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KOMATSU CK35-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A40001 & UP) KOMATSU CK35 1 – PDF DOWNLOAD
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- KOMATSU CK35-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:A40001 & UP
- PUBLICATION NUMBER:CEBM017500
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Description
KOMATSU CK35-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A40001 & UP) KOMATSU CK35 1
KOMATSU CK35-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A40001 & UP) KOMATSU CK35 1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU CK35-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A40001 & UP) KOMATSU CK35 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 CK35-1 COMPACT TRACK LOADER SERVICE REPAIR MANUAL (SN:A40001 & UP) KOMATSU CK35 1
MAIN MENU................................................................... 0 COVER....................................................................... 1 CONTENTS.................................................................... 2 REVISED PAGES............................................................... 3 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........................................................191 INJECTORS...............................................................192 Removal.............................................................192 Installation........................................................192 INJECTION PUMP..........................................................193 Removal.............................................................193 Installation........................................................195 CYLINDER HEAD...........................................................196 Removal.............................................................196 Installation........................................................198 TURBOCHARGER............................................................199 Removal.............................................................199 Installation........................................................199 COOLANT LIQUID PUMP.....................................................200 Removal.............................................................200 Installation........................................................200 RADIATOR GROUP..........................................................201 Removal.............................................................201 Installation........................................................202 FUEL TANK...............................................................203 Removal.............................................................203 Installation........................................................204 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 Removal.............................................................218 Installation........................................................219 BUCKET CYLINDER.........................................................220 Removal.............................................................220 Installation........................................................221 WORK EQUIPMENT CYLINDERS................................................222 Disassembly.........................................................222 Assembly............................................................224 COMPLETE WORKING EQUIPMENT..............................................228 Removal.............................................................228 Installation........................................................230 FULCRUM LEVER...........................................................231 Removal.............................................................231 Installation........................................................231 LIFT LEVER..............................................................232 Removal.............................................................232 Installation........................................................233 WORKING EQUIPMENT SUPPORT FRAME.........................................234 Removal.............................................................234 Installation........................................................234 TRACK...................................................................235 Removal.............................................................235 Installation........................................................236 LOWER IDLER ROLLER......................................................237 Removal.............................................................237 Installation........................................................237 IDLER WHEELS............................................................238 Removal.............................................................238 Installation........................................................238 DRIVE WHEEL.............................................................239 Removal.............................................................239 Installation........................................................239 TRACK TENSIONER CYLINDER................................................240 Removal.............................................................240 Installation........................................................240 FINAL DRIVE.............................................................241 Removal.............................................................241 Installation........................................................243 Disassembly.........................................................244 Assembly............................................................256 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....................................................................299 ELECTRICAL DIAGRAM (STANDARD)...........................................301 ELECTRICAL DIAGRAM (OPTIONAL)...........................................303
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
