Komatsu CK35-1 COMPACT TRACK LOADER Shop Manual CEBM017500 PDF

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Komatsu CK35-1 COMPACT TRACK LOADER Shop Manual CEBM017500 – PDF DOWNLOAD

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Komatsu CK35-1 COMPACT TRACK LOADER Shop Manual CEBM017500 – PDF DOWNLOAD 

Language : English
Pages : 304
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu CK35-1 COMPACT TRACK LOADER Shop Manual CEBM017500 – PDF DOWNLOAD 

SERIAL NUMBERS CK35-1 A40001 and UP

FOREWORD:

• 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 Shop Manual CEBM017500 – PDF DOWNLOAD 

SERIAL NUMBERS CK35-1 A40001 and UP

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

S.V 14/12/24