ω
Between connectors X36, (1) and X50 (9) 0.0 to 1.0Ω 9

Between connectors X36, (1) and X81 (4) 0.0 to 1.0Ω 10

At connector X50, between (22) and chassis ground. (OL) open 11

B. Short to chassis At connector X83, between (1) and (3) (OL) open 12
ground or within Resistance Ω
harness At connector X50, between (9) and chassis ground. (OL) open 13

At connector X81, between (4) and chassis ground. (OL) open 14

SK1020-5N, SK1020-5NA 20-165

TESTING AND ADJUSTING TRAVEL SPEEDS CANNOT BE CHANGED
Related Circuit Diagram

20-166 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING FLOAT CONTROL MALFUNCTION
12
FLOAT CONTROL MALFUNCTION
• The float control cannot be turned ON or cannot be turned OFF.
Contents Of Trouble
• Float control comes ON and OFF inadvertently.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU06 Fuse good? 1 Yes or No

Float Control Relay — Replace relay (K04) with known good relay Float works? 2 Yes or No

1. Float Switch
• With ignition switch in the “OFF” position.
• Disconnect (X84) connector from float switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X84, between (2) and (3), button pressed. 0.0 to 1.0Ω 3
A. Switch test Resistance Ω
At switch X84, between (2) and (3), button released. (OL) open 4

2. Float Valve
• With ignition switch in the “OFF” position.
• Disconnect (X34) connector from float valve and isolate valve.
• Zero meter leads for proper Ω readings.

At valve X36, between (1) and (2) 10.7Ω 5

A. Valve test Resistance Ω
At valve X36, between (1) or (2) and chassis ground. (OL) open 6

3. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X34) connector from float valve and isolate connector.
• Disconnect (K04) relay.
• Disconnect (X84) connector from float switch and isolate connector.
• Disconnect (X81) and (X50) connector from control panel and electronic unit. Install T-adapter on (X50) and (X81) wiring harness
connector only
• * Ignition switch must be on for this test.

* At connector X84, (2) and chassis ground. 12 to15V 7

* At connector X34, (2) and chassis ground,

Voltage 12 to15V 8
button pressed with relay installed.

* At connection X89, (86), (30) and chassis ground. 12 to15V 9

A. Open or high Between connector X89, (87) and X34, (2) 0.0 to 1.0Ω 10
resistance
Between connector X89, (87) and X81, (4) 0.0 to 1.0Ω 11

Resistance Ω Between connectors X89, (85) and X50, (12) 0.0 to 1.0Ω 12

Between connectors X84, (3) and X50, (12) 0.0 to 1.0Ω 13

At connection X34, (1) and chassis ground. 0.0 to 1.0Ω 14

SK1020-5N, SK1020-5NA 20-167

TESTING AND ADJUSTING FLOAT CONTROL MALFUNCTION

At connector X84, between (3) and chassis ground. (OL) open 15

At connector X84, between (2) and (3) (OL) open 16

At connector X34, between (2) and (1) (OL) open 17

B. Short to chassis At connector X89, between (87) and chassis ground. (OL) open 18
ground or within Resistance Ω
harness At connector X89, between (85) and chassis ground. (OL) open 19

At connector X34, between (2) and chassis ground. (OL) open 20

At connector X89, between (30), (86) and (87) (OL) open 21

At connector X89, between (30), (86) and (85) (OL) open 22

Related Circuit Diagram

20-168 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING PARKING BRAKE SYSTEM MALFUNCTION
12
PARKING BRAKE SYSTEM MALFUNCTION
• The parking brake will not set or will not release.
Contents Of Trouble
• The parking brake will not remain set.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

Float Control Relay — Replace relay (K14) with known good relay Brake works? 1 Yes or No

1. Brake Switch
• With ignition switch in the “OFF” position.
• Disconnect (X87) connector from brake switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X87, between (2) and (3), button pressed. 0.0 to 1.0Ω 2
A. Switch test Resistance Ω
At switch X87, between (2) and (3), button released. (OL) open 3

2. Brake Valve and Switch

• With ignition switch in the “OFF” position.
• Disconnect (X35) connector from brake valve and isolate valve.
• Disconnect (X37) connector from brake pressure switch and isolate switch.
• Zero meter leads for proper Ω readings.

At valve X35, between (1) and (2) 7.4Ω 4

At valve X35, between (1) or (2) and chassis ground. (OL) open 5

A. Valve and switch test Resistance Ω At switch X37, between (1) and chassis ground,
5.35Ω 6
brake set.

At switch X37, between (1) and chassis ground,

(OL) open 7
brake released.

3. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X87) connector from brake push button switch and isolate connector.
• Disconnect (K14) relay.
• Disconnect (X35) connector from brake valve and isolate connector.
• Disconnect (X37) connector from brake pressure switch and isolate connector.
• Disconnect (X80), (X81) and (X50) connector from control panel and electronic unit. Install T-adapter on (X80), (X81) and (X50),
wiring harness connector only

Between connector X87, (6) and X50, (16) 0.0 to 1.0Ω 8

Between connector X87, (3) and X80, (8) 0.0 to 1.0Ω 9

Between connectors X87, (2) and X50, (23) 0.0 to 1.0Ω 10

Between connector X87, (7) and X80, (8) 0.0 to 1.0Ω 11

A. Open or high
Resistance Ω
resistance
Between connector X37, (1) and X81, (3) 0.0 to 1.0Ω 12

Between connectors X35, (1) and X44, (2) 0.0 to 1.0Ω 13

At connection X35, (2) and chassis ground. 0.0 to 1.0Ω 14

Between connectors X44, (1) and X50, (17) 0.0 to 1.0Ω 15

SK1020-5N, SK1020-5NA 20-169

TESTING AND ADJUSTING PARKING BRAKE SYSTEM MALFUNCTION
12
Between connectors X44, (3) and X50, (17) 0.0 to 1.0Ω 16

At a diode X44, between point (4) and X80 (16) Continuity one
B. Diode test Resistance Ω 17 Yes or No
reverse meter lead polarity each time to check diode. way only?

At connector X87, between (6) and chassis ground. (OL) open 18

At connector X87, between (3) and chassis ground. (OL) open 19

At connector X87, between (6) and (3) (OL) open 20

At connector X87, between (2) and (7) (OL) open 21

At connector X87, between (2) and chassis ground. (OL) open 22

At connector X87, between (7) and chassis ground. (OL) open 23

C. Short to chassis
At connector X37, between (1) and chassis ground. (OL) open 24
ground or within Resistance Ω
harness At connector X35, between (1) and (2) (OL) open 25

At connector X35, between (1) and chassis ground. (OL) open 26

At connector X44, between (1), (3) and (2) (OL) open 27

At connector X44, between (1), (3) and (4) (OL) open 28

At connector X44, between (1) or (3) and

(OL) open 29
chassis ground.

At connector X44, between (2) and chassis ground. (OL) open 30

Related Circuit Diagram

20-170 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING PATTERN CHANGE MALFUNCTION
12
PATTERN CHANGE MALFUNCTION
Contents Of Trouble • Pattern change feature cannot be changed.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU06 Fuse good? 1 Yes or No

1. Pattern Change Switch

• With ignition switch in the “OFF” position.
• Disconnect (X94) connector from pattern change switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X94, between (1) and (2), switch closed. 0.0 to 1.0Ω 2

At switch X94, between (1) and (2), switch open. (OL) open 3
A. Switch test Resistance Ω
At switch X94, between (3) and (4), switch closed. 0.0 to 1.0Ω 4

At switch X94, between (3) and (4), switch open. (OL) open 5

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X94) connector from pattern change switch and isolate connector.
• Disconnect (X93) connector from pattern DX and isolate connector.
• Disconnect (X92) connector from pattern SX and isolate connector.
• * Ignition switch must be on for this test.

Voltage * At connector X94, (2), (3) and chassis ground. 12 to15V 6

Between connectors X94, (4) and X92 (1) 0.0 to 1.0Ω 7

Between connectors X94, (1) and X93 (3) 0.0 to 1.0Ω 8

A. Open or high
Between connector X93, (2) and chassis ground. 0.0 to 1.0Ω 9
resistance
Resistance Ω
Between connector X92, (2) and chassis ground. 0.0 to 1.0Ω 10

Between connectors X94, (4) and X93 (1) 0.0 to 1.0Ω 11

Between connectors X94, (1) and X92 (3) 0.0 to 1.0Ω 12

At connector X94, between (4) and chassis ground. (OL) open 13

B. Short to chassis At connector X94, between (4) and (3) (OL) open 14
ground or within Resistance Ω
harness At connector X94, between (1) and chassis ground. (OL) open 15

At connector X94, between (2) and (1) (OL) open 16

SK1020-5N, SK1020-5NA 20-171

TESTING AND ADJUSTING PATTERN CHANGE MALFUNCTION
12
Related Circuit Diagram

20-172 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING STABALIZER SYSTEM MALFUNCTION
12
STABALIZER SYSTEM MALFUNCTION
Contents Of Trouble • Stabilizer system does nor work properly or does not work.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU06 Fuse good? 1 Yes or No

B. Fuse — Check condition of fuse FU04 Fuse good? 2 Yes or No

1. Left Stabilizer Switch

• With ignition switch in the “OFF” position.
• Disconnect (X106) connector from left stabilizer switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X106, between (1) and (3), switch in

0.0 to 1.0Ω 3
position 1.

At switch X106, between (7) and (3), switch in

0.0 to 1.0Ω 4
position 2.
A. Switch test Resistance Ω
At switch X106, between (7) and (3), switch in
(OL) open 5
position 0.

At switch X106, between (1) and (3), switch in

(OL) open 6
position 0.

2. Right Stabilizer Switch

• With ignition switch in the “OFF” position.
• Disconnect (X107) connector from right stabilizer switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X107, between (1) and (3), switch in

0.0 to 1.0Ω 7
position 1.

At switch X107, between (7) and (3), switch in

0.0 to 1.0Ω 8
position 2.
A. Switch test Resistance Ω
At switch X107, between (7) and (3), switch in
(OL) open 9
position 0.

At switch X107, between (1) and (3), switch in

(OL) open 10
position 0.

