Komatsu SK715-8E0 Skid-Steer Loader Shop Manual WENBM00390 PDF

Description

Komatsu SK715-8E0 Skid-Steer Loader Shop Manual WENBM00390 – PDF DOWNLOAD

FILE DETAILS:

Komatsu SK715-8E0 Skid-Steer Loader Shop Manual WENBM00390 – PDF DOWNLOAD 

Language : English
Pages : 638
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu SK715-8E0 Skid-Steer Loader Shop Manual WENBM00390 – PDF DOWNLOAD 

SERIAL NUMBERS F10002 and up

00 Index and Foreword 3
Index 4
Foreword, Safety, Basic Information 9
How to Read the Shop Manual 9
Safety Notice for Operation 11
Precautions to Prevent Fire 18
Procedures If Fire Occurs 20
Precautions When You Dispose of Waste Materials 21
Precautions When You Handle Hydraulic Equipment 22
Precautions When You Disconnect and Connect Pipings 25
Precautions When You Handle Electrical Equipment 32
Precautions When You Handle Fuel System Equipment 34
Precautions When You Handle Intake System Equipment 35
Practical Use of KOMTRAX 36
Disconnect and Connect Push-Pull Type Coupler 37
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 37
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 38
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 39
Precautions for Disconnection and Connection of Connectors 41
How to Disconnect and Connect Deutsch Connector 45
How to Disconnect and Connect Slide Lock Type Connector 46
How to Disconnect and Connect Connector with Lock to Pull 48
How to Disconnect and Connect Connector with Lock to Push 49
How to Disconnect and Connect Connector with Housing to Rotate 51
Standard Tightening Torque Table 52
Conversion Table 59
Abbreviation List 64
01 Specifications 67
Table of Contents 68
Specifications 69
Specification Drawing 69
Specification 74
Weight Table 76
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 77
10 Structure and Function 79
Table of Contents 80
NOx Control System 82
Function of NOx Control System 82
Boot-up System 84
Layout Drawing of Boot-up System 84
System Operating Lamp System 85
System Diagram of System Operating Lamp System 85
Function of Operation Lamp System 85
Quick Release Battery Terminal (-) 87
Function of Quick Release Battery Terminal (-) 87
Engine System 88
Layout Drawing of Engine System 88
Engine Control System 89
System Diagram of Engine Control 89
Function of Engine Control System 90
Component Parts of Engine System 92
PTO 92
Layout Drawing of Engine System 93
Cooling System 94
Layout Drawing of Cooling System 94
Control System 95
Layout Drawing of Control System 95
Machine Monitor System 96
System Diagram of Machine Monitor System 96
KOMTRAX System 97
System Diagram of KOMTRAX System 97
Function of KOMTRAX System 97
Component Parts of Control System 98
Machine Monitor 98
KOMTRAX Terminal 107
Machine Controller 109
Hydraulic System 113
Layout Drawing of Hydraulic System 113
CLSS 114
Structure of CLSS 114
Function of CLSS 114
Component Parts of Hydraulic System 116
Hydraulic Tank 116
Hydraulic Pump 117
Control Valve 133
Work Equipment System 147
Layout Drawing of Work Equipment System 147
PPC Lock System 148
System Diagram of PPC Lock 148
Function of PPC Lock System 148
Component Parts of Work Equipment System 149
Work Equipment PPC Valve 149
Attachment PPC Valve 154
Solenoid Valve Group 156
Super Flow Solenoid Valve 157
Pilot Circuit Accumulator 158
Travel System 159
Layout Drawing of Travel System 159
System Diagram of Travel Control System 160
Function of Travel Control System 160
Component Parts of Travel System 161
Travel PPC Valve 161
Final Drive 165
Power Train 171
Transmission 172
Work Equipment 174
Structure of Work Equipment 174
Function of Work Equipment 175
Work Equipment Clearance Adjustment Shim 176
Function of Work Equipment Clearance Adjustment Shim 176
20 Standard Value Table 177
Table of Contents 178
Standard Value Table for Engine 179
Standard Value Table for Machine 181
Machine Posture and Procedures to Measure Performance 190
30 Testing and Adjusting 193
Table of Contents 194
Engine and Cooling System 196
Examine Engine Speed 196
How to Examine Engine High Idle Speed 196
How to Examine Engine Low Idle Speed 196
How to Examine Engine at Travel Relief 196
