KOMATSU SK815-5N SK815-5NA SKID STEER LOADER Operation and Maintenance Manual – PDF DOWNLOAD

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KOMATSU SK815-5N SK815-5NA SKID STEER LOADER Operation and Maintenance Manual

KOMATSU SK815-5N SK815-5NA SKID STEER LOADER OPERATION AND MAINTENANCE MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

KOMATSU SK815-5N SK815-5NA SKID STEER LOADER Operation and Maintenance Manual

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel achieve peak performance through effective, economical and safe machine operation and maintenance. Keep this manual handy and have all personnel read it periodically.
• If this manual is lost, damaged or becomes dirty and can not be read, request a replacement manual from your local distributor. If you sell the machine, be sure to give this manual to the new owner. Continuing improvements in the design of this machine can lead to changes, which may not be reflected in this manual.
• Consult your local KOMATSU distributor or for the latest available information on your machine or for questions regarding information in this manual. This manual may contain attachments and optional equipment that are not available in your area. Consult your local KOMATSU Distributor or for those items that you may require

TABLE OF CONTENTS:

KOMATSU SK815-5N SK815-5NA SKID STEER LOADER Operation and Maintenance Manual

COVER...........................................................................................................................  1
INTRODUCTION....................................................................................................................  3
	FOREWORD....................................................................................................................  4
	SAFETY INFORMATION..........................................................................................................  5
		Directions Of Machine...................................................................................................  6
	APPROVED AND NON APPROVED USES..............................................................................................  7
		Approved................................................................................................................  7
		Non Approved............................................................................................................  7
	PRODUCT INFORMATION.........................................................................................................  8
		Main Features...........................................................................................................  8
		Break In Period.........................................................................................................  8
		Synthetic Biodegradable Oil Types.......................................................................................  8
	PRODUCT IDENTIFICATION......................................................................................................  9
		Machine Serial Number...................................................................................................  9
		Machine Identification Plate and Product Identification Number (PIN)....................................................  9
		Engine Serial Number And Emission Plate.................................................................................  9
		Travel Reduction Gear Serial Number..................................................................................... 10
		Cab Serial Number....................................................................................................... 10
		Excavator Identification Plate (if installed)........................................................................... 10
		Serial Numbers and Distributor Information.............................................................................. 11
	TABLE OF CONTENTS........................................................................................................... 12
SAFETY.......................................................................................................................... 19
	SAFETY LABELS............................................................................................................... 20
		Safety Label Using Both Words And Pictorial Message..................................................................... 20
		Hazard Panel............................................................................................................ 20
		Avoidance Panel......................................................................................................... 20
	SAFETY AND WARNING DECALS................................................................................................... 21
	PICTOGRAMS AND RELEVANT MEANINGS............................................................................................ 30
		Danger In The Work Area................................................................................................. 30
		Do Not Open The Hood.................................................................................................... 30
		Consult The Manual...................................................................................................... 30
		Hydraulic Oil Fill...................................................................................................... 30
		Biological Hydraulic Oil Fill........................................................................................... 31
		Refuelling.............................................................................................................. 31
		Engine Lubricating Oil Filter........................................................................................... 31
		Fuel Filter............................................................................................................. 31
		Engine Air Suction Filter............................................................................................... 31
		Engine Coolant.......................................................................................................... 31
		Engine Coolant Pressure................................................................................................. 32
		Hydraulic Oil Level..................................................................................................... 32
		Hydraulic Oil Filter.................................................................................................... 32
		Electric Outlet......................................................................................................... 32
		Anchorage Point......................................................................................................... 32
		Emergency Exit.......................................................................................................... 33
		Lifting Point........................................................................................................... 33
	GENERAL PRECAUTIONS......................................................................................................... 34
		Safety Rules............................................................................................................ 34
		If Abnormalities Are Found.............................................................................................. 34
		Clothing And Personal Protective Items.................................................................................. 34
		Fire Extinguisher And First Aid Kit..................................................................................... 34
		Safety Features......................................................................................................... 35
		Keep Machine Clean...................................................................................................... 35
		Inside Operator's Compartment........................................................................................... 35
		Leaving Operator’s Seat................................................................................................. 35
	CHECKING THE REAR-VIEW MIRRORS (if installed)............................................................................... 37
	Mounting And Dismounting.................................................................................................... 38
	Prevention Of Burns......................................................................................................... 38
		Hot Coolant............................................................................................................. 38
	High Temperature Oil........................................................................................................ 38
	Fire Prevention............................................................................................................. 39
		Fire Caused By Fuel Or Oil.............................................................................................. 39
		Fire Caused By Accumulation Of Flammable Material....................................................................... 39
		Fire Coming From Electric Wiring........................................................................................ 39
		Fire Coming From Hydraulic Line......................................................................................... 39