SK1020-5N, SK1020-5NA 20-173

TESTING AND ADJUSTING STABALIZER SYSTEM MALFUNCTION
12
3. Wiring Harness Assembly Test
• With ignition switch in the “OFF” position.
• Disconnect (X91) connector from switch EV ENPI and isolate connector.
• Disconnect (X106) connector from left stabilizer button and isolate connector.
• Disconnect (X107) connector from right stabilizer button and isolate connector.
• * Ignition switch must be on for this test.

* At connector X106, (9) and chassis ground. 12 to15V 11

* At connector X106, (3) and chassis ground. 12 to15V 12

Voltage
* At connector X107, (9) and chassis ground. 12 to15V 13

* At connector X107, (3) and chassis ground. 12 to15V 14

Between connectors X107, (10) and X91 (10) 0.0 to 1.0Ω 15

Between connectors X107, (1) and X41 (3) 0.0 to 1.0Ω 16

A. Open or high
resistance
Between connector X107, (10) and chassis ground. 0.0 to 1.0Ω 17

Between connector X106, (10) and chassis ground. 0.0 to 1.0Ω 18

Resistance Ω
Between connectors X107, (7) and X41 (4) 0.0 to 1.0Ω 19

Between connectors X106, (10) and X91 (10) 0.0 to 1.0Ω 20

Between connectors X106, (1) and X41 (1) 0.0 to 1.0Ω 21

Between connectors X106, (7) and X41 (2) 0.0 to 1.0Ω 22

At connector X107, between (1) and chassis ground. (OL) open 23

B. Short to chassis At connector X107, between (7) and chassis ground. (OL) open 24
ground or within Resistance Ω
harness At connector X106, between (1) and chassis ground. (OL) open 25

At connector X106, between (7) and chassis ground. (OL) open 26

20-174 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING STABALIZER SYSTEM MALFUNCTION
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-175

TESTING AND ADJUSTING LOW OR WEAK TRAVEL, WEAK BRAKE-OUT FORCE
12
LOW OR WEAK TRAVEL, WEAK BRAKE-OUT FORCE
• Work equipment force is slow or weak.
Contents Of Trouble • Attachments work slow or have no power
• Slow travel or no high speed travel.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU06 Fuse good? 1 Yes or No

1. Super High Flow Detent Solenoid

• With ignition switch in the “OFF” position.
• Disconnect (X39) connector from detent solenoid and isolate solenoid.
• Zero meter leads for proper Ω readings.

At solenoid X39, between (1) and (2). 2

A. Solenoid test Resistance Ω At solenoid X39, between (1) or (2) and chassis
(OL) open 3
ground.

2. Detent Switch (S37)

• With ignition switch in the “OFF” position.
• Disconnect (X83) connector from left lever and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X83, between (1) and (5) switch closed. 0.0 to 1.0Ω 4

A. Switch test Resistance Ω At switch X83, between (1) and (5) switch open. (OL) open 5

At switch X83, between (5) and chassis ground. (OL) open 6

3. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X83) connector from left lever switch and isolate connector.
• Disconnect (X90) connector from relay unit and isolate connector.
• Disconnect (X39) connector from super high flow solenoid and isolate connector.
• * Ignition switch must be on for this test.

Voltage * At connector X83, (1) and chassis ground. 12 to 15V 7

Between connector X83, (5) and X90, (12) 0.0 to 1.0Ω 8

A. Open or high
Between connectors X39, (1) and X90, (13) 0.0 to 1.0Ω 9
resistance
Resistance Ω
Between connector X39, (1) and X83, (6) 0.0 to 1.0Ω 10

Between connector X39, (2) and chassis ground. 0.0 to 1.0Ω 11

At a diode X83, between point (6) and X83 (11) Continuity one
B. Diode test Resistance Ω 12 Yes or No
reverse meter lead polarity each time to check diode. way only?

At connector X39, between (1) and chassis ground. (OL) open 18

C. Short to chassis
ground or within Resistance Ω At connector X38, between (5) and chassis ground. (OL) open 19
harness
At connector X90, between (13) chassis ground. (OL) open 20

20-176 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING LOW OR WEAK TRAVEL, WEAK BRAKE-OUT FORCE
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-177

TESTING AND ADJUSTING WEAK TRAVEL, WEAK BREAK-OUT FORCE IN REVERSE
12
WEAK TRAVEL, WEAK BREAK-OUT FORCE IN REVERSE
• Work equipment force is slow or weak.
Contents Of Trouble • Attachments work slow or have no power
• Slow travel in reverse.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU06 Fuse good? 1 Yes or No

1. Reverse High Flow Detent Solenoid

• With ignition switch in the “OFF” position.
• Disconnect (X40) connector from detent solenoid and isolate solenoid.
• Zero meter leads for proper Ω readings.

At solenoid X40, between (1) and (2). 2

A. Solenoid test Resistance Ω At solenoid X40, between (1) or (2) and chassis
(OL) open 3
ground.

2. Detent Switch (S36)

• With ignition switch in the “OFF” position.
• Disconnect (X83) connector from left lever and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X83, between (1) and (4) switch closed. 0.0 to 1.0Ω 4

A. Switch test Resistance Ω At switch X83, between (1) and (4) switch open. (OL) open 5

At switch X83, between (4) and chassis ground. (OL) open 6

3. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X83) connector from left lever switch and isolate connector.
• Disconnect (X90) connector from relay unit and isolate connector.
• Disconnect (X39) connector from super high flow solenoid and isolate connector.
• * Ignition switch must be on for this test.

Voltage * At connector X83, (1) and chassis ground. 12 to 15V 7

A. Open or high Between connector X83, (4) and X90, (2) 0.0 to 1.0Ω 8
resistance
Resistance Ω Between connectors X40, (1) and X90, (1) 0.0 to 1.0Ω 9

Between connector X40, (2) and chassis ground. 0.0 to 1.0Ω 10

At connector X40, between (1) and chassis ground. (OL) open 11

B. Short to chassis
ground or within Resistance Ω At connector X38, between (4) and chassis ground. (OL) open 12
harness
At connector X40, between (1) and (2). (OL) open 13

20-178 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING WEAK TRAVEL, WEAK BRAKE-OUT FORCE IN REVERSE
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-179

TESTING AND ADJUSTING ROTATING BEACON INNOPERABLE
12
ROTATING BEACON INNOPERABLE
Contents Of Trouble • Top rotating beacon does not operate.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU07 Fuse good? 1 Yes or No

B. Fuse — Check condition of fuse FU04 Fuse good? 2 Yes or No

1. Beacon Switch
• With ignition switch in the “OFF” position.
• Disconnect (X88) connector from beacon switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X88, between (9) and (10). 3

A. Switch test Resistance Ω At switch X88, between (1) and (5) switch ON. 0.0 to 1.0Ω 4

At switch X88, between (1) and (5) switch OFF. (OL) open 5

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X88) connector from beacon switch and isolate connector.
• Disconnect (XP1A) connector from rotating beacon.
• * Ignition switch must be on for this test.

* At connector X88 (1) and chassis ground. 12 to15V 6

Voltage
* At connector X88 (9) and chassis ground. 12 to15V 7
A. Open or high
resistance Between connectors X88 (5) and XP1A (1) 0.0 to 1.0Ω 8
Resistance Ω
At connector X88 (10) and chassis ground. 0.0 to 1.0Ω 9

B. Short to chassis
ground or within Resistance Ω At connector X88, between (5) and chassis ground. (OL) open 10
harness

20-180 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING ROTATING BEACON INNOPERABLE
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-181

TESTING AND ADJUSTING REAR WORK LIGHTS WILL NOT OPERATE
12
REAR WORK LIGHTS WILL NOT OPERATE
Contents Of Trouble • Rear work lights will not operate.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU05 Fuse good? 1 Yes or No

B. Fuse — Check condition of fuse FU04 Fuse good? 2 Yes or No

1. Light Switch
• With ignition switch in the “OFF” position.
• Disconnect (X85) connector from light switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X85, between (9) and (10). 3

A. Switch test Resistance Ω At switch X85, between (1) and (5) switch ON. 0.0 to 1.0Ω 4

At switch X88, between (1) and (5) switch OFF. (OL) open 5

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X85) connector from light switch and isolate connector.
• Disconnect rear work lights connector and isolate connector.
• * Ignition switch must be on for this test.

* At connector X85 (1) and chassis ground. 12 to15V 6

Voltage
* At connector X85 (9) and chassis ground. 12 to15V 7
A. Open or high
resistance Between connectors X85 (5) and rear work lights. 0.0 to 1.0Ω 8
Resistance Ω
At connector X85 (10) and chassis ground. 0.0 to 1.0Ω 9

B. Short to chassis
ground or within Resistance Ω At connector X85, between (5) and chassis ground. (OL) open 10
harness

20-182 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING REAR WORK LIGHTS WILL NOT OPERATE
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-183

TESTING AND ADJUSTING HORN DOES NOT SOUND
12
HORN DOES NOT SOUND
Contents Of Trouble • When button is pressed the horn does not work.
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU06 Fuse good? 1 Yes or No

B. Fuse — Check condition of fuse FU03 Fuse good? 2 Yes or No

1. Horn Button
• With ignition switch in the “OFF” position.
• Disconnect (X83) connector from horn switch and isolate switch.
• Zero meter leads for proper Ω readings.

At switch X83, between (1) and (2) switch ON. 0.0 to 1.0Ω 3
A. Switch test Resistance Ω
At switch X83, between (1) and (2) switch OFF. (OL) open 4

2. Wiring Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X83) connector from horn switch and isolate connector.
• Disconnect (X113) connector from horn and isolate connector.
• Disconnect (X50) connector from electronic unit. Install T-adapter on (X50) wiring harness connector only.
• * Ignition switch must be on for this test.

* At connector X83 (1) and chassis ground. 12 to15V 5

Voltage
A. Open or high * At connector X50 (5) and chassis ground. 12 to15V 6
resistance
Between connectors X83 (2) and X50 (4). 0.0 to 1.0Ω 7
Resistance Ω
Between connectors X50 (7) and X113 (1). 0.0 to 1.0Ω 8

B. Short to chassis At connector X83, between (2) and chassis ground. (OL) open 9
ground or within Resistance Ω
harness At connector X50, between (7) and chassis ground. (OL) open 10

20-184 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING HORN DOES NOT SOUND
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-185

TESTING AND ADJUSTING POSSIBLE DEFECTIVE SAFETY RELAY UNIT
12
POSSIBLE DEFECTIVE SAFETY RELAY UNIT
• Engine will not crank or will not start.
Contents Of Trouble
• Charging system operates poorly
Tools and Procedures

• Digital Volt Ohm Meter. T-adapter kit.

