Komatsu CK25-1 Crawler Skid-Steer Loader Shop Manual WEBM007000 PDF
$28.95
Komatsu CK25-1 Crawler Skid-Steer Loader Shop Manual WEBM007000 – PDF DOWNLOAD
- Serial Number CK25-1 F00003 and up
Description
Komatsu CK25-1 Crawler Skid-Steer Loader Shop Manual WEBM007000 – PDF DOWNLOAD
FILE DETAILS:
Komatsu CK25-1 Crawler Skid-Steer Loader Shop Manual WEBM007000 – PDF DOWNLOAD
Language : English
Pages : 306
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu CK25-1 Crawler Skid-Steer Loader Shop Manual WEBM007000 – PDF DOWNLOAD
- Serial Number CK25-1 F00003 and up
CONTENTS 2
REVISED PAGES 3
k SAFETY 5
FOREWORD 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
STANDARD TIGHTENING TORQUE 10
COATING MATERIALS 12
ELECTRIC 13
WEIGHT TABLE 14
TABLE OF OIL AND COOLANT QUANTITIES 15
METHOD OF USING THE CONVERSION TABLE 17
10 STRUCTURE AND FUNCTION 25
P T O 26
POWER TRAIN 27
FRAME 28
TRACK TENSIONER IDLER WHEEL 29
TRACK TENSIONER CYLINDER AND BUMPER SPRING 30
LOWER IDLER ROLLER 31
REAR IDLER ROLLER 32
HYDRAULIC CIRCUIT (STANDARD) 33
HYDRAULIC CIRCUIT (FLOAT) 34
HYDRAULIC CIRCUIT (FLOAT + PATTERN CHANGE) 35
HYDRAULIC CIRCUIT (HIGH-FLOW) 36
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW) 37
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW / PATTERN CHANGE) 38
HYDRAULIC PUMP 39
SUCTION SAFETY VALVE (HST Circuit) 45
CHARGE SAFETY VALVE (Charge circuit) 49
CHARGE PUMP 51
ANTI ENGINE-STALL CONTROL VALVE (AS VALVE) 53
SHUTTLE VALVE 55
TRAVEL SYNCHRONIZATION VALVE 56
CONTROL VALVE (3-SPOOL) 57
CONTROL VALVE (4-SPOOL) 67
CLSS 71
SOLENOID VALVE 79
SOLENOID VALVE GROUP ST1 79
SOLENOID VALVE ST2 80
SOLENOID VALVE ST3 81
ACCUMULATOR 82
PATTERN CHANGE VALVE (OPTIONAL) 83
OPERATION 85
PATTERN ISO 85
PATTERN OPTIONAL 85
R H PPC VALVE (STANDARD) 86
EQUIPMENT CONTROL 86
R H PPC VALVE (PATTERN CHANGE) (OPTIONAL) 90
EQUIPMENT AND TRAVEL CONTROL 90
L H PPC VALVE (STANDARD) 94
TRAVEL CONTROL 94
L H PPC VALVE – PATTERN CHANGE (OPTIONAL) 98
EQUIPMENT AND TRAVEL CONTROL 98
EQUIPMENT CONTROL PPC VALVE 102
CYLINDERS 105
ELECTRICAL DIAGRAM (ENGINE LINE) (1/3) 107
ELECTRICAL DIAGRAM (ENGINE LINE) (2/3) 108
ELECTRICAL DIAGRAM (ENGINE LINE) (3/3) 109
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3) 110
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (2/3) 111
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (3/3) 112
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3) 113
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (2/3) 114
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (3/3) 115
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5) 116
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (2/5) 117
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (3/5) 118
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (4/5) 119
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (5/5) 120
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7) 121
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (2/7) 122
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (3/7) 123
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (4/7) 124
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (5/7) 125
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (6/7) 126
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7) 127
