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KOMATSU CK30-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) KOMATSU CK30-1 – PDF DOWNLOAD
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- KOMATSU CK30-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30001 & UP
- PUBLICATION NUMBER:CEBM017100
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Description
KOMATSU CK30-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) KOMATSU CK30-1
KOMATSU CK30-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) KOMATSU CK30-1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU CK30-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) KOMATSU CK30-1
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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.The manual is divided into chapters on each main group of components; these chapters are further divided into the following sections.
- 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 AND ADJUSTMENTS
This sections 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. - REMOVAL AND INSTALLATION
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. - STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU CK30-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A30001 & UP) KOMATSU CK30-1
MAIN MENU................................................................... 0 COVER....................................................................... 1 CONTENTS.................................................................... 2 FOREWORD.................................................................... 7 SAFETY NOTICE........................................................... 5 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 CONTROL VALVE (3-SPOOL)................................................. 57 CONTROL VALVE (4-SPOOL)................................................. 67 CLSS.................................................................... 71 SOLENOID VALVE.......................................................... 79 ACCUMULATOR............................................................. 82 PATTERN CHANGE VALVE (OPTIONAL)......................................... 83 OPERATION............................................................... 85 R.H. PPC VALVE (STANDARD)............................................... 86 R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL).............................. 90 L.H. PPC VALVE (STANDARD)............................................... 94 L.H. PPC VALVE - PATTERN CHANGE (OPTIONAL).............................. 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 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 Dump................................................................176 REMOVAL.............................................................201 INSTALLATION........................................................204 BATTERY.................................................................180 REMOVAL ............................................................180 INSTALLATION........................................................180 STARTING MOTOR..........................................................181 REMOVAL ............................................................181 INSTALLATION........................................................181 ALTERNATOR..............................................................182 REMOVAL.............................................................182 INSTALLATION........................................................182 AIR INTAKE FILTER.......................................................183 REMOVAL.............................................................183 INSTALLATION........................................................183 MUFFLER.................................................................184 REMOVAL.............................................................184 INSTALLATION........................................................185 VALVE COVER.............................................................186 REMOVAL.............................................................186 INSTALLATION........................................................187 INJECTORS...............................................................188 Removal.............................................................188 Installation........................................................188 INJECTION PUMP..........................................................189 Removal.............................................................189 Installation........................................................191 CYLINDER HEAD...........................................................192 Removal.............................................................192 Installation........................................................194 TURBOCHARGER............................................................195 removal.............................................................195 Installation........................................................195 COOLANT LIQUID PUMP.....................................................196 Removal.............................................................196 Installation........................................................196 RADIATOR GROUP..........................................................197 Removal.............................................................197 Installation........................................................198 FUEL TANK...............................................................199 Removal.............................................................199 Installation........................................................200 ENGINE-PUMP GROUP.......................................................205 Removal.............................................................205 Installation........................................................208 COMPLETE HYDRAULIC PUMP.................................................209 Removal.............................................................209 Installation........................................................211 GEAR PUMP...............................................................212 Removal.............................................................212 Installation........................................................212 ENGINE-PUMP COUPLING....................................................213 Removal.............................................................213 Installation........................................................213 CONTROL VALVE...........................................................214 Removal.............................................................214 Installation........................................................214 PPC VALVES..............................................................215 Removal.............................................................215 Installation........................................................215 HEATING SYSTEM BLOWER FAN...............................................216 Removal.............................................................216 Installation........................................................217 LIFT CYLINDER...........................................................218 Removal.............................................................218 Installation........................................................218 BUCKET CYLINDER.........................................................219 Removal.............................................................219 Installation........................................................220 WORK EQUIPMENT CYLINDERS................................................221 Disassembly.........................................................221 Assembly............................................................223 COMPLETE WORKING EQUIPMENT..............................................227 Removal.............................................................227 Installation........................................................228 WORKING EQUIPMENT SUPPORT FRAME.........................................229 Removal.............................................................229 Installation........................................................229 TRACK...................................................................230 Removal.............................................................230 Installation........................................................231 LOWER IDLER ROLLER......................................................232 Removal.............................................................232 Installation........................................................232 IDLER WHEELS............................................................233 Removal.............................................................233 Installation........................................................233 DRIVE WHEEL.............................................................234 Removal.............................................................234 Installation........................................................234 TRACK TENSIONER CYLINDER................................................235 Removal.............................................................235 Installation........................................................235 FINAL DRIVE.............................................................236 Removal.............................................................236 Installation........................................................238 Disassembly.........................................................239 Assembly............................................................251 40 STANDARD MAINTENANCE.....................................................265 P.T.O...................................................................266 FRAME AND BUMPER SPRING.................................................267 TRACK TENSIONER IDLER WHEEL.............................................268 DRIVE WHEEL.............................................................269 LOWER IDLER ROLLERS.....................................................270 REAR IDLER WHEEL........................................................271 HYDRAULIC PUMP..........................................................272 CONTROL VALVE...........................................................274 R.H. PPC VALVE..........................................................287 L.H. PPC VALVE..........................................................288 PATTERN CHANGE VALVE (OPTIONAL).........................................290 CYLINDERS...............................................................291 WORKING EQUIPMENT.......................................................292 90 OTHER....................................................................295 ELECTRICAL DIAGRAM (STANDARD)...........................................297 ELECTRICAL DIAGRAM (OPTIONAL)...........................................299
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