• Do not mark on original page of service manual. Remove this page from the service manual and make a copy for recording information
while performing these tests.
• If you are unable to copy this page, record readings on a separate paper referring to the (No.) numbers listed on the right of the procedure.
• Follow each step throughout this procedure, do not skip steps, jump ahead or stop when a fault is found unless otherwise instructed to in the
procedure. It is important to complete all steps and record information for final analyzing.

Steps Circuit Diagnostic Procedures Specifications No. Readings

A. Fuse — Check condition of fuse FU10 Fuse good? 1 Yes or No

1. Safety Relay Harness Assembly Test

• With ignition switch in the “OFF” position.
• Disconnect (X08) connector from safety relay and isolate connector.
• Disconnect (XM) connector from starter motor and isolate connector.
• Disconnect (X11) connector from alternator and isolate connector.
• * Ignition switch must be on for this test.

* At connector XS1 (A) and chassis ground. 12 to15V 2

Voltage
* At connector X08 (1) and chassis ground. 12 to15V 3

Between connectors XS1 (B) and XM (1). 0.0 to 1.0Ω 4

A. Open or high
resistance Between connectors X08 (3) and S10 (C). 0.0 to 1.0Ω 5
Resistance Ω
Between connectors X08 (6) and X11 (3). 0.0 to 1.0Ω 6

Between connectors X08 (5) and chassis ground. 0.0 to 1.0Ω 7

At connector XS1, between (B) and chassis ground. (OL) open 9

B. Short to chassis At connector X08, between (1) and chassis ground. (OL) open 10
ground or within Resistance Ω
harness At connector X08, between (3) and chassis ground. (OL) open 11

At connector X08, between (6) and chassis ground. (OL) open 12

20-186 SK1020-5N, SK1020-5NA

TESTING AND ADJUSTING POSSIBLE DEFECTIVE SAFETY RELAY UNIT
Related Circuit Diagram

SK1020-5N, SK1020-5NA 20-187

TESTING AND ADJUSTING POSSIBLE DEFECTIVE SAFETY RELAY UNIT
12

MEMORANDUM

20-188 SK1020-5N, SK1020-5NA

 30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3

PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
CONTACT TERMINAL REMOVAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
STRIPPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
CRIMPING CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
INSERTION OF CONTACT TERMINAL (HD30 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
CONTACT TERMINAL REMOVAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
STRIPPING INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
CRIMPING CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
INSERTION OF CONTACT TERMINAL (DT TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
ENGINE FRONT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
ENGINE REAR SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
ENGINE HOOD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
REMOVAL OF ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
INSTALLATION OF ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
OPERATOR’S CAB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
TILTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
LOWERING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
REMOVING THE CAB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
INSTALLING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
WORK EQUIPMENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
REMOVING LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
INSTALLATION OF LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
REMOVING EQUIPMENT SUPPORT FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
INSTALLING SUPPORT FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28

SK1020-5N, SK1020-5NA 30-1

DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
AIR FILTER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
MUFFLER ASSEMBLY (SK1020-5N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
MUFFLER ASSEMBLY (SK1020-5N TURBO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
RADIATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
FUEL TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
ENGINE-PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
GEAR PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
ENGINE-PUMP COUPLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-47
PPC VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
CAB HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
WHEEL HUB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
WHEEL HUB DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
ASSEMBLY OF THE HUB WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
FINAL DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
LIFT AND BUCKET CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
REMOVAL OF LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
INSTALLATION OF THE LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
REMOVAL OF BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
INSTALLATION OF BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-59
WORK EQUIPMENT CYLINDER OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62

30-2 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
12
METHOD OF USING MANUAL
1. When removing or installing unit assemblies

A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal
operation; the order of work for the installation operation is not given.

B. Any special techniques applying only to the installation procedure are marked , and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example Explanation

(COMPONENT) REMOVAL Title of operation

WARNING!
Safety precautions to observe when performing an operation

1. XXX Text of or name of procedural step

A. Text of procedural step if 1 was procedural name

★ Technique or important point

Reference to a special technique during assembly or installation (note that

this symbol is right-aligned).

(COMPONENT) INSTALLATION Title of operation

• Installation is the reverse of removal. Overall directive

Special technique during assembly or installation (note that this symbol is

left-aligned).

Specification
(Component/assembly)

2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when performing out
the operation.

3. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure,
see the SPECIAL TOOL LIST later in this section.

SK1020-5N, SK1020-5NA 30-3

DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
12
PRECAUTIONS DURING OPERATION
★ Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or
assembly) of units.

PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK

• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places before removal
to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the
connectors.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
★ Precautions when handling piping during disassembling
• Fit the following blind plugs into the piping after disconnecting it during disassembly operations.

1. Hoses and tubes using sleeve nuts

Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set

02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)

03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)

04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)

05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)

06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)

10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)

12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)

2. Split flange type hoses and tubes

Nominal number Flange (hose end) Sleeve head (tube end) Split flange

04 07379-00400 07378-10400 07371-30400

05 07379-00500 07378-10500 07371-30500

30-4 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
3. If the part is not under hydraulic pressure, the following corks can be
used:

Dimensions
Nominal
Part Number
number
D d L

06 07049-00608 6 5 8

08 07049-00811 8 6.5 11

10 07049-01012 10 8.5 12

12 07049-01215 12 10 15

14 07049-01418 14 11.5 18

16 07049-01620 16 13.5 20

18 07049-01822 18 15 22

20 07049-02025 20 17 25

22 07049-02228 22 18.5 28

24 07049-02430 24 20 30

27 07049-02734 27 22.5 34

PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three
drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage,
then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of
the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

SK1020-5N, SK1020-5NA 30-5

DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
12
PRECAUTIONS WHEN COMPLETING THE OPERATIONS
• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate
the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.

OTHER PRECAUTIONS
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters,
check that the oil container and area around the filler of the hydraulic tank are clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when
disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be
disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that
have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
• Do not use seal tape for the thread of the plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry
out thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the
air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air
from piston pump.
Remark
After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing
any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always
bleed the air as follows after completion of installation.

A. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without
going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.)
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.

B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.

C. Raise the engine speed and repeat Step B to bleed the air. Repeat this procedure until no more air comes out from the
plugs.

D. After completing bleeding the air, tighten the plugs.

Plug: 11.3 ±1.5 Nm (8.33 ±1.10 ft/lbs)

E. After repair or long storage, follow the same procedure.

30-6 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES
These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.

CONTACT TERMINAL REMOVAL (HD30 TYPE)

1. Obtain the correct removal tool according to the wire size used in
the connector.

2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.

Remark
Using a removal tool that is too large or too small will hinder wire
removal and may damage the connector or removal tool. Always
use the correct removal tool size for the wire gauge you are
servicing.

3. In a straight line, carefully slid the removal tool along the wire and
into the grommet until a contact resistance is felt.

Remark
Do not pull on the wire or twist the tool when inserting removal tool
into the grommet. Damage to the tool or connector may result.

4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.

5. If contact terminal-wire will not come out, remove tool and reinsert
removal tool again.

SK1020-5N, SK1020-5NA 30-7

DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
STRIPPING INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table

Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)

0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)

0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)

0460 - 215 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0460 - 204 - 0490 6 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 - .492)

Using wire insulation stripers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the “Strip Length” above.

Wire Inspection

After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.

30-8 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CRIMPING CONTACT TERMINAL (HD30 TYPE)
1. After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.

2. Loosen locknut, turn adjusting screw in until it stops.

3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.

4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.

5. Close crimp tool handle until crimp cycle is completed.

6. Release the tool handle and remove the crimped contact terminal.

7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.

Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.

SK1020-5N, SK1020-5NA 30-9

DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
INSERTION OF CONTACT TERMINAL (HD30 TYPE)
1. Grasp contact terminal approximately 25.2mm (1in) behind the
crimped barrel.

2. Holding connector with rear grommet facing you.

3. Insert completed contact terminal straight into connector grommet

until a positive stop is felt.

4. Once contact terminal is in connector, a slight tug will confirm that

the contact terminal is properly locked in place.

5. For unused wire cavities, insert sealing plugs for full environmental
sealing.

30-10 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CONTACT TERMINAL REMOVAL (DT TYPE)
1. Remove the wedge lock using needle nose pliers or a hooked
shaped wire.

2. Pull the wedge lock straight out and save for reinstallation.

3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.

4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.

SK1020-5N, SK1020-5NA 30-11

DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
STRIPPING INSULATION
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the Deutsch Table below.
Deutsch Table

Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)

0460 - 202 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (.156 - .218)

0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (.250 - .312)

0460 - 215 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (.250 - .312)

0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (.222 - .284)

0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (.430 - .492)

0460 - 204 - 0490 6 AWG 10.92 - 12.47 (.430 - .492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (.430 - .492)

Using wire insulation stripers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed in
the “Strip Length” above.

Wire Inspection

After stripping insulation from wire, inspect wire strands for:

• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.

30-12 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CRIMPING CONTACT TERMINAL (DT TYPE)
1. After insulation has been striped from the wire and contact
terminal is ready for crimping, raise selector knob on
Crimp Tool #HDT48-00 and rotate until arrow is aligned with
wire size to be crimped.

2. Loosen locknut, turn adjusting screw in until it stops.

3. Insert contact terminal with barrel up. Turn adjusting screw

counterclockwise until contact terminal surface is flush with
indenter cover. Tighten locknut.

4. Insert wire into contact terminal. Be sure contact terminal is

centered between indicators.

5. Close crimp tool handle until crimp cycle is completed.

6. Release the tool handle and remove the crimped contact terminal.

7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.

Remark
The tool must be readjusted for each type/size of contact. Use
Crimp tool HDT04-08 for size 8 and 4 contacts.

SK1020-5N, SK1020-5NA 30-13

DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
INSERTION OF CONTACT TERMINAL (DT TYPE)
1. Grasp the crimped contact terminal approximately 25.2mm (1in)
behind the crimped barrel.