		Explosion Caused By Lighting Equipment.................................................................................. 39
		Action If Fire Occurs................................................................................................... 40
		Window Washer Liquid.................................................................................................... 40
		Precautions When Using ROPS (Roll Over Protective Structure)............................................................ 40
		Precautions For Attachments............................................................................................. 40
		Unauthorized Modification............................................................................................... 40
	Safety At Work Site......................................................................................................... 41
	Working On Loose Ground..................................................................................................... 41
	Do Not Go Close To High-voltage Cables...................................................................................... 41
	Ensure Good Visibility...................................................................................................... 42
	Ventilation For Enclosed Areas.............................................................................................. 42
	Checking Signalman's Signals And Signs...................................................................................... 42
	Emergency Exit From Operator's Cab.......................................................................................... 42
	Be Careful About Asbestos Dust.............................................................................................. 43
	Seat Belt Inspection........................................................................................................ 44
	PRECAUTIONS FOR OPERATION................................................................................................... 45
		Starting Engine......................................................................................................... 45
		Checks Before Starting Engine........................................................................................... 45
		Precautions When Starting............................................................................................... 45
		Precautions In Cold Areas............................................................................................... 46
		Hydraulic Oil Travel Circuit Warm-Up.................................................................................... 46
		Operation............................................................................................................... 47
		Precautions When Traveling In Forward Or Reverse........................................................................ 47
		Precautions When Traveling.............................................................................................. 48
		Working On Slopes....................................................................................................... 48
		Prohibited Operations................................................................................................... 50
		Precautions When Operating.............................................................................................. 51
		Operate Carefully On Snow............................................................................................... 52
		Parking The Machine..................................................................................................... 52
		Precautions For Emergency Recovery...................................................................................... 54
		Transportation.......................................................................................................... 55
		Loading And Unloading................................................................................................... 55
		Shipping................................................................................................................ 55
	BATTERY..................................................................................................................... 56
		Battery Hazard Prevention............................................................................................... 56
		Starting With Booster Cables............................................................................................ 57
	STOP ENGINE BEFORE PERFORMING MAINTENANCE................................................................................... 58
		Two Workers For Maintenance When Engine Is Running...................................................................... 59
		Proper Tools............................................................................................................ 60
		Personnel............................................................................................................... 60
		Attachments............................................................................................................. 60
		Work Under The Machine.................................................................................................. 60
		Noise................................................................................................................... 61
		Precautions When Using Hammer........................................................................................... 61
		Repair Welding.......................................................................................................... 61
		Removing Battery Terminal............................................................................................... 61
		Precautions With High-pressure Oil...................................................................................... 61
		Handling High-pressure Hoses............................................................................................ 61
		Waste Materials......................................................................................................... 62
		Compressed Air.......................................................................................................... 62
		Periodic Replacement Of Safety Critical Parts........................................................................... 62
	PRECAUTIONS WITH TIRES...................................................................................................... 63
		Handling Tires.......................................................................................................... 63
		Precautions When Storing Tires.......................................................................................... 63
	SAFETY LOCKS................................................................................................................ 64
		Loader Locks............................................................................................................ 64
OPERATION....................................................................................................................... 67
	GENERAL VIEWS............................................................................................................... 68
		Front General View...................................................................................................... 68
		Rear General View....................................................................................................... 69
		Cab Inside General View................................................................................................. 70
	INSTRUMENTS AND CONTROLS.................................................................................................... 72
		Instruments............................................................................................................. 72
		Warning Lights.......................................................................................................... 74
		Switches And Push Buttons............................................................................................... 79
		Electrical Accessories.................................................................................................. 84
		Machine Controls........................................................................................................ 86
		Safety Bars............................................................................................................. 88
	ISO PATTERN CONTROL SYSTEM.................................................................................................. 89
		Servo Control Lever (Travel And Steering)............................................................................... 89
		Right Servo Control Lever (Loader Arm And Bucket)....................................................................... 91
	OPTIONAL PATTERN CONTROL SYSTEM............................................................................................. 93
		Right Servo Control Lever (Right Wheel Travel And Bucket Folding)....................................................... 95
		Auxiliary Hydraulic Kit Control Pedal (If Installed).................................................................... 98
		Foot Accelerator........................................................................................................ 99
		Hand Accelerator........................................................................................................ 99
