Komatsu CK25-1 Crawler Skid Steer Loader Operation and Maintenance Manual (WEAM011100)
On a CK25-1, you’re usually pushing dirt, grading pads, or loading trucks on rough, often muddy jobsites. This Operation and Maintenance Manual is what I’d keep handy to set a sane service rhythm and make sure the loader stays predictable day after day. When a customer complains the machine feels “sluggish” or tracks are chattering, I use this book to walk through the basic checks in order, rule out operator setup issues, and then move into wear and adjustment points before we start swapping parts.
Applications & Use Cases
- Plan routine servicing so filters, tracks, and key linkages get attention before they start causing downtime.
- Walk operators through daily and weekly inspections to catch leaks, loose hardware, or abnormal noises early.
- Verify correct warm-up and shutdown habits to avoid hard starts, condensation problems, and premature component wear.
- Trace performance complaints (poor pushing power, rough tracking, jerky hydraulics) using the manual’s recommended check sequence.
- Align maintenance with job schedules so you can cluster services between pours, hauls, or grading windows.
FAQ
Q: Can I keep this manual on a tablet in the cab?
A: Yes, as long as the file opens clearly and you can zoom diagrams, it’s fine for quick checks on site.
Q: Is it worth printing parts of this manual?
A: I’d print the inspection and service pages you use most and keep them in a binder that can live in the service truck.
Safety Note
Always follow the manual’s shutdown and lockout steps before putting hands near moving or pressurized components.
Komatsu CK25-1 Crawler Skid Steer Loader Index:
- 1.1 FOREWORD
- 1.2 INFORMATION ON SAFETY
- 1.3 INTRODUCTION
- 1.3.1 INTENDED USES
- 1.3.2 IMPROPER OR UNAUTHORIZED USES
- 1.3.3 MAIN CHARACTERISTICS
- 1.3.4 RUNNING-IN
- 1.3.5 POSITIONS AND DIRECTIONS OF THE MACHINE
- 1.4 PRODUCT IDENTIFICATION
- 1.4.1 MACHINE SERIAL NUMBER
- 1.4.2 MACHINE IDENTIFICATION PLATE AND PRODUCT IDENTIFICATION NUMBER (PIN)
- 1.4.2.1 MACHINE SERIAL NUMBER PLATE
- 1.4.2.2 MACHINE SERIAL NUMBER PLATE (according directive 2006/42/EC)
- 1.4.3 ENGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE
- 1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER
- 1.4.5 CAB SERIAL NUMBER
- 1.4.6 EXCAVATOR IDENTIFICATION PLATE (if installed)
- 1.4.7 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR
- 1.4.8 DECLARATION OF CONFORMITY (for machines placed on the market as from 29 December 2009)
- 1.5 KOMTRAX SYSTEM
- 1.5.1 GENERAL PRECAUTIONS
- TABLE OF CONTENTS
- 2.1 SAFETY, NOISE AND VIBRATION PLATES
- 2.1.1 POSITION OF THE SAFETY PLATES
- 2.1.1.1 SAFETY PLATES
- 2.1.1.2 SAFETY PLATES FOR MACHINES WITH EXCAVATOR
- 2.1.2 PICTOGRAMS AND RELEVANT MEANINGS
- 2.1.3 POSITION OF THE NOISE PLATES