2. Hold the connector with the rear grommet facing you and insert the
completed wire into the connector.

3. Push the contact terminal straight into the connector until a “click”
is felt. A slight tug will confirm that the contact terminal is properly
locked in place.

4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The
wedge lock will snap into place. Rectangular wedges are not
oriented and may fit either way.

Remark
As the connector receptacle is shown - use the same procedures for
a plug.

30-14 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY ENGINE

ENGINE
Remark
Disassembly and assembly of the following components, see the ENGINE SHOP MANUAL.

ALTERNATOR

CYLINDER HEAD

ENGINE FRONT SEAL

ENGINE OIL COOLER

ENGINE REAR SEAL

FUEL INJECTION PUMP

NOZZLE HOLDER

THERMOSTAT

TURBOCHARGER

WATER PUMP

SK1020-5N, SK1020-5NA 30-15

DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY
12
ENGINE HOOD ASSEMBLY

WARNING! Before proceeding with any removal or disassembly procedures, be sure all work equip-
ment is on the ground and there controls neutralized. Be sure the parking brake is set and
the machine is on a flat level surface. Be sure the engine is in the OFF position and the
battery is disconnected.

REMOVAL OF ENGINE HOOD

1. Remove the retaining fasteners (1) from hinges (2) and (3).

2. While lifting the hood, remove the retaining nut (4) from the shock
strut (5).

WARNING! Engine hood: 18.5 kg (41 lbs)

INSTALLATION OF ENGINE HOOD

1. To install, reverse removal procedure.

2. Check and centre the lock engagement.

30-16 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12
OPERATOR’S CAB ASSEMBLY

TILTING THE CAB

1. Completely raise the working equipment and secure them in their
safety positions.

2. Loosen the four fasteners (1) and remove the foot-rest (2).

Remark
Only if the engine or the complete pump are to be removed. see
“REMOVIAL OF ENGINE HOOD”.

Front Door

3. Loose fasteners (3), remove the bracket (4) and close the front door.

4. Loosen the fasteners (5) (two to each side) and raise the cab as far
as the safety cables allow.

5. Insert the safety pin

★ If the engine or pump are to be removed, proceed as follows:

• Disconnect the four lines (6) on the RH side, the two
servo-control supply-lines (7), and the four lines (8) on the LH
side.
• To disconnect the lines, remove the retainer (9), push line (6)
completely inside the union (10) and extract the line (6).
• Mark the lines to avoid mixing them up during reassembly.

SK1020-5N, SK1020-5NA 30-17

DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12
6. Disconnect cable (12) from the accelerator lever and from the
engine (11).

With Heating System

8. Drain engine coolant from the system and disconnect the washer
hose from the washer tank.

9. Loosen the fastener (13) and remove clamp (14).

10. Remove the clamps (15).

11. Disconnect the heating system supply (16) and return (17) hoses
from the engine.
• Mark the lines to avoid exchanging them during reassembly.

12. Attach the cab (18) to hoist. Be sure hook and straps (23) are in
place

30-18 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12
13. Remove pin (19) and the washers (20).

14. Remove the safety pin.

15. Push cab (18) gently towards ”its at rest” position to relieve the
tension on the safety cables (21), and disconnect them from the pins
(22).

16. Apply a slight tension to the hoist-tackle chains to prevent the cab
from moving unexpectedly.

17. Tilt the cab (18) slowly until the distance between the centres of the
hooks (23) is 1100 mm (43 in).

18. The distance of 1100 mm (43 in) corresponds to the maximum

stretch of the dumper hooks.

19. Remove pins (22) from the dumper hooks (23).

20. Position a stand “A”, about 1200 mm (47 in) high, and tilt the cab
(18) until it is resting on the stand.
★ Make sure that the connecting cables between the cab and the
engine are not being strained.

LOWERING THE CAB

• To lower the cab back into position, reverse the procedures.

Fasteners: 98 ± 7.3 Nm (72 ± 5 ft/lbs)

• Connect all the fluid lines.

• Check to be sure all connections are correct.
• Adjust the stroke of the accelerator lever cable. (For details, see
“20. TESTING ADJUSTING AND TROUBLSHOOTING”).

• Fill the cooling system.

• Start the engine to circulate the coolant. Stop the engine and check the level.

SK1020-5N, SK1020-5NA 30-19

DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12
REMOVING THE CAB ASSEMBLY

1. Remove the working equipment. (For details, see “REMOVING

WORK EQUIPMENT”).

2. Loosen nuts (1) and tilt the rear panel (2) towards the front of the
machine.

3. Disconnect connectors (3) from the cab cabling (4) and release the
engine cable (5) from its retaining clamps.

4. Tilt the cab. (For details, see “TILTING THE CAB”).

5. Disconnect the four lines (6) on the RH side, the two servo-control
feed-lines (7) and the four lines (8) on the LH side.
• To disconnect the lines, remove the retainer (9) push line (6)
completely inside the union (10) and extract line (6).
• Mark all hoses to avoid any mix-up during reassembly.

6. Pull out cable (5).

30-20 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12
With Front Door

1. Loosen fastener (11) and remove clamp (12).

2. Remove clamps (13) the secure the lines.

3. Disconnect the heating systems supply (14) and return (15) hoses
from the engine and drain any engine coolant from the hoses.
★ Mark the hoses to avoid mixing them during installation.

4. Remove clamp (16) and disconnect the line (18) from washer tank
(17).

5. Disconnect the accelerator lever cable (19) from the engine (20).

SK1020-5N, SK1020-5NA 30-21

DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB ASSEMBLY
12
6. Connect the cab (21) to hoist and tackle.

7. Remove the safety pins (22) and the washers (23).

8. Push the cab slightly towards its “at rest” position to relieve the
strain on the safety cables (24), and disconnect the cables from the
pins (25).

9. Apply a slight tension to the chains of the hoist to prevent the cab
from moving about unexpectedly.

10. Tilt the cab (21) slowly until the distance between the centres of the
hooks is 1100 mm (43 in)

• The distance of 1100 mm (43 in) corresponds to the maximum

stretch of the hooks.

11. Remove the pins (25) from the hooks (26).

12. Loosen nuts (27) and remove the fasteners (28) and washers (29).

13. Remove the complete cab (21).

INSTALLING THE CAB

1. To install, reverse removal procedure.
• Install nuts (9) on the hoses and connect the pipes by
pushing them fully into their seats.
• Check the connections.

2. Adjust the accelerator lever cable. (For details,

see “20. TESTING ADJUSTING AND TROUBLESHOOTING”).
• Fill up the cooling system.
• Start the engine to circulate the coolant and check for leaks.
• Stop the engine, check the levels and, if necessary, top them off.

30-22 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
12
WORK EQUIPMENT SYSTEM

WARNING! Before proceeding with any removal or disassembly procedures, be sure all work equip-
ment is on the ground and there controls neutralized. Be sure the parking brake is set and
the machine is on a flat level surface. Be sure the engine is in the OFF position and the
battery is disconnected. Release hydraulic tank pressure.

REMOVING LIFT ARMS

1. Loosen fastener (1) and remove the pins (2) and (3).

For The RH Cylinder.

2. Disconnect the safety rod (4) from the boom (5).

For The Supper-Flow Version

3. Disconnect the electrical outlet (6) and its wiring from the boom
(5).

SK1020-5N, SK1020-5NA 30-23

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
4. Attach the complete boom to a hoist and tackle and raise it until the
hoses (7) connected to the frame become easily accessible.

5. Disconnect the hoses (7) and (8).

★ Mark the tubes to avoid exchanging them during reassembly.

6. Remove the pins (9) and (10) and remove the working equipment.
★ Check and make a note of the positions of the adjustments to a
given clearance.

Work equipment: 470 kg (1037 lbs)

INSTALLATION OF LIFT ARMS

• To install, reverse removal procedure.
• When aligning the positions between the hole and the pin, run the
engine at low idling.

WARNING! Do not insert fingers into the holes to

check alignment.

Inside the bushings: Lithium EP MS2 NLGI 2

• Insert shims between the boom and frame until the clearance is less than 1 mm. (0.04 in)
• Start the engine to circulate the oil, and bleed the air from the circuits.
• After bleeding the air, stop the engine and check the level of oil in the tank.

30-24 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT SYSTEM
12
REMOVING EQUIPMENT SUPPORT FRAME

1. Lower the working equipment until the supporting frame is lying

flat on some blocks “A”.

2. Remove pins (1) and retract the cylinder piston rods (2).

3. Make a note as to the positions of the adjustments to a given

clearance.

4. Remove pins (3) and take off the complete working equipment
support frame (4).

Equipment support frame: 57 kg (127 lbs)

INSTALLING SUPPORT FRAME

• To install, reverse removal procedure.
• Insert the removed shims and if necessary add more until the
residual clearance is less than 3 mm (0.1 in).
• When aligning the positions between the hole and the pin, run the
engine at low idle.

WARNING! Do not insert fingers into the holes to

check alignment.

Inside the bushings: Lithium EP MS2 NLGI 2

SK1020-5N, SK1020-5NA 30-25

DISASSEMBLY AND ASSEMBLY BATTERY
12
BATTERY

WARNING! When handling batteries always wear personal protective equipment including face
shield, rubber gloves and apron. Never allow an open flame or smoke around batteries,
explosive gasses may be present.

REMOVAL

1. Loosen fasteners and remove the cover (2).

2. Disconnect the negative cable (--) (3) first and the positive cable (+)
(4) next from the battery (5) in that sequence.

3. Loosen the nuts (6) that secure the battery clamp (7) and remove
the hold downs (8) of the battery support.

4. Tilt the battery clamp (7) towards the front of the machine and lift
out the battery.
• Disconnect the temperature sensor connector (9) from the
battery clamp (7)

INSTALLATION
• To replace, reverse removal procedure.

30-26 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY STARTER MOTOR
12
STARTER MOTOR

REMOVAL
1. Tilt the cab and secure it in its safety position.

2. Remove the battery (1). (For details, see “BATTERY”).

3. Disconnect all cables (2) and (3).

Remark
Do not allow the starter motor to hang from the cables, damage
to the cables may result.

4. Loosen the fasteners (4) and remove the starting motor

INSTALLATION
• To install, reverse removal procedure.