		Parking Brake...........................................................................................................100
		Equipment Control Locking Lever (If Installed)..........................................................................100
		Standard Flow Hydraulic System Control (2 Lines)........................................................................101
		"High Flow" Hydraulic System Control (3 Lines) (If Installed)...........................................................102
		Instruments And Controls Super Flow” Hydraulic System Control(5 Lines) (If Installed)...................................103
		Speed Increase Control..................................................................................................104
		Floating Device Control (If Installed)..................................................................................104
		Instruments And Controls Pattern Shifting Control (If Installed)........................................................105
		Stabilizer Control (If Installed).......................................................................................106
		Left Stabilizer Control (If Installed)..................................................................................106
		Optional................................................................................................................106
	FUSES AND RELAYS............................................................................................................107
		Machine Function Fuses..................................................................................................107
		Main Fuse...............................................................................................................108
		Relays..................................................................................................................109
	GUARDS AND DRIVER’S SEAT....................................................................................................111
		Engine Hood.............................................................................................................111
		Rear Panel..............................................................................................................112
		Cab.....................................................................................................................113
			Raising The Cab.....................................................................................................114
		Standard Seat...........................................................................................................116
		Cushioned Seat..........................................................................................................116
		Safety Belt.............................................................................................................117
		Seat Safety Switch......................................................................................................117
		Emergency Exit..........................................................................................................118
		Technical Documentation Case............................................................................................119
		Fire Extinguisher.......................................................................................................119
		First Aid Kit...........................................................................................................119
	USE OF THE MACHINE..........................................................................................................120
		Checks Before Starting The Engine.......................................................................................120
			Visual Checks.......................................................................................................120
			Daily Checks........................................................................................................120
			Operational Checks..................................................................................................121
		Starting The Engine.....................................................................................................122
			Starting With Warm Engine Or In Temperate Climates..................................................................122
			Starting With Cold Engine Or In Cold Climates.......................................................................123
		Warming The Engine......................................................................................................124
		Heating The Hydraulic Oil...............................................................................................124
		How To Move The Machine (Iso Pattern Control System)....................................................................124
			Steering (Changing Direction).......................................................................................126
		How To Move The Machine (Optional Pattern Control System)...............................................................128
			Steering (Changing Direction).......................................................................................130
		Moving On Slopes........................................................................................................132
		Maximum Immersion Depth.................................................................................................133
	PARKING THE MACHINE.........................................................................................................134
		Parking On Level Ground.................................................................................................134
		Parking On Slopes.......................................................................................................135
	STOPPING THE ENGINE.........................................................................................................136
	TRANSPORTING THE MACHINE ON OTHER VEHICLES..................................................................................137
		Loading And Unloading The Machine.......................................................................................137
		Transport...............................................................................................................138
	HOW TO LIFT THE MACHINE.....................................................................................................139
	PRECAUTIONS TO BE TAKEN IN THE COLD SEASON..................................................................................140
		Fuel And Lubricants.....................................................................................................140
		Coolant.................................................................................................................140
		Battery.................................................................................................................141
		Other Precautions.......................................................................................................141
		Precautions To Be Taken At The End Of Work..............................................................................141
	PRECAUTIONS TO BE TAKEN IN THE WARM SEASON..................................................................................142
	USING THE WORK EQUIPMENT....................................................................................................143
		Lowering The Equipment In Case Of Machine Failure.......................................................................143
		Organizing The Work Area................................................................................................144
		Loading Material On Heaps And On Level Surfaces.........................................................................145
		Loading Material On Slopes..............................................................................................146
		Digging Method..........................................................................................................147
		Changing the Bucket or Attachment with Standard Quick Coupler...........................................................149
			Removing the Bucket or Attachment...................................................................................150
			Installing the Bucket or Attachment.................................................................................151
			Checking Position of Locking Pins...................................................................................152
	LONG PERIODS OF INACTIVITY..................................................................................................153
		Before The Period Of Inactivity.........................................................................................153
		During The Period Of Inactivity.........................................................................................154
		After The Period Of Inactivity..........................................................................................154
	TROUBLESHOOTING.............................................................................................................155
		How To Remove The Machine...............................................................................................155