- 2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED
- 2.2 GENERAL PRECAUTIONS
- 2.2.1 GENERAL SAFETY RULES
- 2.2.2 SAFETY DEVICES AND GUARDS
- 2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS
- 2.2.4 UNAUTHORIZED MODIFICATIONS
- 2.2.5 LEAVING THE OPERATORS SEAT
- 2.2.6 GETTING ON AND OFF THE MACHINE
- 2.2.7 CHECKING THE REAR-VIEW MIRRORS (if installed)
- 2.2.8 PREVENTING FIRES DUE TO FUEL AND OIL
- 2.2.9 LIFTING OF PERSONNEL PROHIBITED
- 2.2.10 PREVENTING BURNS
- 2.2.11 PREVENTING DAMAGE DUE TO ASBESTOS POWDER
- 2.2.12 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
- 2.2.13 DETERGENT FOR THE WINDOWS (only for cab with front door)
- 2.2.14 FIRE EXTINGUISHERS AND FIRST AID KIT
- 2.2.15 PRECAUTIONS CONCERNING THE CAB STRUCTURE
- 2.2.16 PRECAUTIONS CONCERNING THE EQUIPMENT
- 2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE
- 2.3.1 SAFETY ON THE WORK SITE
- 2.3.2 FIRE PREVENTION
- 2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR’S CAB
- 2.3.4 ROOM VENTILATION
- 2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS (if installed)
- 2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS – CHECKING THE WINDSHIELD WIPER BLADES (if installed)
- 2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING
- 2.4.1 STARTING THE ENGINE
- 2.4.2 RULES TO BE FOLLOWED WHEN TRAVELLING ON ROADS
- 2.4.3 CHECKS FOR TRAVELLING IN REVERSE
- 2.4.4 HAND SIGNALS
- 2.4.5 MOVING THE MACHINE
- 2.4.6 WORKING ON SLOPES
- 2.4.7 PROHIBITED OPERATIONS
- 2.4.8 PREVENTING ELECTROCUTION
- 2.4.9 VISIBILITY
- 2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES
- 2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT
- 2.4.12 WORKING ON LOOSE GROUND
- 2.4.13 PARKING THE MACHINE
- 2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES
- 2.5.1 LOADING AND UNLOADING THE MACHINE
- 2.5.2 TRANSPORT
- 2.6 BATTERY
- 2.6.1 PREVENTING RISKS THAT MAY BE DUE TO THE BATTERY
- 2.6.2 STARTING WITH BOOSTER CABLES
- 2.7 PRECAUTIONS FOR EMERGENCY RECOVERY
- 2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE
- 2.8.1 WARNING PLATES
- 2.8.2 TOOLS
- 2.8.3 PERSONNEL
- 2.8.4 EQUIPMENT
- 2.8.5 WORKING UNDER THE MACHINE
- 2.8.6 STABILITY
- 2.8.7 REPAIR WELDS
- 2.8.8 KEEPING THE MACHINE CLEAN
- 2.8.9 USE OF THE ENGINE DURING MAINTENANCE
- 2.8.10 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY
- 2.8.11 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION
- 2.8.12 BATTERY MAIN SWITCH PRECAUTIONS
- 2.8.13 RULES FOR REFUELLING AND ADDING OIL
- 2.8.14 CHECKING THE COOLANT LEVEL IN THE RADIATOR
- 2.8.15 USING LAMPS
- 2.8.16 PRECAUTIONS TO BE TAKEN WHEN HANDLING THE BATTERY AND THE ALTERNATOR
- 2.8.17 PRECAUTIONS CONCERNING THE STARTER
- 2.8.18 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES
- 2.8.19 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMS
- 2.8.20 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES
- 2.8.21 PRECAUTIONS TO BE TAKEN WHEN USING HIGH-PRESSURE GREASE TO ADJUST THE RUBBER TRACK TENSION
- 2.8.22 DO NOT REMOVE THE SHOCK ABSORBING SPRING FROM THE SHOCK ABSORBER UNIT
- 2.8.23 HYDRAULIC ACCUMULATOR
- 2.8.24 COOLING FAN AND FAN BELT
- 2.8.25 CHEMICAL HAZARD
- 2.8.26 WASTE MATERIALS
- 2.8.27 PRECAUTIONS TO BE TAKEN WHEN HANDLING TECHNOPOLYMERS AND ELASTOMERS
- 2.8.28 PRECAUTIONS TO BE TAKEN WHEN USING THE SYNTHETIC BIODEGRADABLE OIL TYPE «HEES»
- 2.8.29 FINAL DISPOSAL OF THE MACHINE
- 3.1 SAFETY LOCKS
- 3.1.1 LOADER LOCKS
- 3.1.2 EXCAVATOR LOCKS (if installed)
- 3.1.3 ASPHALT CUTTER LOCKS (if installed)
- 3.2 GENERAL VIEWS
- 3.2.1 FRONT GENERAL VIEW
- 3.2.2 REAR GENERAL VIEW
- 3.2.3 CAB INSIDE GENERAL VIEW
- 3.3 INSTRUMENTS AND CONTROLS
- 3.3.1 INSTRUMENTS
- 3.3.2 WARNING LIGHTS
- 3.3.3 SWITCHES UND PUSH BUTTONS
- 3.3.4 ELECTRICAL ACCESSORIES
- 3.3.5 MACHINE CONTROLS
- 3.4 FUSES AND RELAYS
- 3.4.1 MACHINE FUNCTION FUSES
- 3.4.2 MAIN FUSE
- 3.4.3 RELAYS
- 3.5 GUARDS AND DRIVER’S SEAT
- 3.5.1 ENGINE HOOD
- 3.5.2 REAR PANEL
- 3.5.3 CAB
- 3.5.4 STANDARD SEAT
- 3.5.5 CUSHIONED SEAT
- 3.5.6 SAFETY BELT
- 3.5.7 EMERGENCY EXIT
- 3.5.8 TECHNICAL DOCUMENTATION CASE
- 3.5.9 FIRE EXTINGUISHER
- 3.5.10 FIRST AID KIT
- 3.6 USE OF THE MACHINE
- 3.6.1 CHECKS BEFORE STARTING THE ENGINE
- 3.6.1.1 VISUAL CHECKS
- 3.6.1.2 DAILY CHECKS
- 3.6.1.3 OPERATIONAL CHECKS
- 3.6.2 STARTING THE ENGINE
- 3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES
- 3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES
- 3.6.3 WARMING THE ENGINE
- 3.6.4 HEATING THE HYDRAULIC OIL
- 3.6.5 HOW TO MOVE THE MACHINE (ISO PATTERN CONTROL SYSTEM)
- 3.6.5.1 STEERING (CHANGING DIRECTION)
- 3.6.6 HOW TO MOVE THE MACHINE (OPTIONAL PATTERN CONTROL SYSTEM)
- 3.6.6.1 STEERING (CHANGING DIRECTION)
- 3.6.7 MOVING ON SLOPES
- 3.6.8 MAXIMUM IMMERSION DEPTH
- 3.7 PARKING THE MACHINE
- 3.7.1 PARKING ON LEVEL GROUND
- 3.7.2 PARKING ON SLOPES
- 3.8 STOPPING THE ENGINE
- 3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES
- 3.9.1 LOADING AND UNLOADING THE MACHINE
- 3.9.2 TRANSPORT
- 3.10 HOW TO LIFT THE MACHINE
- 3.11 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON
- 3.11.1 FUEL AND LUBRICANTS
- 3.11.2 COOLANT
- 3.11.3 BATTERY
- 3.11.4 OTHER PRECAUTIONS
- 3.11.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK
- 3.12 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON
- 3.13 USING THE WORK EQUIPMENT
- 3.13.1 LOWERING THE EQUIPMENT IN CASE OF MACHINE FAILURE
- 3.13.2 ORGANIZING THE WORK AREA
- 3.13.3 LOADING MATERIAL ON HEAPS AND ON LEVEL SURFACES
- 3.13.4 LOADING MATERIAL ON SLOPES
- 3.13.5 DIGGING METHOD
- 3.13.6 CHANGING THE BUCKET OR THE EQUIPMENT WITH STANDARD RAPID COUPLING
- 3.13.6.1 RELEASING THE BUCKET
- 3.13.6.2 COUPLING THE BUCKET
- 3.13.7 CHANGING THE BUCKET OR THE EQUIPMENT WITH OPTIONAL RAPID COUPLING
