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Komatsu CK30-1 Compact Track Loader Operation & Maintenance Manual A30001 and up – PDF DOWNLOAD
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Komatsu CK30-1 Compact Track Loader Operation & Maintenance Manual
Book Code: CEAM017300
SERIAL NUMBERS CK30-1 A30001 and up
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Description
Komatsu CK30-1 Compact Track Loader Operation & Maintenance Manual
FILE DETAILS:
Komatsu CK30-1 Compact Track Loader Operation & Maintenance Manual
Brands: Komatsu
Equipment Type: Compact Track Loader
Manuals Type: Operation & Maintenance Manual
Machine Model: CK30-1
Serial Number: A40001 and up
Book Code: CEAM017300
Language: English
Pages: 256
File Format: Portable Document Format (PDF)
KOMATSU CK30-1 COMPACT TRACK LOADER OPERATION & MAINTENANCE MANUAL A30001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu CK30-1 Compact Track Loader Operation & Maintenance Manual
FOREWORD :
- This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and maintenance.
- Keep this manual handy and have all personnel read it periodically. If this manual is lost, damaged or becomes dirty and cannot be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner.
- Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual. Consult your local distributor or for the latest available information on your machine or for questions regarding information in this manual.
- This manual may contain attachments and optional equipment that are not available in your area. Consult your local distributor for those items that you may require.
TABLE OF CONTENTS:
Komatsu CK30-1 Compact Track Loader Operation & Maintenance Manual
INTRODUCTION............................................................................................................................ 2 FOREWORD............................................................................................................................ 3 SAFETY INFORMATION.................................................................................................................. 4 APPROVED AND NON APPROVED USES...................................................................................................... 6 Approved........................................................................................................................ 6 Non Approved.................................................................................................................... 6 PRODUCT INFORMATION................................................................................................................. 7 Main Features................................................................................................................... 7 Break In Period................................................................................................................. 7 Synthetic Biodegradable Oil Types........................................................................................... 7 PRODUCT IDENTIFICATION.............................................................................................................. 8 Machine Serial Number........................................................................................................... 8 Machine Identification Plate And Product Identification Number (Pin)............................................................ 8 Engine Serial Number And Emission Plate......................................................................................... 9 Travel Reduction Gear Serial Number............................................................................................. 9 Cab Serial Number............................................................................................................... 9 SERIAL NUMBERS AND DISTRIBUTOR INFORMATION.......................................................................................... 10 Model: CK30-1................................................................................................................... 10 TABLE OF CONTENTS................................................................................................................... 11 SAFETY.................................................................................................................................. 20 SAFETY LABELS....................................................................................................................... 21 Example Of Safety Label Using Words............................................................................................. 21 Example Of Safety Label Using Pictogram......................................................................................... 21 SAFETY AND WARNING DECALS........................................................................................................... 22 Location Of The Safety Decals................................................................................................... 22 Decals Defined.................................................................................................................. 30 SAFETY RULES AND PRECAUTIONS........................................................................................................ 40 General Safety Rules............................................................................................................ 40 Safety Features................................................................................................................. 40 Personal Protective Equipment................................................................................................... 41 Unauthorized Modifications...................................................................................................... 41 Leaving The Operator’s Seat..................................................................................................... 41 Mounting And Dismounting........................................................................................................ 42 Checking The Rear-view Mirrors (If Installed)................................................................................... 43 Fire Prevention For Fuel And Oil................................................................................................ 43 Preventing Burns................................................................................................................ 43 Asbestos Dust Hazard Precautions................................................................................................ 44 Preventing Accidents Caused By Improper Operation Of The Work Equipment......................................................... 44 Fire Extinguisher And First Aid Kit............................................................................................. 44 Precautions Concerning The Cab Structure........................................................................................ 45 Precautions When Using ROPS..................................................................................................... 45 Precautions Concerning The Equipment............................................................................................ 45 PRECAUTIONS BEFORE STARTING THE ENGINE.............................................................................................. 46 Safety On The Work Site......................................................................................................... 46 Fire Prevention................................................................................................................. 46 Precautions To Be Taken For The Operator’s Cab.................................................................................. 46 Room Ventilation................................................................................................................ 47 Precautions To Be Taken For The Lights (If Installed)........................................................................... 47 Cleaning The Windows And The Rear-view Mirrors - Checking The Windshield Wiper Blades........................................... 47 PRECAUTIONS TO BE TAKEN WHEN WORKING................................................................................................ 48 Starting The Engine............................................................................................................. 48 Rules For Traveling In Reverse.................................................................................................. 48 Moving The Machine.............................................................................................................. 49 Working On Slopes............................................................................................................... 50 Preventing Electrocution........................................................................................................ 51 Visibility...................................................................................................................... 52 Working On Icy Or Snow-covered Surfaces......................................................................................... 