How to Examine Engine at Travel and Work Equipment Relief 197
Examine Exhaust Gas Color 198
How to Examine Exhaust Gas Color with the Handy Smoke Checker 198
How to Examine Exhaust Gas Color with Smoke Meter 199
Examine and Adjust Valve Clearance 200
How to Examine Valve Clearance 200
How to Adjust Valve Clearance 201
Examine Compression Pressure 202
How to Examine Compression Pressure 202
Examine Engine Oil Pressure 204
How to Examine Engine Oil Pressure 204
Bleed Air from Fuel System 205
How to Bleed Air from Fuel System 205
Examine Fuel Circuit for Leakage 206
How to Examine Fuel Circuit for Leakage at Engine Stop 206
How to Examine Fuel Circuit for Leakage at Engine Low Idle 206
How to Examine Fuel Circuit for Leakage at Engine High Idle 206
Handle Cylinder Cut-out Mode Operation 207
Examine and Adjust Alternator Belt Tension 208
How to Examine Alternator Belt Tension 208
How to Adjust Alternator Belt Tension 208
Frame 210
Examine and Adjust Gear Chain Tension 210
How to Examine Gear Chain Tension 210
How to Adjust Gear Chain Tension 210
Hydraulic System 211
Release Remained Pressure in Hydraulic Circuit 211
How to Release Remained Pressure from Hydraulic Tank 211
How to Release Remained Pressure in PPC Accumulator Circuit 211
How to Release Remained Pressure in Hydraulic Cylinder Circuit 211
Examine Oil Pressure of Work Equipment 212
How to Examine Unload Pressure 212
How to Examine Oil Pressure of Work Equipment 213
Adjust Oil Pressure of Work Equipment 215
How to Adjust Unload Pressure 215
How to Adjust Oil Pressure of Work Equipment Relief Pressure 215
Examine Oil Pressure of Control Circuit 217
How to Examine Oil Pressure of Control Circuit 217
Examine and Adjust Oil Pressure of Pump Circuit 219
How to Examine Oil Pressure of Travel Pump HST Charge Circuit 219
How to Adjust Oil Pressure of Travel Pump HST Charge Circuit 219
How to Examine Oil Pressure of Travel Pump AS Valve 220
How to Adjust Oil Pressure of Travel Pump AS Valve at Low Idling 221
How to Adjust Oil Pressure of Travel Pump AS Valve at High Idling 221
Examine Outlet Pressure of Solenoid Valve 223
How to Examine Outlet Pressure of Solenoid Valve 223
Operating Condition of Solenoid Valve 224
Examine PPC Valve Outlet Pressure 225
How to Examine Outlet Pressure of PPC Valve 225
How to Examine Outlet Pressure of PPC Valve for Travel System 227
Examine Parking Brake Release Pressure 229
How to Examine Parking Brake Release Pressure 229
Examine and Adjust Travel Deviation 230
How to Examine Travel Deviation at High Idling 230
How to Examine Travel Deviation at Medium Idling 230
How to Adjust Travel Deviation 231
Adjust Play of Work Equipment and Travel PPC Valves 233
How to Adjust Play of Work Equipment and Travel PPC Valves 233
Examine Parts Which Cause Hydraulic Drift of Work Equipment 234
How to Examine Parts Which Cause Hydraulic Drift of Arm Cylinder and Bucket Cylinder 234
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 234
Bleed Air from Hydraulic System 235
How to Bleed Air from Travel Pump 235
How to Bleed Air from Cylinder 236
Pressurize Hydraulic Tank 237
How to Pressurize Hydraulic Tank 237
Electrical System 238
How to Set and Operate Machine Monitor 238
Operator Mode 240
Examine Function by LCD (Liquid Crystal Display) 240
Examine Function of Service Meter 241
Usage Limitation and Maintenance Password Change Function 241
Service Mode 241
How to Start Up KOMTRAX Terminal 273
Handle Voltage Circuit of Engine Controller 278
40 Troubleshooting 279
Table of Contents 280
Abbreviation List 283
Related Information to Troubleshooting 289
General Troubleshooting Points 289
Sequence of Events in Troubleshooting 290
Troubleshooting Points for Aftertreatment System 292
Checks Before Troubleshooting 300
Inspection Procedure Before Troubleshooting 302
Walk-Around Check 302
Test in Accordance with Testing Procedure 304
Examine Fuel Level, Add Fuel 304
Examine Water Separator, Drain Water and Sediment 304
Replace Fuel Prefilter Element 305
Replace Fuel Main Filter Cartridge 307
Examine Oil Level in Engine Oil Pan, Add Oil 309
Replace Oil in Engine Oil Pan and Engine Oil Filter Cartridge 310