- 3.13.7.1 REMOVING THE BUCKET OR THE EQUIPMENT
- 3.13.7.2 CONNECTING THE BUCKET
- 3.13.7.3 CHECKING THE POSITION OF THE LOCKING PINS
- 3.13.7.4 ADJUSTING THE LOCKING PINS
- 3.13.8 USING THE RUBBER TRACKS
- 3.13.8.1 OPTIMAL USE OF THE RUBBER TRACKS
- 3.13.8.2 RUBBER TRACK WARRANTY
- 3.13.8.3 PRECAUTIONS TO BE TAKEN WHEN USING THE RUBBER TRACKS
- 3.13.8.4 PRECAUTIONS FOR USE
- 3.14 LONG PERIODS OF INACTIVITY
- 3.14.1 BEFORE THE PERIOD OF INACTIVITY
- 3.14.2 DURING THE PERIOD OF INACTIVITY
- 3.14.3 AFTER THE PERIOD OF INACTIVITY
- 3.14.4 AMBIENT TEMPERATURE RANGE FOR OPERATION AND LONG TERM STORAGE
- 3.15 TROUBLESHOOTING
- 3.15.1 HOW TO REMOVE THE MACHINE
- 3.15.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED
- 3.15.3 IF THE BATTERY IS DOWN
- 3.15.3.1 STARTING WITH BOOSTER CABLES
- 3.15.4 OTHER TROUBLES
- 3.15.4.1 ELECTRICAL CIRCUIT
- 3.15.4.2 HYDRAULIC SYSTEM
- 3.15.4.3 ENGINE
- 3.15.4.4 HYDROSTATIC TRANSMISSION
- 4.1 GUIDE TO MAINTENANCE
- 4.2 MAINTENANCE NOTES
- 4.2.1 NOTES REGARDING THE ENGINE
- 4.2.1.1 ENGINE OIL
- 4.2.1.2 COOLANT
- 4.2.1.3 FUEL
- 4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM
- 4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM
- 4.2.4 NOTES REGARDING LUBRICATION
- 4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING
- 4.3 FUEL, COOLANT AND LUBRICANTS
- 4.3.1 COOLANT
- 4.3.2 HOMOLOGATED SYNTHETIC BIODEGRADABLE LUBRICANTS TYPE HEES
- 4.4 DRIVING TORQUES
- 4.4.1 STANDARD DRIVING TORQUES FOR SCREWS AND NUTS
- 4.4.2 SPECIFIC DRIVING TORQUES FOR SCREWS AND NUTS
- 4.4.3 STANDARD DRIVING TORQUES FOR HOSES WITH ORFS
- 4.5 LUBRICATION
- 4.5.1 LUBRICATION DIAGRAM
- 4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY
- 4.6.1 CRITICAL PARTS FOR SAFETY
- 4.7 MAINTENANCE PLAN
- 4.8 MAINTENANCE PROCEDURE
- 4.8.1 WHEN REQUIRED
- 4.8.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE
- 4.8.1.b DRAINING THE FUEL TANK
- 4.8.1.c RELEASING THE PARKING BRAKE (Only in case of failure and if it is impossible to start the engine)
- 4.8.1.d CHECKING THE BATTERY CHARGE LEVEL
- 4.8.1.e CHECKING THE RUBBER TRACKS
- 4.8.1.f CHECKING AND ADJUSTING THE RUBBER TRACK TENSION
- 4.8.1.g CHANGING THE RUBBER TRACKS
- 4.8.2 CHECKS BEFORE STARTING
- 4.8.2.a VARIOUS CHECKS
- 4.8.2.b CHECKING THE COOLANT LEVEL
- 4.8.2.c CHECKING THE FUEL LEVEL
- 4.8.2.d CHECKING THE ENGINE OIL LEVEL
- 4.8.2.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT
- 4.8.2.f CHECKING THE WATER SEPARATOR FOR SEDIMENTS AND WATER
- 4.8.2.g CHECKING THE WIRING SYSTEM
- 4.8.3 MAINTENANCE AFTER THE FIRST 10 HOURS OF OPERATION
- 4.8.4 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION
- 4.8.5 MAINTENANCE EVERY 50 HOURS OF OPERATION
- 4.8.5.a CHECKING THE RUBBER TRACK TENSION
- 4.8.5.b CHECKING THE COOLANT LEVEL IN THE RADIATOR
- 4.8.5.c CHECKING THE OIL LEVEL IN THE REDUCTION GEARS