52 Preventing Accidents Caused By The Improper Operation Of The Work Equipment..................................................... 52 Working On Loose Ground......................................................................................................... 52 Parking The Machine............................................................................................................. 53 TRANSPORTING THE MACHINE............................................................................................................ 54 Loading And Unloading The Machine............................................................................................... 54 The Route....................................................................................................................... 54 BATTERY............................................................................................................................. 55 Safety Precautions For Work On Batteries........................................................................................ 55 Starting With Booster Cables.................................................................................................... 56 Precautions For Emergency Recovery.............................................................................................. 56 PRECAUTIONS DURING MAINTENANCE...................................................................................................... 58 Warning Tags.................................................................................................................... 58 Tools........................................................................................................................... 58 Personnel....................................................................................................................... 59 Equipment Storage............................................................................................................... 59 Working Under The Machine....................................................................................................... 59 Keeping The Machine Clean....................................................................................................... 59 Engine Operation During Maintenance............................................................................................. 60 Critical Parts.................................................................................................................. 60 Stop The Engine Before Carrying Out Any Maintenance Operation Or Inspection..................................................... 60 Rules For Refueling The Machine................................................................................................. 61 Cooling System Precautions...................................................................................................... 61 Using Lamps..................................................................................................................... 61 Precautions Concerning The Battery And Alternator............................................................................... 62 Precautions Concerning The Starter.............................................................................................. 63 Precautions Concerning High Pressure Hoses...................................................................................... 63 Precautions For Working On High Pressure Systems................................................................................ 63 Precautions For Maintenance Work Involving High Temperatures And Pressures...................................................... 64 Rotating Parts.................................................................................................................. 64 Precautions To Be Taken When Using High-pressure Grease To Adjust The Rubber Track Tension...................................... 64 Do Not Remove The Shock Absorbing Spring From The Shock Absorber Unit........................................................... 65 Hydraulic Accumulator........................................................................................................... 65 Disposal Of Waste Materials..................................................................................................... 66 Hydraulic Environmental Ester Synthetic (HEES) Oil.............................................................................. 66 OPERATION............................................................................................................................... 68 SAFETY LOCKS........................................................................................................................ 69 Loader Arm Support.............................................................................................................. 69 GENERAL VIEWS....................................................................................................................... 71 Front View Of Machine........................................................................................................... 71 Rear View Of Machine............................................................................................................ 72 Inside View Of Cab.............................................................................................................. 73 INSTRUMENTS AND CONTROLS............................................................................................................ 75 Instruments..................................................................................................................... 75 Hour Meter.................................................................................................................. 75 Engine Coolant Temperature Indicator........................................................................................ 76 Fuel Level Indicator........................................................................................................ 76 Indicator Lights................................................................................................................ 77 Alternator Warning Light.................................................................................................... 77 Preheating Warning Light.................................................................................................... 78 Engine Oil Pressure Warning Light........................................................................................... 78 Air Cleaner Clogging Warning Light.......................................................................................... 78 Hydraulic Oil Filter Clogging Warning Light................................................................................. 78 Parking Brake Warning Light................................................................................................. 79 Speed Increase Indicator Light.............................................................................................. 79 Float Switch Indicator Light................................................................................................ 79 Direction Indicator Light................................................................................................... 79 Working Light Indicator Light............................................................................................... 80 Safety Device Functionality Control Unit.................................................................................... 80 Switches And Push Buttons....................................................................................................... 82 Parking Brake Push Button................................................................................................... 83 Rotating Beacon Light Switch................................................................................................ 83 Left Stabilizer Button (If Installed)....................................................................................... 84 Right Stabilizer Button (If Installed)...................................................................................... 84 Working Light Switch........................................................................................................ 84 Emergency (Hazard) Switch (If Installed).................................................................................... 84 Parking Light And Low Beam Switch........................................................................................... 85 Direction Indicator Switch.................................................................................................. 85 Ignition Switch............................................................................................................. 85 Horn........................................................................................................................ 85 Front Equipment High Flow Hydraulic System Momentary Switch (3 Lines)....................................................... 86 Front Equipment Super Flow Hydraulic System Continuous Switch (5 Lines)..................................................... 