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (1/2) 128
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (2/2) 129
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (1/2) 130
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (2/2) 131
20 TESTING AND ADJUSTMENTS 133
NORMAL OR STANDARD TECHNICAL DATA 135
SPECIAL TOOLS 144
CHECKING THE ENGINE SPEED 145
ADJUSTMENT OF VALVE CLEARANCE 146
MEASUREMENT OF THE COMPRESSION PRESSURE 148
CONTROL AND ADJUSTMENT OF THE FAN BELT TENSION 149
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING 150
CHECKING ENGINE OIL PRESSURE 152
ADJUSTING THE STROKE OF THE ACCELERATOR CABLES 153
REGULATION OF PPC VALVES’ DRIVE PRESSURE 154
ADJUSTMENT OF THE PPC VALVE CLEARANCES 156
ADJUSTING THE POSITION OF THE SERVO-CONTROL ENGAGEMENT SAFETY SENSOR 157
CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS 158
TESTING THE HYDRAULIC PUMP 159
VALVE CALIBRATION 160
CHECKING THE TRAVEL DEVIATION 162
CONTROL VALVE 164
CONTROL AND REGULATION OF THE SERVO-CONTROLPOWER SUPPLY 165
ELIMINATION OF RESIDUAL PRESSURES – PRESSURISATION OF THE TANK 167
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS 168
TRACK TENSION TEST AND ADJUSTMENT 170
30 REMOVAL AND INSTALLATION 171
HOW TO READ THE MANUAL 173
PRECAUTIONS TO BE TAKEN WHILE WORKING 174
ENGINE HOOD 175
Removal 175
Installation 175
CAB 176
Removal 180
Installation 183
BATTERY 184
Removal 184
Installation 184
STARTING MOTOR 185
Removal 185
Installation 185
ALTERNATOR 186
Removal 186
Installation 186
AIR INTAKE FILTER 187
Removal 187
Installation 187
MUFFLER 188
Removal 188
Installation 189
VALVE COVER 190
Removal 190
Installation 190
INJECTORS 191
Removal 191
Installation 191
INJECTION PUMP 192
Removal 192
Installation 194
CYLINDER HEAD 195
Removal 195
Installation 197
COOLANT LIQUID PUMP 198
Removal 198
Installation 198
RADIATOR GROUP 199
Removal 199
Installation 200
FUEL TANK 201
Removal 201
Installation 202
ENGINE-PUMP GROUP 203
Removal 203
Installation 206
COMPLETE HYDRAULIC PUMP 207
Removal 207
Installation 209
GEAR PUMP 210
Removal 210
Installation 210
ENGINE-PUMP COUPLING 211
Removal 211
Installation 211
CONTROL VALVE 212
Removal 212
Installation 212
PPC VALVES 213
Removal 213
Installation 213
RAISING CYLINDER 214
Removal 214
BUCKET CYLINDER 216
Removal 216
Installation 217
WORK EQUIPMENT CYLINDERS 218
Disassembly 218
Assembly 220
COMPLETE WORKING EQUIPMENT 224
Removal 224
Installation 226
Removal 227
LIFT LEVER 228
Removal 228
Installation 229
WORKING EQUIPMENT SUPPORT FRAME 230
Removal 230
Installation 230
HEATING SYSTEM BLOWER FAN 231
Removal 231
Installation 232
TRACK 233
Removal 233
Installation 234
LOWER IDLER ROLLER 235
Removal 235
Installation 235
IDLER WHEELS 236
Removal 236
Installation 236
DRIVE WHEEL 237
Removal 237
Installation 237
TRACK TENSIONER CYLINDER 238
Removal 238
Installation 238
FINAL DRIVE 239
Removal 239
Installation 241
Disassembly 242
Assembly 254
40 STANDARD MAINTENANCE 269
P T O 270
FRAME AND BUMPER SPRING 271
TRACK TENSIONER IDLER WHEEL 272
DRIVE WHEEL 273
LOWER IDLER ROLLERS 274
REAR IDLER WHEEL 275
HYDRAULIC PUMP 276
CONTROL VALVE 278
R H PPC VALVE 291
L H PPC VALVE 292
PATTERN CHANGE VALVE (OPTIONAL) 294
CYLINDERS 295
WORKING EQUIPMENT 296
90 OTHER 301
ELECTRICAL DIAGRAM (STANDARD) 303