Examine Coolant Level, Add Coolant 312
Examine Clogging of Air Cleaner 312
Examine Oil Level in Hydraulic Tank, Add Oil 317
Replace Hydraulic Oil Drain Filter 318
Examine Gear Chains Tension 319
Examine Oil Level in Final Transmission 320
Bleed Air from Fuel System 321
Bleed Air from Hydraulic System 321
Examine Electric Equipment 322
Procedure for Troubleshooting 330
Information Shown in Troubleshooting Table 333
Connector Contact Identification (For 4D88E-7 Engine) 335
T-Branch Box and T-Branch Adapter Table 339
Fuse Location Table 345
Failure Code Table 347
Troubleshooting by Failure Code (Display of Code) 356
Failure Code [989L00] 356
Failure Code [989M00] 357
Failure Code [989N00] 358
Failure Code [AQ20R1] 359
Failure Code [AS00R2] 360
Failure Code [AS00R3] 361
Failure Code [AS00R4] 362
Failure Code [B@BCNS] 363
Failure Code [D19JKZ] 364
Failure Code [D811MC] 367
Failure Code [D862KA] 368
Failure Code [D8ALKA] 369
Failure Code [D8ALKB] 371
Failure Code [D8AQKR] 373
Failure Code [DAF0KT] 375
Failure Code [DAF0MB] 376
Failure Code [DAF0MC] 377
Failure Code [DAF3KK] 378
Failure Code [DAFGMC] 380
Failure Code [DAFLKA] 381
Failure Code [DAFLKB] 383
Failure Code [DAFQKR] 385
Failure Code [DB2QKR] 386
Failure Code [DBH0MC] 390
Failure Code [DBH2KK] 391
Failure Code [DBHLKA] 393
Failure Code [DBHLKB] 395
Failure Code [DBHQKR] 397
Failure Code [F@HSZG] 402
Failure Code [F@HSZL] 404
Troubleshooting of Electrical System (E-Mode) 406
Engine Does Not Start (Engine Does Not Crank) 406
Engine Does Not Start (Fuel Feed Pump System) 412
Automatic Preheating System Does Not Operate 413
When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing 415
Engine Coolant Temperature Monitor Comes On in White While Engine Runs 418
Charge Level Monitor Comes On in Red While Engine is in Operation 419
Fuel Level Monitor Comes On in Red While Engine Runs 420
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 421
Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 422
Fuel Gauge Display Does Not Move from Minimum or Maximum 423
Display of Fuel Gauge is Different from Actual Fuel Level 425
Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 426
Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 427
Some Areas of Machine Monitor Screen are Not Shown 428
Function Switch Does Not Operate 429
Alarm Buzzer Does Not Sound 430
Alarm Buzzer Cannot be Canceled 432
Service Meter is Not Shown, While Starting Switch is in OFF Position 433
Service Mode Cannot be Selected 434
Alarm Does Not Sound During Travel 435
Travel Alarm Does Not Stop When Machine Stops 437
Horn Does Not Sound 438
Horn Does Not Stop 440
Front or Rear Working Lamps Do Not Light Up 441
When Front Wiper Switch is Operated, Front Wiper Does Not Operate 445
When Rear Wiper Switch is Operated, Rear Wiper Does Not Operate 447
When Front Wiper Switch is Operated, Front Window Washer Does Not Operate 449
When Rear Wiper Switch is Operated, Rear Window Washer Does Not Operate 451
Travel Indicator is Not Shown Correctly with Monitoring Function 453
Arm IN is Not Shown Normally in Monitoring Function 454
KOMTRAX System Does Not Operate Normally 455
Troubleshooting of Engine (S-Mode) 456
Information Shown in Troubleshooting Table (S-Mode) 456
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 457
S-2 Engine Cranks but No Exhaust Smoke Comes Out 458
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 459
S-4 Engine Startability is Unsatisfactory 460
S-5 Engine Does Not Pick Up Smoothly 462
S-6 Engine Stops During Operation 464
S-7 Engine Runs Rough or is Not Stable 465
S-8 Engine Lacks Power 466
S-9 KDPF Becomes Clogged in a Short Time 468
S-10 Engine Oil Consumption is Excessive 469
S-11 Oil Becomes Dirty Quickly 470
S-12 Fuel Consumption is Excessive 471
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 472
S-14 Oil Pressure Drops 473
S-15 Fuel Mixes Into Engine Oil 475
S-16 Water Mixes Into Engine Oil (Milky) 476
S-17 Coolant Temperature Increases Too High (Overheating) 477
S-18 Unusual Noise is Heard 478
S-19 Vibration is Excessive 479
S-20 Air Cannot be Bled from Fuel Circuit 480
50 Disassembly and Assembly 481