86 Speed Increase Button....................................................................................................... 86 Floating Device Switch...................................................................................................... 86 Seat Override Switch........................................................................................................ 87 Available For Other Functions............................................................................................... 87 Electrical Accessories.......................................................................................................... 88 Audible Alarm............................................................................................................... 88 Electric Outlet............................................................................................................. 89 Master Electrical Disconnect Switch (If Installed).......................................................................... 89 Machine Controls................................................................................................................ 90 Safety Bars................................................................................................................. 92 ISO Pattern Control System...................................................................................................... 93 Left PPC Control Joystick (Travel And Steering)............................................................................. 93 Right PPC Control Joystick (Loader Arm And Bucket).......................................................................... 95 Optional Pattern Control System................................................................................................. 97 Left PPC Control Joystick (Left Track Travel, Steering, And Loader Arm Control)............................................. 97 Right PPC Control Joystick (Right Track Travel, Steering, And Bucket Control)............................................... 99 Auxiliary Hydraulic Kit Control Pedal (If Installed)............................................................................101 Foot Accelerator............................................................................................................102 Hand Accelerator............................................................................................................102 Parking Brake...............................................................................................................103 Standard Flow Hydraulic System Control (2 or 3 Lines).......................................................................103 Super Flow Hydraulic System Control (5 Lines)...............................................................................104 Speed Increase Control......................................................................................................106 Floating Position Control...................................................................................................106 Pattern Shifting Control....................................................................................................107 Right Stabilizer Control....................................................................................................109 Left Stabilizer Control.....................................................................................................109 Optional Electrical Connections.............................................................................................109 Battery Disconnect Switch.......................................................................................................110 Fuses And Relays................................................................................................................111 Machine Function Fuses......................................................................................................111 Standard Version............................................................................................................111 Version With Optional Connections...........................................................................................112 Main Fuse...................................................................................................................112 Relays......................................................................................................................113 GUARDS AND OPERATOR’S SEAT..........................................................................................................115 Engine Hood.....................................................................................................................115 Rear Panel......................................................................................................................116 Cab.............................................................................................................................117 Tilting The Cab.............................................................................................................118 Standard Seat...............................................................................................................120 Suspension Seat.............................................................................................................120 Seat Belt...................................................................................................................121 Emergency Exit..............................................................................................................121 Technical Documentation Case................................................................................................122 Fire Extinguisher...........................................................................................................122 First Aid Kit...............................................................................................................122 OPERATING THE MACHINE...............................................................................................................123 Checks Before Starting The Engine...............................................................................................123 Visual Checks...............................................................................................................123 Daily Checks................................................................................................................123 Operational Checks..........................................................................................................124 Starting The Engine.............................................................................................................125 Starting A Warm Engine Or In Temperate Climates.............................................................................125 Starting The Engine.............................................................................................................125 Starting A Cold Engine Or In Cold Climates..................................................................................126 Warming The Engine..............................................................................................................127 Heating The Hydraulic Oil.......................................................................................................127 Moving The Machine (Iso Pattern Control System).................................................................................127 Steering (Changing Direction)...............................................................................................129 How To Move The Machine (Optional Pattern Control System).......................................................................131 Steering (Changing Direction)...............................................................................................132 Hand And Foot Control System....................................................................................................134 Machine Controls............................................................................................................134 Travel And Steering Control Joysticks...........................................................................................135 Work Equipment Control Pedals (Loader Arm And Bucket).......................................................................137 Auxiliary Hydraulic Control Joystick........................................................................................140 How To Move The Machine (Hand & Foot Control System)........................................................................143 Steering (Changing Direction)...............................................................................................144 Moving On Slopes............................................................................................................146 Maximum Immersion Depth.....................................................................................................147 PARKING THE