ELECTRICAL DIAGRAM (OPTIONAL) 305CONTENTS 2
REVISED PAGES 3
k SAFETY 5
FOREWORD 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
STANDARD TIGHTENING TORQUE 10
COATING MATERIALS 12
ELECTRIC 13
WEIGHT TABLE 14
TABLE OF OIL AND COOLANT QUANTITIES 15
METHOD OF USING THE CONVERSION TABLE 17
10 STRUCTURE AND FUNCTION 25
P T O 26
POWER TRAIN 27
FRAME 28
TRACK TENSIONER IDLER WHEEL 29
TRACK TENSIONER CYLINDER AND BUMPER SPRING 30
LOWER IDLER ROLLER 31
REAR IDLER ROLLER 32
HYDRAULIC CIRCUIT (STANDARD) 33
HYDRAULIC CIRCUIT (FLOAT) 34
HYDRAULIC CIRCUIT (FLOAT + PATTERN CHANGE) 35
HYDRAULIC CIRCUIT (HIGH-FLOW) 36
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW) 37
HYDRAULIC CIRCUIT (SUPER HIGH-FLOW / PATTERN CHANGE) 38
HYDRAULIC PUMP 39
SUCTION SAFETY VALVE (HST Circuit) 45
CHARGE SAFETY VALVE (Charge circuit) 49
CHARGE PUMP 51
ANTI ENGINE-STALL CONTROL VALVE (AS VALVE) 53
SHUTTLE VALVE 55
TRAVEL SYNCHRONIZATION VALVE 56
CONTROL VALVE (3-SPOOL) 57
CONTROL VALVE (4-SPOOL) 67
CLSS 71
SOLENOID VALVE 79
SOLENOID VALVE GROUP ST1 79
SOLENOID VALVE ST2 80
SOLENOID VALVE ST3 81
ACCUMULATOR 82
PATTERN CHANGE VALVE (OPTIONAL) 83
OPERATION 85
PATTERN ISO 85
PATTERN OPTIONAL 85
R H PPC VALVE (STANDARD) 86
EQUIPMENT CONTROL 86
R H PPC VALVE (PATTERN CHANGE) (OPTIONAL) 90
EQUIPMENT AND TRAVEL CONTROL 90
L H PPC VALVE (STANDARD) 94
TRAVEL CONTROL 94
L H PPC VALVE – PATTERN CHANGE (OPTIONAL) 98
EQUIPMENT AND TRAVEL CONTROL 98
EQUIPMENT CONTROL PPC VALVE 102
CYLINDERS 105
ELECTRICAL DIAGRAM (ENGINE LINE) (1/3) 107
ELECTRICAL DIAGRAM (ENGINE LINE) (2/3) 108
ELECTRICAL DIAGRAM (ENGINE LINE) (3/3) 109
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (1/3) 110
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (2/3) 111
ELECTRICAL DIAGRAM (FRAME LINE STANDARD) (3/3) 112
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (1/3) 113
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (2/3) 114
ELECTRICAL DIAGRAM (FRAME LINE OPTIONAL) (3/3) 115
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (1/5) 116
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (2/5) 117
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (3/5) 118
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (4/5) 119
ELECTRICAL DIAGRAM (CABIN LINE STANDARD) (5/5) 120
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (1/7) 121
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (2/7) 122
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (3/7) 123
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (4/7) 124
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (5/7) 125
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (6/7) 126
ELECTRICAL DIAGRAM (CABIN LINE OPTIONAL) (7/7) 127
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (1/2) 128
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE STANDARD) (2/2) 129
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (1/2) 130
ELECTRICAL DIAGRAM (TOP-CABIN LIGHT LINE HOMOLOGATION) (2/2) 131
20 TESTING AND ADJUSTMENTS 133
NORMAL OR STANDARD TECHNICAL DATA 135
SPECIAL TOOLS 144
CHECKING THE ENGINE SPEED 145
ADJUSTMENT OF VALVE CLEARANCE 146
MEASUREMENT OF THE COMPRESSION PRESSURE 148
CONTROL AND ADJUSTMENT OF THE FAN BELT TENSION 149
CONTROL AND ADJUSTMENT OF THE INJECTION TIMING 150
CHECKING ENGINE OIL PRESSURE 152