SK1020-5N, SK1020-5NA 30-27

DISASSEMBLY AND ASSEMBLY ALTERNATOR
12
ALTERNATOR

REMOVAL

1. Remove the battery.

2. (For details, see “BATTERY”).

3. Tilt the cab. (For details, see “TILTING THE CAB”).

4. Disconnect the cable (1), (2) and the connectors (3).

5. Loosen fasteners (4) and (5) to allow the alternator move freely.

6. Remove fan belt (6) from the pulley and remove the alternator (7).

INSTALLATION
• To install, reverse removal procedure.
• Adjust the tension of the fan-belt. (For details, see “20. TESTING
ADJUSTMENTS AND TROUBLESHOOTING”).

30-28 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY AIR FILTER ASSEMBLY
12
AIR FILTER ASSEMBLY

REMOVAL

1. Disconnect the battery negative cable (-).

2. Loosen clamp (1) and remove the inlet hose (2).

3. For SK1020-5N turbo. Loosen clamp (1) and remove the

inlet hose (2).

4. Remove clamp (3).

5. Disconnect connector (4).

6. Loosen the clamps (5) and remove hose (6).

7. Loosen the bolts (7) and remove the complete air

filter assembly (8).

INSTALLATION
• To install, reverse removal procedure.

SK1020-5N, SK1020-5NA 30-29

DISASSEMBLY AND ASSEMBLY MUFFLER ASSEMBLY (SK1020-5N)
12
MUFFLER ASSEMBLY (SK1020-5N)

REMOVAL

1. Loosen the clamp (1) and remove the inlet hose (2).

2. Loosen nuts (3) and the fasteners (4) from muffler support (5) and
remove.

3. Loosen clamps (6), remove the support (7) and cover (8).

4. Loosen fasteners (9) that hold the muffler (10) in place and support
(11).

30-30 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY MUFFLER ASSEMBLY (SK1020-5N)
12
5. Loosen nut (12) and remove muffler (10).

6. A new gasket (13) should be installed each time the muffler is

removed.

INSTALLATION
• To install, reverse removal procedure.

SK1020-5N, SK1020-5NA 30-31

DISASSEMBLY AND ASSEMBLY MUFFLER ASSEMBLY (SK1020-5N TURBO)
12
MUFFLER ASSEMBLY (SK1020-5N TURBO)

REMOVAL

1. Loosen clamp (1) and remove inlet hose (2).

2. Remove the heat shield (3) and remove fasteners (4).

3. Remove the fasteners (5) and the shield (6).

4. Loosen and remove bolt (7) that secures the muffler (8).

5. Remove the four nuts (9) that secure the muffler (8) to the
turbocharger (10).

30-32 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY MUFFLER ASSEMBLY (SK1020-5N TURBO)
6. Remove muffler (8).
★ A new gasket (11) should be installed each time the muffler is
removed.

INSTALLATION
• To install, reverse removal procedure.

SK1020-5N, SK1020-5NA 30-33

DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
12
RADIATOR ASSEMBLY

REMOVAL

1. Completely raise the working equipment and tilt the cab. (For
details, see “TILTING THE CAB”).

2. Drain the hydraulic oil.

Hydraulic oil: max. 32 L (8.5 gal)

3. Drain the coolant:

Coolant: max. 15 L (4 gal)

4. Disconnect hose (2) from the pump (1).

5. Open the coolant drainage cock (3) on the radiator.

6. Disconnect the wire (4) from the hydraulic-oil filter.

7. Loosen the clamp (5) and disconnect the coolant delivery line (6).

8. Disconnect the coolant return line (7).

9. Attach the radiator group (8) to hoist and tackle and apply a slight
tension to the cables.

10. Loosen the fasteners (9) and raise the radiator group (8) until the
lower supports are free.

11. Move assembly way away from the frame.

12. Disconnect the back-up alarm connector (10).

13. Disconnect the lines (11) and (12) and remove the complete
assembly (8).

30-34 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
12
INSTALLATION

★ To install, reverse removal procedure.

1. Fill the hydraulic oil to maximum level.

Hydraulic oil: approx. 32 L (8.5 gal)

2. Fill the coolant to maximum level.

Coolant: approx. 15 L (4 gal)

3. Start the engine to circulate the oil and coolant, and check for leaks.

4. Stop the engine, check the levels and, if necessary, top them off.

Fasteners: 190 Nm (80 ft/lbs)

5. Pressurizes the tank and bleed the air from all circuits. (For details, see “20. TESTING ADJUSTING AND
TROUBLESHOOTING”).

SK1020-5N, SK1020-5NA 30-35

DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
12
FUEL TANK ASSEMBLY

REMOVAL

★ Drain the fuel.

Fuel: max 72 L (20 gal)

1. Remove fasteners (1) and loosen the fastener (2), leaving them in
place.

2. Loosen fastener (3) and remove the support (4).

With Front Door

3. Remove the washer tank (5).

4. Disconnect the return (7) line from filter (6) and the delivery line
(9) from bottle (8).

5. Loosen fastener (10) that secure the front bracket

30-36 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY FUEL TANK ASSEMBLY
6. Loosen fastener (12) that secure the rear bracket (13).

7. Disconnect wire connector (14) from the level sensor.

8. Raise the tank (15) and move it towards the front of the machine.

INSTALLATION
• To install, reverse removal procedure.

SK1020-5N, SK1020-5NA 30-37

DISASSEMBLY AND ASSEMBLY ENGINE-PUMP ASSEMBLY
12
ENGINE-PUMP ASSEMBLY

REMOVAL

1. Tilt the cab until it is resting on a support.

(For details, see “TILTING THE CAB”).

2. Remove the battery. (For details, see “BATTERY”).

3. Drain the engine coolant.

Liquid: max. 15 L (4 gal)

4. Drain the hydraulic oil.

Oil: max. 50 L (13 gal)

5. Drain the fuel.

Fuel: max. 72 L (20 gal)

6. Remove the radiator assembly.

(For details, see “RADIATOR ASSEMBLY”).

7. Remove the cover on the control unit (1), loosen the nuts (2) and
disconnect the control unit (3) from frame.

8. Disconnect the connectors X10 (4), X01 (5), X42 (6) and X02 (7)
that connect the control unit (1) to the engine and frame wiring
harness.

30-38 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY ENGINE-PUMP ASSEMBLY
9. Loosen fastener (8) and remove the pre-heater fuse (9).

10. Disconnect the fuel level sensor (11) connector (10).

With Heating System

11. Loosen fastener (12) and remove the clamp (13).

12. Remove the clamps (14).

13. Disconnect the heating system supply (15) and return (16) hoses
from the engine and drain any engine coolant from the hoses.
★ Mark the lines to avoid mixing them up during reassembly.

SK1020-5N, SK1020-5NA 30-39

DISASSEMBLY AND ASSEMBLY ENGINE-PUMP ASSEMBLY
14. Remove clamp (17), disconnect the line (19) and connector (20)
from tank (18).

15. Disconnect the throttle cable (22) from engine (21).

16. Disconnect the sensor connector on the accelerator cable support.

17. Disconnect the delivery (25) and return (26) lines from container
(23) and filter (24).

18. Disconnect the lines (28), (29) and (30) from the pump (27).
★ Mark the lines to avoid mixing them up during reassembly.

30-40 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY ENGINE-PUMP ASSEMBLY
19. Disconnect the pipes (31), (32), (33) and (34) from the pump.
★ Mark the lines to avoid mixing them up during reassembly.

20. Attach the engine-pump group to hoist and tackle and apply a slight
tension to the cables.

21. Loosen the four nuts (35) that secure the engine and remove the
complete assembly.

Engine-pump group: 335 kg (739 lbs)

INSTALLATION
• To install, reverse removal procedure.

1. Adjust the accelerator cables.

(For details, see ´20. “TESTING ADJUSTING AND TROUBLESHOOTING”)

2. Fill the hydraulic oil tank up to maximum level.

3. While filling the tank, bleed the air from the pump.
(For details, see ´20. “TESTING ADJUSTING AND TROUBLESHOOTING”).

Hydraulic oil: approx. 32 L (8.5 gal)

4. Fill the cooling system up to maximum level.

Coolant liquid: approx. 15 L (4 gal)

5. Fill the fuel tank and bleed the air from the system.
(For details, see ´20. “TESTING ADJUSTING AND TROUBLESHOOTING”).

6. Start the engine to circulate the oil and coolant and check for leaks.

7. Stop the engine, check the levels and, if necessary, top them off.

8. Bleed the air from the hydraulic circuits and pressurize the tank.
(For details, see “20. TESTING ADJUSTING AND TROUBLESHOOTING”).

Engine nuts: 80 Nm (60 ft/lbs)

SK1020-5N, SK1020-5NA 30-41

DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
12
HYDRAULIC PUMP ASSEMBLY

REMOVAL

1. Fully raise the working equipment and tilt the cab. (For details, see “TILTING THE CAB”).

2. Drain the hydraulic oil.

Hydraulic oil: max. 50 L (13.2 gal)

3. Disconnect the pipes (2), (3) and (4) from the pump (1).
★ Mark all lines to avoid mixing them up during reassembly.

4. Disconnect lines (5), (6), (7), and (8) from the pump.
★ Mark all lines to avoid mixing them up during reassembly.

5. Disconnect the servo-control pressure sensor connectors (9) and

disconnect the support (10) from the engine (11).

30-42 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
12
6. Attach the pump (1) to a hoist tackle and apply a slight tension to
the cables.

7. Loosen the eight fasteners (12) and remove the pump (1) complete
with the bell housing (13).

WARNING! Pump: 98 kg (216 lbs)

8. Loosen the fastener (14) and disconnect the pump (1) from bell
housing (13).

SK1020-5N, SK1020-5NA 30-43

DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
12
• To install, reverse removal procedure.

Flange screws: 80 Nm (60 ft/lbs)

Flange screws: Loctite 262

Pump shaft: Litio EP MS2 NLGI2

Pump screws: 195 Nm (145 ft/lbs)

Pump screws: Loctite 262

1. Fill the tank up to maximum level.

Hydraulic oil: max. 32 L (24 gal)

2. Bleed the air from the pump. (For details, see “20. TESTING ADJUSTING AND TROUBLESHOOTING”).

3. Fill the coolant to maximum level.

4. Start the engine to circulate the oil and check that there are no leaks.

5. Stop the engine, check the levels and, if necessary, top them up.

6. Bleed the air from the hydraulic circuits and pressurizes the tank.
(For details, see “20. TESTING ADJUSTING AND TROUBLESHOOTING”).