MACHINE.................................................................................................................148 Parking On Level Ground.........................................................................................................148 Parking On Slopes...............................................................................................................149 STOPPING THE ENGINE.................................................................................................................150 TRANSPORTING THE MACHINE............................................................................................................151 Loading And Unloading...........................................................................................................151 Transport.......................................................................................................................152 HOW TO LIFT THE MACHINE.............................................................................................................153 COLD WEATHER PRECAUTIONS............................................................................................................154 Fuel And Lubricants.............................................................................................................154 Coolant.........................................................................................................................154 Battery.........................................................................................................................155 Other Precautions...............................................................................................................155 Precautions To Be Taken At The End Of Work......................................................................................155 WARM WEATHER PRECAUTIONS............................................................................................................156 OPERATING THE WORK EQUIPMENT........................................................................................................156 Lowering The Equipment In Case Of Machine Failure...............................................................................156 Organizing The Work Area........................................................................................................157 Loading Heaped And Level Material...............................................................................................158 Loading Operations On Slopes....................................................................................................159 Digging Method..................................................................................................................160 Changing The Bucket Or Attachment With Standard Quick Coupler...................................................................162 Removing The Bucket Or Attachment...........................................................................................163 Installing The Bucket Or Attachment.........................................................................................164 Checking The Position Of The Locking Pins...................................................................................165 Adjusting The Locking Pins..................................................................................................166 Using The Rubber Tracks.........................................................................................................167 Optimal Use Of The Rubber Tracks............................................................................................167 Rubber Track Warranty.......................................................................................................167 Precautions To Be Taken When Using The Rubber Tracks........................................................................167 Precautions For Use.........................................................................................................168 Long Periods Of Inactivity......................................................................................................170 Before The Period Of Inactivity.............................................................................................170 During The Period Of Inactivity.............................................................................................171 After The Period Of Inactivity..............................................................................................171 TROUBLESHOOTING.....................................................................................................................172 How To Move The Machine.........................................................................................................172 If The Fuel Has Been Completely Depleted........................................................................................172 Battery Is Exhausted............................................................................................................173 Starting With Booster Cables................................................................................................174 Other Troubles..................................................................................................................175 Electrical Circuit..........................................................................................................175 Hydraulic System............................................................................................................176 Engine......................................................................................................................177 Hydrostatic Transmission....................................................................................................178 MAINTENANCE.............................................................................................................................180 GUIDE TO MAINTENANCE................................................................................................................181 MAINTENANCE NOTES...................................................................................................................182 Notes Regarding The Engine......................................................................................................182 Engine Oil..................................................................................................................182 Coolant.....................................................................................................................183 Fuel........................................................................................................................183 Notes Regarding The Hydraulic System............................................................................................183 Notes Regarding The Electrical System...........................................................................................184 Notes Regarding Lubrication.....................................................................................................184 Parts Subject To Wear That Periodically Need Changing...........................................................................184 FUEL, COOLANT AND LUBRICANTS........................................................................................................185 Selection According To The Ambient Temperature..................................................................................185 Grease..........................................................................................................................186 APPROVED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES...............................................................................188 LUBRICATION DIAGRAMS................................................................................................................190 General.........................................................................................................................190 PERIODIC REPLACEMENT OF COMPONENTS FOR SAFETY.......................................................................................191 Critical Parts For Safety.......................................................................................................192 Fuel Supply System..........................................................................................................192 Standard Flow Hydraulic System..............................................................................................193 Super Flow Hydraulic System.....................................................................................................195 Operator’s Safety...........................................................................................................197 TIGHTENING TORQUE...................................................................................................................198 Standard Torque For Bolts And Nuts..............................................................................................198 Specific