PDF Shop Manual Komatsu CK20-1 Crawler Skid Steer Loader - 3 MB
This comprehensive shop manual provides full repair and service information for the Komatsu CK20-1 Crawler Skid Steer Loader.
It includes step-by-step instructions, diagrams, and specifications for all major systems.
From the engine to the hydraulic controls, this manual is the definitive resource for professional technicians.
Perform every repair with confidence using this factory guide.
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--- Page 1 ---
WEBM006400
CK20-1
CRAWLER SKID-STEER LOADER
SERIAL NUMBER
CK20-1 F00003 and up
--- Page 3 ---
STANDARD TIGHTENING TORQUE
3
2. TIGHTENING TORQUE FOR NUTS OF FLARED
Use these torques for nut part of flared.
Thread diameter Width across flats TIGHTENING TORQUE
of nut part of nut part
(mm) (mm) kgm Nm
1/2” - 20 17 2.6±0.5 25.5±4.9
9/16” - 18 17 4±0.5 39.2±4.9
3/4” - 16 22 6.7±2 65.7±19.6
7/8” - 14 27 8±2 78.5±19.6
1.1/16 - 12 32 9.7±3 95.15±29.4
1.5/16 - 12 38 17±3 166.7±29.4
1.5/8 - 12 50 20±5 196.2±49
22 27 8±2 78.5±19.6
33 41 20±5 196.2±49
Sealing surface
Use these torques for nut part of flared.
Thread diameter Width across flats TIGHTENING TORQUE
of nut part of nut part
(mm) (mm) kgm Nm
9/16” - 18 17 2.3–2.5 23–25
11/16” - 16 22 3.4–3.9 33–38
13/16” - 16 24 5.2–5.8 51–57
1” - 14 30 8.2–9.2 80–90
1.3/16 - 12 36 12.2–13.3 120–130
1.7/16 - 12 41 15.3–17.3 150–170
1.11/16 - 12 50 18.4–20.4 180–200
2” - 12 57 20.4–24.4 200–240
CK20-1 00-11
--- Page 4 ---
METHOD OF USING THE CONVERSION TABLE
From Nm to kgm
1 Nm = 0.102 kgm
0 1 2 3 4 5 6 7 8 9
0 0 0.102 0.204 0.306 0.408 0.510 0.612 0.714 0.816 0.918
10 1.020 1.222 1.224 1.326 1.428 1.530 1.632 1.734 1.836 1.938
20 2.040 2.142 2.244 2.346 2.448 2.550 2.652 2.754 2.856 2.958
30 3.060 3.162 3.264 3.366 3.468 3.570 3.672 3.774 3.876 3.978
40 4.080 4.182 4.284 4.386 4.488 4.590 4.692 4.794 4.896 4.998
50 5.100 5.202 5.304 5.406 5.508 5.610 5.712 5.814 5.916 6.018
60 6.120 6.222 6.324 6.426 6.528 6.630 6.732 6.834 6.936 7.038
70 7.140 7.242 7.344 7.446 7.548 7.650 7.752 7.854 7.956 8.058
80 8.160 8.262 8.364 8.466 8.568 8.670 8.772 8.874 8.976 9.078
90 9.180 9.282 9.384 9.486 9.588 9.690 9.792 9.894 9.996 10.098
100 10.200 10.302 10.404 10.506 10.608 10.710 10.812 10.914 11.016 11.118
110 11.220 11.322 11.424 11.526 11.628 11.730 11.832 11.934 12.036 12.138
120 12.240 12.342 12.444 12.546 12.648 12.750 12.852 12.954 13.056 13.158
130 13.260 13.362 13.464 13.566 13.668 13.770 13.872 13.974 14.076 14.178
140 14.280 14.382 14.484 14.586 14.688 14.790 14.892 14.994 15.096 15.198
150 15.300 15.402 15.504 15.606 15.708 15.810 15.912 16.014 16.116 16.218
160 16.320 16.422 16.524 16.626 16.728 16.830 16.932 17.034 17.136 17.238
170 17.340 17.442 17.544 17.646 17.748 17.850 17.952 18.054 18.156 18.258
180 18.360 18.462 18.564 18.666 18.768 18.870 18.972 19.074 19.176 19.278
190 19.380 19.482 19.584 19.686 19.788 19.890 19.992 20.094 20.196 20.298
CK20-1 00-21
--- Page 5 ---
STRUCTURE AND FUNCTION LOWER IDLER ROLLER
LOWER IDLER ROLLER
2-LIP TYPE
1
2
6
5 4 3 RKS04180
1. Roller 4. Shaft
2. Shoulder 5. Gasket
3. Bushing 6. Snap ring
3-LIP TYPE
1
2
6
5 4 3 RKS04190
1. Roller 4. Shaft
2. Shoulder 5. Gasket
3. Bushing 6. Snap ring
CK20-1 10-7
--- Page 6 ---
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HST PUMP LPV45 +45 (STANDARD FLOW AND HIGH FLOW)
FUNCTION
• The rotation and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurised 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)
4 2 5 6 14
3
15 (Standard version)
1
11
A 7 12 8 9 10 13 15 (High-flow version)
RKS04530
1. Shaft 6. Slider 11. Main bearing
2. Case 7. Shoe 12. Spline
3. Cradle bearing 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 • Piston (8) carries out relative movement in the axial
• Cylinder block (9) is supported to shaft (1) by a spline direction inside each cylinder chamber of cylinder
(12), and shaft (1) is supported by the front and rear block (9).
bearings (11), (13). • The cylinder block seals the pressurised oil to valve
• The tip of piston (8) is a concave ball, and shoe (7) is plate (10) and carries out relative rotation.
caulked to it to form one unit. Piston (8) and shoe (7) This surface is designed so that the oil pressure
form a spherical bearing. balance is maintained at a suitable level.