Table of Contents 482
Related Information on Disassembly and Assembly 484
How to Read This Manual 484
Coating Materials List 486
Engine and Cooling System 490
Remove and Install Starter Assembly 490
How to Remove Starter Assembly 490
How to Install Starter Assembly 490
Remove and Install Radiator Assembly 491
How to Remove Radiator Assembly 491
How to Install Radiator Assembly 494
Remove and Install Engine and Pump Assembly 498
How to Remove Engine and Pump Assembly 498
How to Install Engine and Pump Assembly 503
Remove and Install Fuel Tank Assembly 508
How to Remove Fuel Tank Assembly 508
How to Install Fuel Tank Assembly 509
Remove and Install Alternator Assembly 511
How to Remove Alternator Assembly 511
How to Install Alternator Assembly 511
Remove and Install Air Cleaner Assembly 512
How to Remove Air Cleaner Assembly 512
How to Install Air Cleaner Assembly 513
Frame 514
Remove and Install Engine Hood 514
How to Remove Engine Hood 514
How to Install Engine Hood 515
Remove and Install Heater Assembly 516
How to Remove Heater Assembly 516
How to Install Heater Assembly 518
Raise Arm and Tilt Cab 521
How to Raise Arm 521
How to Tilt Cab 522
Fully Tilt and Rest the Cab Assembly 524
How to Tilt of Cab 524
How to Rest of Cab 527
Remove and Install Cab Assembly 530
How to Remove Cab Assembly 530
How to Install Cab Assembly 533
Remove and Install Wheel Hub Assembly 537
How to Remove Wheel Hub Assembly 537
How to Install Wheel Hub Assembly 539
Remove and Install Travel Motor Assembly 541
How to Remove Travel Motor Assembly 541
How to Install Travel Motor Assembly 543
Hydraulic System 546
Remove and Install Pump Assembly 546
How to Remove Pump Assembly 546
How to Install Pump Assembly 548
Remove and Install Gear Pump Assembly 550
How to Remove Gear Pump Assembly 550
How to Install Gear Pump Assembly 551
Remove and Install Pump Coupling 552
How to Remove Pump Coupling 552
How to Install Pump Coupling 553
Remove and Install Control Valve 555
How to Remove Control Valve 555
How to Install Control Valve 557
Remove and Install PPC Valve 559
How to Remove PPC Valve 559
How to Install PPC Valve 560
Work Equipment 562
Remove and Install Arm 562
How to Remove Arm 562
How to Install Arm 564
Remove and Install Lift Cylinder 566
How to Remove Lift Cylinder 566
How to Install Lift Cylinder 567
Remove and Install Bucket Cylinder 568
How to Remove Bucket Cylinder 568
How to Install Bucket Cylinder 568
Remove and Install Equipment Support Frame 570
How to Remove Equipment Support Frame 570
How to Install Equipment Support Frame 570
Electrical System 572
Remove and Install Battery 572
How to Remove Battery 572
How to Install Battery 572
60 Maintenance Standard 575
Table of Contents 576
Engine and Cooling System 577
Maintenance Standard for PTO 577
Hydraulic System 578
Maintenance Standard for Control Valve (Standard Flow) 578
Maintenance Standard for Control Valve (Super Flow) 583
Maintenance Standard for Work Equipment PPC Valve 588
Maintenance Standard for Travel PPC Valve 591
Maintenance Standard for Attachment PPC Valve 594
Power Train 596
Maintenance Standard for Transmission 596
Work Equipment 598
Maintenance Standard for Work Equipment Linkage 598
Maintenance Standard for Lift Cylinder 600
Maintenance Standard for Tilt Cylinder 601
90 Circuit Diagrams 603
Table of Contents 604
How to Read the Codes for Electric Cable 605
Hydraulic Circuit Diagram 609
Symbols Used in Hydraulic Circuit Diagram 609
Hydraulic Circuit Diagram 613
Electrical Circuit Diagram 615
Symbols Used in Electric Circuit Diagram 615
Electrical Circuit Diagram (1/6) 619
Electrical Circuit Diagram (2/6) 621
Electrical Circuit Diagram (3/6) 623
Electrical Circuit Diagram (4/6) 625
Electrical Circuit Diagram (5/6) 627
Electrical Circuit Diagram (6/6) 629
INDEX 631

DESCRIPTION:

Komatsu SK715-8E0 Skid-Steer Loader Shop Manual WENBM00390 – PDF DOWNLOAD 

SERIAL NUMBERS F10002 and up

Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for Testing and Adjusting are described in
“Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Other Information
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL:

S.V 28/12/24