Torques................................................................................................................198 MAINTENANCE PLAN....................................................................................................................199 When Required...................................................................................................................199 Checks Before Starting..........................................................................................................199 After The First 50 Hours Of Operation...........................................................................................199 Every 50 Hours Of Operation.....................................................................................................199 Maintenance After The First 250 Hours Of Operation..............................................................................200 Every 250 Hours Of Operation....................................................................................................200 After The First 500 Hours Of Operation..........................................................................................200 Every 500 Hours Of Operation....................................................................................................200 Every 1000 Hours Of Operation...................................................................................................201 Every 2000 Hours Of Operation...................................................................................................201 When Required...................................................................................................................202 Air Cleaner Cartridge.......................................................................................................202 Draining The Fuel Tank......................................................................................................203 Releasing The Parking Brake.................................................................................................204 Checking The Battery Charge Level...........................................................................................205 Checking The Rubber Tracks..................................................................................................206 Checking And Adjusting The Rubber Track Tension.............................................................................208 Changing The Rubber Tracks..................................................................................................211 Checks Before Starting..........................................................................................................213 Various Checks..............................................................................................................213 Checking The Coolant Level..................................................................................................213 Checking The Fuel Level.....................................................................................................214 Engine Oil Level............................................................................................................215 Hydraulic System Oil Level..................................................................................................216 Draining Water Separator....................................................................................................217 Checking The Wiring System..................................................................................................217 Maintenance After The First 50 Hours Of Operation...............................................................................218 Maintenance Every 50 Hours Of Operation.........................................................................................218 Checking The Rubber Track Tension...........................................................................................218 Checking The Coolant Level In The Radiator..................................................................................219 Checking The Oil Level In The Travel Motor..................................................................................219 First 250 Hours Of Operation....................................................................................................220 Every 250 Hours Of Operation....................................................................................................220 Fan Belt Tension............................................................................................................220 Cleaning The Outside Of The Radiators.......................................................................................221 Lubricating The Joints......................................................................................................222 Changing The Engine Oil.....................................................................................................223 Changing The Engine Oil Filter..............................................................................................224 Checking The Torque Of The Bolts And Nuts That Fasten The Carriages To The Machine Frame....................................225 Maintenance After The First 500 Hours Of Operation..............................................................................225 Maintenance Every 500 Hours Of Operation........................................................................................226 Changing The Fuel Filter....................................................................................................226 Changing The Hydraulic Oil Drain Filter.....................................................................................227 Changing The Oil In The Travel Motors.......................................................................................228 Cleaning The Water Separator................................................................................................229 Draining Condensate From The Hydraulic Oil Tank.............................................................................230 Maintenance Every 1000 Hours Of Operation.......................................................................................232 Changing The Hydraulic System Oil And Cleaning The Suction Filter...........................................................232 Checking And Adjusting The Engine Valve Clearance...........................................................................234 Maintenance Every 2000 Hours Of Operation.......................................................................................235 Changing The Coolant........................................................................................................235 Changing The Suction Filter.................................................................................................237 Checking The Alternator And The Starter.....................................................................................238 SPECIFICATIONS..........................................................................................................................240 SPECIFICATIONS......................................................................................................................241 Standard Machine Overall Dimensions.............................................................................................241 Technical Specifications........................................................................................................242 OPTIONS, ATTACHMENTS....................................................................................................................244 AVAILABLE OPTIONAL ATTACHMENTS......................................................................................................245 Basic Precautions...............................................................................................................245 Precautions Regarding The Installation Of Attachments...........................................................................246 Characteristics Of The Standard Machine With Optional (Factory Supplied) Equipment..............................................246 Characteristics Of The Optional (Factory Supplied) Equipment For The Machine With High Flow And Super-flow Hydraulic Systems....247 Changing The Available Attachments..............................................................................................248 Connecting The Hydraulic Circuit................................................................................................249 Connecting The Return Circuit With Direct Drainage Into The Tank................................................................251 Preparing The Machine For Use With The Excavator................................................................................252 Using The Machine With The Excavator............................................................................................252 Pallet Forks....................................................................................................................253
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