• Rocker cam (4) has flat surface A, and shoe (7) is The oil inside each cylinder chamber of cylinder block
always pressed against this surface while sliding in a (9) is sucked in and discharged through valve plate
circular movement. There is a cradle bearing (3) (10).
between cradle and rocker cam (4) which is secured
to the case.Rocker cam (4) sways on cradle bearing.
CK20-1 10-17
--- Page 7 ---
STRUCTURE AND FUNCTION HYDRAULIC PUMP
CHARGE PUMP
1
2
3
6
7
4
5
RKS00150
1. Slide plate FUNCTION
2. Coupling • HST charge pump is built-in the HST pump and driven
3. Shaft with HST pump at the same time.
4. Outer ring • The pressurised oil generated by the charge pump is
5. Case sent to safety valve in the charge circuit and to AS
valve.
6. Inner roter
• Charge pump sucks oil from hydraulic tank.
7. Outer roter
SPECIFICATIONS
• Type: trochoid pump
• Theoretical delivery: 32 cm³/rev
CK20-1 10-27
--- Page 8 ---
STRUCTURE AND FUNCTION CONTROL VALVE (3-SPOOL)
3 8
3
4
2 7
6
5
1
Section A - A Section B- B
AA
BB 9 11
12
AA 10
BB
Section C - C Section AA-AA Section BB-BB
RKS04400
1. Main relief valve 7. Spool (bucket)
2. Suction valve (bucket bottom side) 8. Spool (attachment)
3. Plug 9. Flow divider
4. Plug 10. Check valve (circulating circuit)
5. Series - parallel circuit switching valve 11. Combination circulating valve
6. Spool (lift arm) 12. Leveling circulating valve
CK20-1 10-37
--- Page 9 ---
STRUCTURE AND FUNCTION CLSS
CLSS
1. OUTLINE
Features
CLSS stands for Closed centre Load Sensing System, and has the followings characteristics.
a. Controlability, not influenced by load;
b. Controllable digging force at fine control range;
c. Easy simultaneous operation by spool opening proportional flow dividing function.
2. 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 actuators, this valve acts to make pressure difference ∆Pconstant for the
upstream flow (inlet port) and downstream flow (outlet port) of the notch 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.
Load Load
W W
Actuator Actuator
ÐP ÐP
S1 S2
Pressure Pressure
compensation compensation
valve valve
RKS00691
Pump
CK20-1 10-47
--- Page 10 ---
STRUCTURE AND FUNCTION SOLENOID VALVE
SOLENOID VALVE ST3
OVERRIDE CONTROL
a c
b
1
RKS04490
1. SV4 - Backhoe boom lockout
a. T port - To transmission
b. Port 1 - From transmission
c. T1 port - Boom lockout cylinder
CK20-1 10-57
--- Page 11 ---
STRUCTURE AND FUNCTION R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
6
5 7
4
8
3
9
2 1
1
Section A - A Section B - B
Section D - D
Section C - C
Section E - E
RKS00810
1. Spool 6. Nut
2. Metering spring 7. Joint
3. Centering spring 8. Cover
4. Piston 9. Stopper
5. Disc 10. Body
CK20-1 10-67
--- Page 12 ---
STRUCTURE AND FUNCTION L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL)
3. During fine control (when the lever is returned)
(fine control o neutral)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3) and 5
the pressure at port P1.
When this happens, fine control hole f is connected 4
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
9
pushed down by metering spring (2), and fine 3
control hole f is shut off from drain chamber D. 2 D
At almost the same time, it is connected to pump T
f
pressure chamber PP, and the pump pressure is
supplied until the pressure at port P1 recovers to a f
pressure that corresponds to the lever position. P
When control valve spool returns, oil goes back into 1 PP
port D, through fine control hole f', into port B of the
P1 P2
spool opposite the active spool. Oil flows through
port P2 and into port B to maintain the fill level (Fig. Fig. 3 RKS00840
3).
CK20-1 10-77
--- Page 13 ---
STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (2/3)
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (2/3)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
X01.1 R-N2.5
4
X01.1 M2.5
3
X01.1 R4 M1
2 X48
1
X01.1 R4 M-V1
1 X48
2
R-V1
X48
3
GND5 L-G1
X48
4
R-N2.5
X46
FROM ENGINE LINE STD/OPT
X02.1 4
l M2.5
X02.1 L-R1.5
X46
3
- R4
X46
2
R4
X46
TO CABIN LINE EURO/USA STD
X10.1 R-N1.5 1
13
X10.1
12 R-N1.5
X10.1 R1
X45
13
11 V-N1
X10.1 X45
12
10 M-B1
X10.1 B1
X45
11
9 L-R1.5
X10.1 S1
X45
10
8 B1
X10.1 C-N1
X45
9
7 M-N1
X10.1 C-L1
X45
8
6 R-G1
X10.1 S-G1
X45
7
5 S1
X10.1 X45
6
4 C-N1
X10.1 B-N1
X45
5
3 C-L1
X10.1 R-G1
X45
4
2 S-G1
X10.1 B-G1
X45
3