- 4.8.6 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION
- 4.8.7 MAINTENANCE EVERY 250 HOURS OF OPERATION
- 4.8.7.a ADJUSTING THE FAN BELT TENSION
- 4.8.7.b CLEANING THE OUTSIDE OF THE RADIATORS
- 4.8.7.c LUBRICATING THE JOINTS
- 4.8.7.d CHANGING THE ENGINE OIL
- 4.8.7.e CHANGING THE ENGINE OIL FILTER
- 4.8.7.f CHECKING THE DRIVING TORQUE OF THE SCREWS AND NUTS THAT FASTEN THE CARRIAGES TO THE MACHINE FRAME
- 4.8.8 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines filled with synthetic biodegradable oil type HEES)
- 4.8.9 MAINTENANCE EVERY 500 HOURS OF OPERATION
- 4.8.9.a CHANGING THE FUEL FILTER
- 4.8.9.b CHANGE THE HYDRAULIC OIL DRAIN FILTER
- 4.8.9.c CHANGE THE OIL IN THE TRAVEL REDUCTION GEARS
- 4.8.9.d CLEANING THE WATER SEPARATOR
- 4.8.9.e DRAINING THE HYDRAULIC OIL TANK (Only for machines filled with synthetic biodegradable oil type HEES)
- 4.8.9.f REVERSING THE SPROCKETS AND THE RUBBER TRACKS
- 4.8.10 MAINTENANCE EVERY 1000 HOURS OF OPERATION
- 4.8.10.a CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER
- 4.8.10.b CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE
- 4.8.11 MAINTENANCE EVERY 2000 HOURS OF OPERATION
- 4.8.11.a CHANGING THE COOLANT
- 4.8.11.b CHANGING THE SUCTION FILTER
- 4.8.11.c CHECKING THE ALTERNATOR AND THE STARTER
- 4.9 END OF SERVICE LIFE
- 5.1 TECHNICAL PRECAUTIONS
- 5.1.1 STANDARD MACHINE OVERALL DIMENSIONS
- 5.1.1.1 OVERALL DIMENSIONS WITH STANDARD BUCKET L 1730
- 5.1.1.2 OVERALL DIMENSIONS WITH BUCKET L 1550
- 5.1.1.3 OVERALL DIMENSIONS WITH BUCKET L 1800
- 5.1.2 MACHINE OVERALL DIMENSIONS WITH OPTIONAL EQUIPMENT
- 5.1.2.1 MACHINE OVERALL DIMENSIONS WITH EXCAVATOR (E30)
- 5.1.2.2 MACHINE OVERALL DIMENSIONS WITH ASPHALT CUTTER
- 5.1.2.3 OVERALL DIMENSIONS WITH MIXING BUCKET
- 5.1.2.4 OVERALL DIMENSIONS WITH SWEEPER
- 5.1.3 TECHNICAL CHARACTERISTICS
- 6.1 AUTHORIZED OPTIONAL EQUIPMENT
- 6.1.1 PRECAUTIONS REGARDING SAFETY
- 6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT
- 6.2 SPECIFICATIONS
- 6.2.1 ARM-PIN INFORMATION
- 6.3 ATTACHMENT GUIDE
- 6.3.1 COMBINATIONS OF WORK EQUIPMENT
- 6.3.2 ATTACHMENT CONFIGURATION
- 6.4 CHANGING THE AUTHORIZED EQUIPMENT
- 6.4.1 CONNECTING THE EXCAVATOR
- 6.4.2 CONNECTING THE HYDRAULIC CIRCUIT
- 6.4.3 CONNECTING THE RETURN CIRCUIT WITH DIRECT DRAINAGE INTO THE TANK
- 6.4.4 PREPARING THE MACHINE FOR THE USE OF THE EXCAVATOR
- 6.4.5 USING THE MACHINE WITH THE EXCAVATOR
- 6.5 PALLET FORKS
- 6.6 CHANGING THE OPERATING PATTERN
- 6.6.1 HOW TO CHANGE THE OPERATING PATTERN
- 6.7 HAND & FOOT CONTROL SYSTEM
- 6.7.1 MACHINE CONTROLS
- 6.7.1.1 TRAVEL AND STEERING CONTROL LEVERS
- 6.7.1.2 WORK EQUIPMENT CONTROL PEDALS (LOADER ARM AND BUCKET)
- 6.7.1.3 AUXILIARY HYDRAULIC KIT CONTROL
- 6.7.2 HOW TO MOVE THE MACHINE (HAND & FOOT CONTROL SYSTEM)
- 6.7.2.1 STEERING (CHANGING DIRECTION)
Link Belt