30-44 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY GEAR PUMP ASSEMBLY
12
GEAR PUMP ASSEMBLY

REMOVAL

1. Fully raise the working equipment and tilt the cab. (For details, see
“TILTING THE CAB”).

2. Drain the hydraulic oil.

Hydraulic oil: max. 50 L (38 gal)

3. Disconnect from pump (1) the suction line (2) and (3) (one for the
normal version, two for the HIGHFLOW version).

4. Loosen the two fasteners (4) and remove the pump (1) complete
with the O-ring (5).

INSTALLATION
• To install, reverse removal procedure.

Fasteners: 59-74 Nm (45-55 ft/lbs)

SK1020-5N, SK1020-5NA 30-45

DISASSEMBLY AND ASSEMBLY ENGINE-PUMP COUPLING
12
ENGINE-PUMP COUPLING

REMOVAL

1. Fully raise the working equipment and tilt the cab.

(For details, see “TILTING THE CAB”).

2. Remove the pump. (For details, see “HYDRAULIC PUMP”).

Half-coupling On Pump

1. Loosen dowel (1) that secures the coupling (2).

2. Heat the dowel at 85-100 °C (185-212 °F) temperature.

3. Remove the pump coupling (2).

4. Use an extractor if necessary.

Half-coupling On Flywheel

1. Remove fastener (3) and the flange (4).

INSTALLATION
• To install, reverse the removal procedure.

Coupling fastener: Loctite 262

Coupling fastener: 195 Nm (144 ft/lbs)

Flange fastener: Loctite 262

Flange fastener: 80 Nm (70 ft/lbs)

1. Fill the tank up to maximum level bleed the air from piston pump and pressurize the tank. (For details, see ´20. TESTING
ADJUSTING AND TROUBLESHOOTING”).

2. Start the engine to circulate the oil and check for leaks.

3. Stop the engine, check the levels and, if necessary, top them up.

30-46 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY CONTROL VALVE
12
CONTROL VALVE

REMOVAL

1. Fully raise the working equipment and tilt the cab. (For details, see
“TILTING THE CAB”).

2. Release residual pressures from all circuits and from the tank.
(For details, see “20. TESTING ADJUSTING AND
TROUBLESHOOTING”).

3. Drain the hydraulic oil.

Hydraulic oil: max. 50 L (13 gal)

4. Disconnect from the control valve (1) the servo-control lines (2), the delivery lines to the actuators, and the delivery and
return lines (3).
★ Mark all lines to avoid mixing them up during reassembly.

5. Loosen the three fasteners (4) and remove the control valve (1).

Control valve: max. 24 kg (53 lbs)

INSTALLATION
1. To install, reverse removal procedure.

Control valve screws:35 Nm (26 ft/lbs)

2. Fill the hydraulic oil tank up to maximum level.

Hydraulic oil: max. 32 L (8.5 gal)

3. Start the engine and run at low idle to circulate the oil throughout the system.

4. Pressurize the tank and bleed the air from all circuits.
(For details, see “20. TESTING ADJUSTING AND TROUBLESHOOTING”).

SK1020-5N, SK1020-5NA 30-47

DISASSEMBLY AND ASSEMBLY PPC VALVES
12
PPC VALVES

REMOVAL

1. Lower the working equipment until it is resting on the ground, stop

the engine and remove the ignition key.

2. Release residual pressures from all circuits and from the tank.
With Front Door

1. Remove the heater assembly. Raise the box cover (1) disconnect the
connectors (2) and remove the cover (1).

2. Disconnect the protective sleeve (3).

★ Take care not to damage the frame (4).

3. Loosen the four fasteners (5) and remove the casing (6).

4. Take out the three fasteners (7) and disconnect the PPC valve (8)
from the support (9).

5. Disconnect the six lines (10) from the PPC valve and plug the ends
to prevent entry of impurities.
★ Check and mark the lines to avoid mixing them up during
re-assembly.
INSTALLATION
• To install, reverse removal procedure.
Left Hand PPC Valve

Position
P T P1 P2 P3 P4
M S A R L R
White White Yellow Yellow Blue Blue

Right Hand PPC Valve

Position
P T P1 P2 P3 P4
M S D S C A
White White Red Red Yellow Yellow

• If the unions are removed from the PPC valves, make sure that a
union with a filter is mounted at the “P” inlet.
• Check the positions for the line connections carefully.

30-48 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY CAB HEATER ASSEMBLY

CAB HEATER ASSEMBLY

REMOVAL

1. Disconnect the negative terminal cable (-) from the battery.

2. Loosen the fastener (1) and remove the clamp (2).

3. Remove the hose retainer clamp (3).

4. Disconnect the heating systems supply (4) and return (5) hoses
from the engine and drain any engine coolant from the hoses.

5. Mark the hoses to avoid mixing them up during reassembly.

6. Loosen the fastener (6) and remove the front part of the air intake
line (7).

7. Remove the upper retaining fastener (8) from the heater assembly.

SK1020-5N, SK1020-5NA 30-49

DISASSEMBLY AND ASSEMBLY CAB HEATER ASSEMBLY
12
8. Remove the lower retaining screws (9) from the heater assembly.

9. Rotate the heater assembly (10) towards the inside of the machine
and remove the retainer clamp (11) from the washer pipe (12).

10. Disconnect the connector (13) and remove the heater assembly (10)
together with the supply and return hoses.

INSTALLATION
• To install, reverse removal procedure.

1. Fill the cooling system with engine coolant.

2. Start the engine to let the coolant circulate.

3. Stop the engine and top off.

30-50 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
12
WHEEL HUB ASSEMBLY

REMOVAL
1. Place the machine on blocks that are high enough to raise the
wheels off the ground, and fully raise the working equipment.

2. Loosen the nuts (1) and take off the tire (2).

3. Loosen the drain plug (3) in order to drain the chain and gearing
lube oil.

Gear-box oil: max. 15.5 L (5 gal)

4. To facilitate oil drainage, remove the vent plug (4).

5. Loosen the nuts (5) and take off the cover (6).
★ Check the condition of the seal (7) and install a new one if
necessary.

SK1020-5N, SK1020-5NA 30-51

DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
12
6. Start the engine and allow the pinion (8) to turn slowly until the
master links (9) are both positioned on the upper section of the
chain.

7. Remove the pins (10) and pull out the master link (9).

8. Turn the wheel hub (11) to release it from the chain.

9. Attach the complete hub assembly (11) to a hoist and tackle and
apply a slight tension to the cables.

10. Loosen the nuts (12) and remove the hub (11).

11. Check the condition of the O-ring and replace it if necessary.

Hub: 61 kg (134 lbs)

INSTALLATION
• To install, reverse removal procedure.

Nuts: 186 ± 9.8 Nm (137 ± 7 ft/lbs)

Nuts: 29 Nm (68 ft/lbs)

1. Make sure that the master link is in the correct position with respect
to the pinion.

2. Adjust the tension of the chains. (For details, see “20. TESTING
ADJUSTING AND TROUBLRSHOOTING”).

3. Fill the oil up to maximum level.

Transmission oil: max. 13.5 L (4 gal)

Nuts: 196 Nm (145 ft/lbs)

30-52 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
12
WHEEL HUB DISASSEMBLY

1. Remove the wheel hub (1). (For details, see “REMOVAL”).

2. Place the wheel hub (1) in a vice and loosen the fastener (2).

3. Remove the disk (3) and the shims (4).

★ Make a note of the number and positions of the shims (4).

4. Remove the sprocket gear (5).

★ Make a note of which way the sprocket gear (5) is facing with
respect to the hub (1)

5. Position the wheel hub (1) beneath a press and slowly extract the
axle shaft (6) until it is released from the inner ring (7).

6. Place the wheel hub (1) on two supports “A” about 520 mm
(20.4 in) high.

7. Remove the inner bearing (7).

8. Proceed with the removal of the axle shaft (6) until it is fully
removed from the bearing (8).

SK1020-5N, SK1020-5NA 30-53

DISASSEMBLY AND ASSEMBLY WHEEL HUB ASSEMBLY
12
9. Place the hub (1) in a vice and extract the seal ring (9).

10. Mount a new seal ring (9) each time the hub is dismantled.

11. Extract the outer rings (7) and (8).

ASSEMBLY OF THE HUB WHEEL

• To install, reverse removal procedure.

Fastener: 294 Nm (217 ft/lbs)

1. Take the existing measurement “X” between the axle shaft (6) and
the ring bevel gear (5).

2. Calculate the thickness of shims that should be inserted between the

disc (3) and the ring bevel gear (5) using the following formula:
S=X-Z
• S = the shim pack
• X = the measurement taken
• Z = residual clearance [0.05-0.125]
★ For example: clearance measured X = 0.570 Addition of two shims of 0.2 and one of 0.1

3. Check that the measurement X lies within the permissible limits.

4. Grease the bearings (7) and (8).

Bearings: Litio EP NLGI 2

5. Grease the lip of the seal ring (9).

Seal ring: Litio EP NLGI 2

30-54 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
12
FINAL DRIVE ASSEMBLY

REMOVAL

1. Disconnect the gearing chains (1) from the final drive (2).
(For details, see “WHEEL HUB”).

2. Remove the complete hydraulic pump.

(For details, see “HYDRAULIC PUMP ASSEMBLY”).

3. Disconnect from the final drive (2) the supply pipes (3), the speed
increment pipe (4) and the drainage pipe (5).
★ Cap all lines to prevent entry of impurities.

4. Attach the final drive (2) to some type of hoist and tackle and apply
a slight tension to the chains.

5. Loosen the 10 fastener (6) and remove the complete final drive (2).
★ Check the condition of the O-ring (7) and replace it with a new
one if necessary.

Final drive: 68 kg (450 lbs)

SK1020-5N, SK1020-5NA 30-55

DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
12
INSTALLATION
• To install, reverse removal procedure.
Grease the O-ring.

O-ring: Litio EP NLGI 2

Fasteners: 120 Nm (90 ft/lbs)

Fasteners: Loctite 270

30-56 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY LIFT AND BUCKET CYLINDERS
12
LIFT AND BUCKET CYLINDERS

REMOVAL OF LIFT CYLINDER

1. Lower the working equipment until it is resting on the ground.

2. Release residual pressures from all circuits. (For details,

see “20. TESTING ADJUSTING AND TROUBLESHOOTING”).

