Komatsu CK35-1 Compact Track Loader 2006–2012 Service Manual (P/N CEBM017500)

This 304-page PDF is the July 2006 Komatsu shop manual for the CK35-1 Compact Track Loader, serial number A40001 and up. The cover is marked CEBM017500, and the technical-data section specifies the S4D98E-2NFE engine. Its service-shop procedures, hydraulic test equipment, heavy-component handling, and detailed overhaul work make it best suited to technicians and experienced owners who already have the required tools and safe lifting capability.

• Documents every listed hydraulic build: standard, float, float with optional pattern change, high-flow, super high-flow, and super high-flow with pattern change. Component coverage includes the tandem HST pump, charge pump, AS and shuttle valves, travel synchronization valve, accumulator, solenoid valve groups, and CLSS operation.
• Distinguishes the control hardware by configuration, with 3-spool valve coverage for standard, float, and high-flow systems, plus the 4-spool valve used with super high-flow. Standard and pattern-change R.H./L.H. PPC valves and the equipment-control PPC valve receive separate functional treatment.
• Includes factory testing and adjustment procedures for engine speed, valve clearance, compression, injection timing, engine oil pressure, hydraulic circuit pressure, HST and AS valve calibration, travel deviation, servo-control and parking-brake pressure, hydraulic bleeding, and track tension.
• Covers major removal and repair work on the cab, S4D98E-2NFE cylinder head and fuel-injection components, radiator, engine-pump group, complete hydraulic pump, control and PPC valves, work-equipment cylinders, lift linkage, tracks, idlers, tensioner, and final drives.
• Provides a full final-drive teardown and reassembly section, along with work-equipment cylinder disassembly and assembly. Maintenance-standard tables add component-specific torques, spring-load data, inspection clearances, wear limits, and repair limits for the undercarriage, hydraulic valves, cylinders, and working equipment.
• Supplies hydraulic and electrical reference drawings, including the Float + Pattern Change and Super High-Flow/Pattern Change hydraulic circuits, 3-spool and 4-spool control-valve section views, engine-line and optional cabin-line electrical diagrams, and standard or homologation top-cabin light-line diagrams.

Hydraulic and Control-System Detail

The hydraulic chapter goes beyond hose routing. It explains how swash-plate movement controls HST pump output, how the anti-stall valve responds to engine speed, how shuttle valves select pump-control pressure, and how the travel synchronization valve compensates right-to-left flow during forward travel. The CLSS section describes load compensation, self-leveling, series-to-parallel switching under bucket load, and flow division between regular attachment and high-flow functions. These descriptions help identify the correct repair path before a pump or valve is removed.

Bench Checks, Adjustments, and Service Data

Normal and permissible data are organized for the engine, pilot and main hydraulic circuits, work-equipment drift and cycle time, travel speed, and travel deviation. The special-tool list identifies commercially available tachometers, pressure gauges, adapters, and a differential-pressure Sensocontrol kit, as well as the Yanmar compression-gauge kit TOL-97190080. Fluid type and capacity tables cover the engine, hydraulic/HST system, final drives, fuel tank, cooling system, and biodegradable hydraulic-oil application; standard fastener and hydraulic fitting torque tables are also included.

This is a workshop repair publication rather than an operator or routine maintenance guide. It covers cylinder-head removal and installation, valve adjustment, injection-pump timing, and related engine checks, but it does not contain a complete internal engine-overhaul chapter or the operating instructions found in the separate Operation and Maintenance Manual.

Repair Cautions Built Into the Procedures

Injection-pump removal requires preserving the gear alignment reference and keeping the nut, lock washer, and shaft key out of the timing housing; misplaced hardware or lost indexing can damage the gear train or leave the engine mistimed. During final-drive repair, the manual calls out marked component relationships and the correct orientation of bearings, piston parts, seals, and the bronze-faced valve plate, because reversed or mismatched parts can damage sealing surfaces and the brake/hydrostatic motor assembly.

Support the raised cab and work equipment with the specified safety devices, use rated lifting gear for heavy assemblies, and fully release main, pilot, and tank pressure before opening any hydraulic connection. The track tensioner contains pressurized grease and requires the manual's dedicated safety procedure.