ADJUSTING THE STROKE OF THE ACCELERATOR CABLES 153
REGULATION OF PPC VALVES’ DRIVE PRESSURE 154
ADJUSTMENT OF THE PPC VALVE CLEARANCES 156
ADJUSTING THE POSITION OF THE SERVO-CONTROL ENGAGEMENT SAFETY SENSOR 157
CONTROL AND REGULATION OF THE PRESSURES IN THE HYDRAULIC CIRCUITS 158
TESTING THE HYDRAULIC PUMP 159
VALVE CALIBRATION 160
CHECKING THE TRAVEL DEVIATION 162
CONTROL VALVE 164
CONTROL AND REGULATION OF THE SERVO-CONTROLPOWER SUPPLY 165
ELIMINATION OF RESIDUAL PRESSURES – PRESSURISATION OF THE TANK 167
BLEEDING AIR FROM THE HYDRAULIC CIRCUITS 168
TRACK TENSION TEST AND ADJUSTMENT 170
30 REMOVAL AND INSTALLATION 171
HOW TO READ THE MANUAL 173
PRECAUTIONS TO BE TAKEN WHILE WORKING 174
ENGINE HOOD 175
Removal 175
Installation 175
CAB 176
Removal 180
Installation 183
BATTERY 184
Removal 184
Installation 184
STARTING MOTOR 185
Removal 185
Installation 185
ALTERNATOR 186
Removal 186
Installation 186
AIR INTAKE FILTER 187
Removal 187
Installation 187
MUFFLER 188
Removal 188
Installation 189
VALVE COVER 190
Removal 190
Installation 190
INJECTORS 191
Removal 191
Installation 191
INJECTION PUMP 192
Removal 192
Installation 194
CYLINDER HEAD 195
Removal 195
Installation 197
COOLANT LIQUID PUMP 198
Removal 198
Installation 198
RADIATOR GROUP 199
Removal 199
Installation 200
FUEL TANK 201
Removal 201
Installation 202
ENGINE-PUMP GROUP 203
Removal 203
Installation 206
COMPLETE HYDRAULIC PUMP 207
Removal 207
Installation 209
GEAR PUMP 210
Removal 210
Installation 210
ENGINE-PUMP COUPLING 211
Removal 211
Installation 211
CONTROL VALVE 212
Removal 212
Installation 212
PPC VALVES 213
Removal 213
Installation 213
RAISING CYLINDER 214
Removal 214
BUCKET CYLINDER 216
Removal 216
Installation 217
WORK EQUIPMENT CYLINDERS 218
Disassembly 218
Assembly 220
COMPLETE WORKING EQUIPMENT 224
Removal 224
Installation 226
Removal 227
LIFT LEVER 228
Removal 228
Installation 229
WORKING EQUIPMENT SUPPORT FRAME 230
Removal 230
Installation 230
HEATING SYSTEM BLOWER FAN 231
Removal 231
Installation 232
TRACK 233
Removal 233
Installation 234
LOWER IDLER ROLLER 235
Removal 235
Installation 235
IDLER WHEELS 236
Removal 236
Installation 236
DRIVE WHEEL 237
Removal 237
Installation 237
TRACK TENSIONER CYLINDER 238
Removal 238
Installation 238
FINAL DRIVE 239
Removal 239
Installation 241
Disassembly 242
Assembly 254
40 STANDARD MAINTENANCE 269
P T O 270
FRAME AND BUMPER SPRING 271
TRACK TENSIONER IDLER WHEEL 272
DRIVE WHEEL 273
LOWER IDLER ROLLERS 274
REAR IDLER WHEEL 275
HYDRAULIC PUMP 276
CONTROL VALVE 278
R H PPC VALVE 291
L H PPC VALVE 292
PATTERN CHANGE VALVE (OPTIONAL) 294
CYLINDERS 295
WORKING EQUIPMENT 296
90 OTHER 301
ELECTRICAL DIAGRAM (STANDARD) 303
ELECTRICAL DIAGRAM (OPTIONAL) 305
DESCRIPTION:
Komatsu CK25-1 Crawler Skid-Steer Loader Shop Manual WEBM007000 – PDF DOWNLOAD
- Serial Number CK25-1 F00003 and up
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
PREPARATIONS FOR WORK:
7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.
14. 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 hit- ting any other part. Do not work with any part still raised by the hoist or crane.
15. 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.
16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
17. 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.
G.B 18/12/24