3. Loosen the fasteners (1) and remove the pin (2).

Only For The RH Cylinder

1. Disconnect the safety rod (3) from the boom (4).

2. Loosen clamps (5) and remove the protection (6).

3. Disconnect line (7).

★ Cap the line (7) and the union to prevent entry of impurities.

4. Disconnect line (8).

★ Cap the tube (8) and the union to prevent entry of impurities.

5. Loosen the screw (9) and remove the pin (10).

INSTALLATION OF THE LIFT CYLINDER

• To install, reverse removal procedure.
• Inside the bushings:

Lithium EP MS2 NLGI 2

Pin screws: 49 Nm (36 ft/lbs)

• When aligning the positions between the hole and the pin, run the
engine at low idling.
• Start the engine and bleed the air from the cylinder. (For details, see
“20. TESTING ADJUSTING AND TROUBLESHOOTING”).

WARNING! Do not insert fingers into the holes to

check alignment.

• After bleeding the air, check the level of oil in the tank.

SK1020-5N, SK1020-5NA 30-57

DISASSEMBLY AND ASSEMBLY LIFT AND BUCKET CYLINDERS
12
REMOVAL OF BUCKET CYLINDER

1. Lower the working equipment and rest the equipment support

frame on the ground.

2. Remove pin (1) and fully retract the piston rod (2).
★ Make a note as to the position of the adjustments and given
clearance.

3. Disconnect lines (4) and (5) from the cylinder (3).

★ Cap the lines to prevent entry of impurities.
★ Mark all lines to avoid mixing them up during reassembly.

4. Remove pin (6) and lift off cylinder (3).

★ Make a note as to the position of the adjustments in relation to
the given clearance.

30-58 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY LIFT AND BUCKET CYLINDERS

INSTALLATION OF BUCKET CYLINDER

• To install, reverse removal procedure.

WARNING! When aligning the positions between the hole and the pin, do not insert
fingers into the holes to check alignment.

• Inside the bushings:

Lithium EP MS2 NLGI 2

Pin screws: 49 Nm (36 ft/lbs)

1. Insert the removed shims and, if necessary, add more until the
residual clearance is about 1 mm (0.04 in).

2. Insert the removed shims and, if necessary, add more until the
residual clearance is about 1 mm (0.04 in).

3. Start the engine and bleed the air from the cylinder. (For details, see
“20. TESTING ADJUSTING AND TROUBLESHOOTING”).

4. After bleeding the air, check the level of oil in the tank

SK1020-5N, SK1020-5NA 30-59

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
12
WORK EQUIPMENT CYLINDER OVERHAUL

DISASSEMBLY

1. Take off the guard (1) from both sides of the cylinder and from the
piston rod.

2. Make sure the tube unions are not plugged.

3. Place the cylinder (2) on the apparatus “A”. Install cylinder in tool
“B”, having the same bushing diameter.

4. Attach the special wrench “C” (adjusted to fit the cylinder) to the
gland (3) and apply the impact tool “D”.

5. Unscrew the gland nut (3) and remove it completely from the
cylinder (2).

30-60 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
6. Raise the cylinder, piston and rod as a group using tool “A”.

7. Extract the piston rod assembly (4) from the cylinder.

8. Remove the cylinder (2) and the piston assembly.

9. Lock the complete piston and rod (4) onto the apparatus “A”.

10. Attach the wrench “E” to the lock nut (5) of the piston (6) and,
using the impact tool with a multiplier “D”, remove the nut.
★ Socket wrench measurement: 41 mm

11. Take all the parts and remove all the seals, guard rings and guide
rings.
★ The seals, guard rings, and guide rings cannot be re-used.

SK1020-5N, SK1020-5NA 30-61

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
12
ASSEMBLY
★ Be careful not to damage the seal and the sliding surfaces.
★ Prepare each individual component before commencing with the
final assembly.
Assembly Of The Gland Nut

1. Position the seal ring (7) and, using a press and push rod “F”, press
it in to the head (3).
★ Check the orientation carefully.

2. Install snap ring (8).

3. Using the tool “G”, install the lip-seal (9).

★ Be sure the lips face into the cylinder.

4. Install O-ring (10), and the anti-extrusion ring (11) and the O-ring
(12) on to the cylinder head (3).

Piston Assembly

1. Using the tool “H”, install the piston seal. Install the rubber ring
(13), the outer seal (14) and the anti-extrusion rings (15).

30-62 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
2. Install the guide ring (16).

3. Install gasket (14) to the piston (6), placing them on a press and
using the calibrating ring “J” attach and adjust the piston diameter.

Piston Rod Assembly

1. Using a press and tool “B” adjusted to the diameter, insert the
bushing (17) into the piston rod (4).

2. Insert the support “K” beneath the piston rod.

3. Install the pilot boss “L” set to the diameter onto the outside of the
piston rod.

4. Slide the gland nut (3) onto the piston rod (4).

5. Remove the pilot boss “L” from the outside of the piston rod.

6. Install the complete piston (6).

SK1020-5N, SK1020-5NA 30-63

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
7. Install nut (5) that secures the piston and tighten it with the wrench
“E” and the impact tool with a multiplier “D”.

Nut: Loctite 262

Nut: 1127 ± 112 Nm (831 ± 83 ft/lbs)

Cylinder Assembly

1. Set the tools “A” onto the apparatus “B”.

2. Position the bushing (20) and install it onto the cylinder (2).

3. Leave the cylinder in position, ready for the next assembly

operation.

4. Lubricate the threading and the first part of the cylinder (2).

Cylinder: Lithium EP NLGI 2

5. Place the two halves of the tool “M”, set to the diameter, onto the
end of the cylinder (2).

30-64 SK1020-5N, SK1020-5NA

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
6. Install the piston rod group (4) onto the tool “A” and raise the
movable part up to the end of its stroke.

7. Position the cylinder (2) into a vertical position and guide the piston
into the tool “M”.

8. Lower the apparatus supporting the piston rod (4) in order to insert
the piston into the cylinder liner (2).

9. Remove the tool “M” from the cylinder and then lower the
apparatus “A” even further, until the gland nut (3) and the piston
rod reach the cylinder.

10. Place the cylinder (2) in position for installing the gland nut (3).

11. Insert the gland nut into the cylinder and screw it in by hand for a
few turns.

12. Attach the special wrench “C” to the impact tool “D” and screw the
gland nut (3) into the cylinder.

Gland Nut: 490 ± 49 Nm (362 ± 36 ft/lbs)

13. Install the guard rings (1) on both sides of the cylinder and the
piston rod.

SK1020-5N, SK1020-5NA 30-65

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CYLINDER OVERHAUL
12

MEMORANDUM

30-66 SK1020-5N, SK1020-5NA

 90 OTHERS

ENGINE ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

FRAME LINE ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
FRAME LINE ELECTRICAL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
OPERATOR COMPARTMENT ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
TOP OPERATOR CAB ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31

SK1020-5N 90-1
OTHERS
12

MEMORANDUM

90-2 SK1020-5N
OTHERS ENGINE ELECTRICAL

ENGINE ELECTRICAL

SK1020-5N 90-3
OTHERS ENGINE ELECTRICAL

90-4 SK1020-5N
OTHERS ENGINE ELECTRICAL
12

FG1-General fuse 50A X12-Alternator frequency signal 1 way connector

G1-Battery 80Ah X13-Fuel pull stop solenoid 3 way connector
G2-Alternator X14-Fuel pump 2 way connector
K01-Pull solenoid relay X15-Preheat start C6 terminal
K02-Pull solenoid timer X16-Air filter clog sensor 2 way connector
K03-Safety relay X17-Fuel level sender 3 way connector
M1-Starter motor X18-Engine coolant temperature sensor 2 way connector
M2-Fuel pump X19-Hydraulic oil filter clog sensor C5 terminal
R1-Preheat start X20-Stop light pressure switch 2 way connector
R2-Fuel level sensor X21-Stop light pressure 2 switch 2 way connector
R3-Engine coolant temperature sensor X22-Back-up pressure 1switch 2 way connector
S25-Air filter clog sensor X23-Back-up pressure2 switch 2 way connector
S26-Hydraulic oil filter blockage sensor YO-Fuel stop solenoid
S27-Stop light pressure switch
S28-Stop light pressure switch
S29-Back-up alarm pressure switch
S30-Back-up alarm pressure switch
S13-Engine oil pressure sensor
V1-Diode
X01-Frame line 3 way connector
X02-Ground 2 way connector
X03-Pool solenoid relay 1 way connector

X04-Pool solenoid relay 2 way 90o connector

X05-Pool solenoid relay 1 way connector
X06-By-pass diode 2 way connector
X07-Pool solenoid timer 4 way connector
X08-Safety relay 4 way connector
X09-C5 Alternator terminal
X10-Frame line mark 13 way connector
X11-Alternator 2 way connector

SK1020-5N 90-5
OTHERS ENGINE ELECTRICAL
12

MEMORANDUM

90-6 SK1020-5N
OTHERS FRAME LINE ELECTRICAL

FRAME LINE ELECTRICAL

SK1020-5N 90-7
OTHERS FRAME LINE ELECTRICAL

90-8 SK1020-5N
OTHERS FRAME LINE ELECTRICAL

GND2-C8 Ground terminal

GND5-C6 Ground terminal
S32-PPC safety pressure switch
S33-Brake valve pressure switch
X01.1-Engine ground 3 way connector
X01.2-Engine ground 2 way connector
X10.1-Engine 13 way connector
X32-PPC safety pressure switch 1 way connector
X32A-PPC safety pressure switch 1 way connector
X33-PPC valve 2 way connector
X34-Float valve 2 way connector
X35-Brake valve 2 way connector
X36-Second speed valve 2 way connector
X37-Brake pressure switch 1 way connector
X45-Operators compartment 13 way connector
X46-Operator compartment 4 way connector
X47-Ground 2 way connector
X48-Operator compartment 5 way connector
Y1-PPC valve
Y2-Float valve
Y3-Second speed valve
Y6-Brake valve

SK1020-5N 90-9
OTHERS FRAME LINE ELECTRICAL
12

MEMORANDUM

90-10 SK1020-5N
OTHERS FRAME LINE ELECTRICAL (OPTIONAL)

FRAME LINE ELECTRICAL (OPTIONAL)

SK1020-5N 90-11
OTHERS FRAME LINE ELECTRICAL (OPTIONAL)

90-12 SK1020-5N
OTHERS FRAME LINE ELECTRICAL (OPTIONAL)

GND1-C8 Ground terminal Y6-Brake valve

GND2-C8 Ground terminal
GND5-C6 Ground terminal
S32-PPC safety pressure switch
S33-Brake valve pressure switch
X01.1-Engine ground 3 way connector
X01.2-Engine ground 2 way connector
X10.1-Engine 13 way connector
X32-PPC safety pressure switch 1 way connector
X32A-PPC safety pressure switch 1 way connector
X33-PPC valve 2 way connector
X34-Float valve 2 way connector
X35-Brake valve 2 way connector
X36-Second speed valve 2 way connector
X37-Brake pressure switch 1 way connector
X39-High-flow detente valve 2 way connector
X40-High-flow monetary valve 2 way connector
X41-Stabilizer 5 way connector
X42-Attachment 5 way connector
X43-ENPI valve 1 way connector
X45-Cabin line 13 way connector
X46-Cabin line 4 way connector
X47-Ground cabin line 2 way connector
X48-Cabin line 6 way connector
X49-Cabin line 11 way connector
Y1-PPC valve
Y2-Float valve
Y3-Second speed valve
Y4-Reverse high-flow momentary valve
Y5-Super flow detente valve

SK1020-5N 90-13
OTHERS FRAME LINE ELECTRICAL (OPTIONAL)

MEMORANDUM

90-14 SK1020-5N
OTHERS OPERATOR COMPARTMENT ELECTRICAL
12
OPERATOR COMPARTMENT ELECTRICAL

SK1020-5N 90-15
OTHERS OPERATOR COMPARTMENT ELECTRICAL

90-16 SK1020-5N
OTHERS OPERATOR COMPARTMENT ELECTRICAL
12

SK1020-5N 90-17
OTHERS OPERATOR COMPARTMENT ELECTRICAL
12

90-18 SK1020-5N
OTHERS OPERATOR COMPARTMENT ELECTRICAL

GND3-C6 Ground terminal S17-Case pattern switch X77-Fuse 1 way connector

FU01-Fuse 3A left side lights X44-Brake relay connector X78-Current intake 1 way connector
FU02-Fuse 3A control panel lights X45.1-From frame line 13 way connector X79-Current intake 1 way connector
FU03-Fuse 15A horn, front work lights X46.1-From frame line 4 way connector X80-Control panel 16 way connector
FU04-Fuse 7.5A switch lights X47.1-From frame line 2 way connector, ground X81-Control panel 8 way connector
FU05-Fuse 15A rear work lamps X48.1-From frame line 5 way connector X82-Lights line 11 way connector
FU06-Fuse 10A lever switch power supply, float X52-Buzzer 1 way connector X-83 Left lever 12 way connector
FU07-Fuse 10A current intake 12V, beacon light X53-Buzzer 1 way connector X84-Right lever 12 way connector
FU08-Fuse 10A control panel, electronic unit, fuel cut off, X54-Proximity bar 3 way connector X85-Rear work lights SWF switch
safety bar proximity, seat safety switch and brake switch X55-Safety seat switch 2 way connector X86-Panel and front lights SWF switch connector
FU09-Fuse 7.5A back-up alarm X56-Fuse 1 way connector X87-Brake push-button connector
FU10-Fuse 7.5A fuel pump, safety engine relay, alternator X57-Fuse 1 way connector X88-Beacon light switch connector
FU11-Fuse 30A pull solenoid coil, PPC safety pressure switch X58-Fuse 1 way connector X89-Float relay connector
HA1-Warning buzzer X59-Fuse 1 way connector X92-Left pattern light 3 way connector
K04-Float relay X60-Fuse 1 way connector X93-Right pattern light 3 way connector
K06-Electronic unit X61-Fuse 1 way connector X94-Pattern switch 4 way connector
K14-Brake relay X62-Fuse 1 way connector
P1-Control panel X63-Fuse 1 way connector
P2-Left display pattern X64-Fuse 1 way connector
P3-Right display pattern X65-Fuse 1 way connector
S01-Rear work lights switch X66-Fuse 1 way connector
S02-Panel lights and low beam light switch X67-Fuse 1 way connector
S07-Beacon light switch X68-Fuse 1 way connector
S08-Brake push button X69-Fuse 1 way connector
S10-Ignition switch X70-Fuse 1 way connector
S11-Seat safety switch X71-Fuse 1 way connector
S12-Bar PNP safety sensor X72-Fuse 1 way connector
S13-Horn button X73-Fuse 1 way connector
S14-Second speed push button X74-Fuse 1 way connector
S15-Float push button X75-Fuse 1 way connector
S16-ISO pattern switch X76-Fuse 1 way connector

SK1020-5N 90-19
OTHERS OPERATOR COMPARTMENT ELECTRICAL

MEMORANDUM

90-20 SK1020-5N
OTHERS OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)
12
OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)

SK1020-5N 90-21
OTHERS OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)

90-22 SK1020-5N
OTHERS OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)
12

SK1020-5N 90-23
OTHERS OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)
12

90-24 SK1020-5N
OTHERS OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)
12

SK1020-5N 90-25
OTHERS OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)
12

90-26 SK1020-5N
OTHERS OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)
12

GND3-C6 Ground terminal S01-Rear work lights switch X57-Fuse 1 way connector X88-Beacon light switch connector
FU01-Fuse 3A left side lights, plate light S02-Panel lights and low beam light switch X58-Fuse 1 way connector X89-Float relay connector
FU02-Fuse 3A control panel lights, right side lights S05-Up-down left stabilizer button X59-Fuse 1 way connector X90-Relay box 21 way connector
FU03-Fuse 15A horn, front work lights or low beam S06-Up-down right stabilizer button X60-Fuse 1 way connector X91-ENPI valve SWF connector
FU04-Fuse 7.5A switch lights S07-Beacon light switch X61-Fuse 1 way connector X92-Left pattern light 3 way connector
FU05-Fuse 15A rear work lamps, stop lights S08-Brake push button X62-Fuse 1 way connector X93-Right pattern light 3 way connector
FU06-Fuse 10A lever switch power supply, float S10-Ignition switch X63-Fuse 1 way connector X94-Pattern switch 4 way connector
FU07-Fuse 10A current intake 12V, beacon light S11-Seat safety switch X64-Fuse 1 way connector X106-Stabilizer push button connector
FU08-Fuse 10A control panel, electronic unit, fuel cut off, S12-Bar PNP safety sensor X65-Fuse 1 way connector X107-Stabilizer push button connector
safety bar proximity, seat safety switch and brake switch S13-Horn button X66-Fuse 1 way connector
FU09-Fuse 7.5A back-up alarm S14-Second speed push button X67-Fuse 1 way connector
FU10-Fuse 7.5A fuel pump, safety engine relay, alternator S15-Float push button X68-Fuse 1 way connector
FU11-Fuse 30A pull solenoid coil, PPC safety pressure switch S16-ISO pattern switch X69-Fuse 1 way connector
HA1-Warning buzzer S17-Case pattern switch X70-Fuse 1 way connector
HL1-Super-flow led diode S36-Reverse high-flow momentary push button X71-Fuse 1 way connector
HL2-”C” way led diode S37-Super-flow detente push button X72-Fuse 1 way connector
HL3-”A” way led diode S38-”C” way push button X73-Fuse 1 way connector
HL4-”B” way led diode S39-”A” way push button X74-Fuse 1 way connector
HL5-Optional diode S40-”B” way push button X75-Fuse 1 way connector
K04-Float relay X44-Brake relay connector X76-Fuse 1 way connector
K05-Relays box (without relays) X45.1-From frame line 13 way connector X77-Fuse 1 way connector
K06-Electronic unit X46.1-From frame line 4 way connector X78-Current intake 1 way connector
K07-”B” way relay X47.1-From frame line 2 way connector, ground X79-Current intake 1 way connector
K08-”A” way relay X48.1-From frame line 5 way connector X80-Control panel 16 way connector
K09-”C” way relay X49.1-From frame line 11 way connector X81-Control panel 8 way connector
K10-Super flow detente step relay X50-Safety control 23 way connector X82-Lights line 11 way connector
K11-Reverse high flow momentary relay X52-Buzzer 1 way connector X-83-Left lever 12 way connector
K14-Brake relay X53-Buzzer 1 way connector X84-Right lever 12 way connector
P1-Control panel X54-Proximity bar 3 way connector X85-Rear work lights SWF switch
P2-Left display pattern X55-Safety seat switch 2 way connector X86-Panel and front lights switch connector
P3-Right display pattern X56-Fuse 1 way connector X87-Brake push-button connector

SK1020-5N 90-27
OTHERS OPERATOR COMPARTMENT ELECTRICAL (OPTIONAL)

MEMORANDUM

90-28 SK1020-5N
OTHERS TOP OPERATOR CAB ELECTRICAL
12
TOP OPERATOR CAB ELECTRICAL

SK1020-5N 90-29
OTHERS TOP OPERATOR CAB ELECTRICAL

90-30 SK1020-5N
OTHERS HYDRAULIC CIRCUIT
12
HYDRAULIC CIRCUIT

SK1020-5N 90-31
OTHERS HYDRAULIC CIRCUIT

MEMORANDUM

90-32 SK1020-5N
Komatsu America Corp.
DataKom Publications & Training PROPOSAL FOR MANUAL OR CSS REVISION
440 North Fairway Drive
Vernon Hills, IL. 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847)-970-4186

DATE: FOR INTERNAL USE ONLY -- No.PMR

NAME OF COMPANY: CITY:

PROPOSER

STATE OR PROVINCE:

DEPARTMENT: COUNTRY:

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MANUAL DESCRIPTION: CSS PROGRAM - e.g: Lookup, Parts or Service

MANUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:

MANUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:

BOOK DESCRIPTION
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MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS

PROBLEM:

Attach photos or sketches.

If more space is needed, use another sheet.

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CORRECTIVE ACTION:

PROPFREV.FM 100903