		If The Fuel Has Been Completely Depleted................................................................................155
		If The Battery Is Depleted..............................................................................................156
			Starting With Booster Cables........................................................................................157
		Other Troubles..........................................................................................................158
			Electric Circuit....................................................................................................158
			Hydraulic System....................................................................................................158
			Engine..............................................................................................................159
	HYDROSTATIC TRANSMISSION....................................................................................................160
MAINTENANCE.....................................................................................................................161
	GUIDE TO MAINTENANCE........................................................................................................162
	MAINTENANCE NOTES...........................................................................................................163
		Notes Regarding The Engine..............................................................................................163
			Engine Oil..........................................................................................................163
			Coolant.............................................................................................................163
			Fuel................................................................................................................164
		Notes Regarding The Hydraulic System....................................................................................164
		Notes Regarding The Electrical System...................................................................................164
		Notes Regarding Lubrication.............................................................................................165
		Parts Subject To Wear That Periodically Need Changing...................................................................165
	FUEL, COOLANT AND LUBRICANTS................................................................................................166
		Approved Synthetic Biodegradable Lubricants Type Hees...................................................................168
	DRIVING TORQUES FOR SCREWS AND NUTS.........................................................................................169
		Standard Driving Torques................................................................................................169
		Specific Driving Torques................................................................................................169
	LUBRICATION.................................................................................................................170
		Lubrication Diagram.....................................................................................................170
	PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY...................................................................171
		Critical Parts For Safety...............................................................................................172
			Operator's Safety...................................................................................................177
	MAINTENANCE PLAN............................................................................................................178
	MAINTENANCE PROCEDURE.......................................................................................................179
		Checks Before Starting..................................................................................................179
			Various Checks......................................................................................................179
			Checking The Coolant Level..........................................................................................179
			Checking The Fuel Level.............................................................................................180
			Checking The Engine Oil Level.......................................................................................181
			Checking The Oil Level In The Hydraulic Circuit.....................................................................182
			Checking The Water Separator For Sediments And Water................................................................183
			Checking The Wiring System..........................................................................................183
		When Required...........................................................................................................184
			Checking, Cleaning Or Changing The Air Cleaner Cartridge............................................................184
			Tire Rotation.......................................................................................................185
			Draining The Fuel Tank..............................................................................................186
			Releasing The Parking Brake.........................................................................................187
			Checking The Battery Charge Level...................................................................................188
		Maintenance After First 50 Hours Of Operation...........................................................................189
		Maintenance Every 50 Hours Of Operation.................................................................................189
			Checking The Tire Pressure..........................................................................................189
			Checking The Coolant Level In The Radiator..........................................................................189
		Maintenance After First 250 Hours Of Operation..........................................................................190
		Maintenance Every 250 Hours Of Operation................................................................................190
			Adjusting The Fan Belt Tension......................................................................................190
			Checking The Gearing Chain Tension..................................................................................191
			Adjusting The Chains................................................................................................192
			Cleaning The Outside Of The Radiators...............................................................................193
			Checking The Wheel Nut Driving Torque...............................................................................193
			Checking The Oil Level In The Final Transmissions...................................................................194
			Lubricating The Joints..............................................................................................195
			Changing The Engine Oil.............................................................................................196
			Changing The Engine Oil Filter......................................................................................197
		Maintenance After First 500 Hours Of Operation (Only For Machines Filled With Synthetic Biodegradable Oil Type Hees)....198
		Maintenance Every 500 Hours Of Operation................................................................................198
			Changing The Fuel Filter............................................................................................198
			Changing The Hydraulic Oil Drain Filter.............................................................................200
			Cleaning The Water Separator........................................................................................201
			Draining The Hydraulic Oil Tank (Only For Machines Filled With Synthetic Biodegradable Oil Type Hees)...............202
		Maintenance Every 1000 Hours Of Operation...............................................................................203
			Changing The Oil In The Final Transmission..........................................................................203
			Changing The Hydraulic System Oil And Cleaning The Suction Filter...................................................204
			Checking And Adjusting The Engine Valve Clearance...................................................................205
		Maintenance Every 2000 Hours Of Operation...............................................................................206
			Changing The Coolant................................................................................................206
			Changing The Suction Filter.........................................................................................207
			Checking The Alternator and The Starter.............................................................................208
SPECIFICATIONS..................................................................................................................209
	TECHNICAL DATA..............................................................................................................210
		Standard Machine Overall Dimensions.....................................................................................210
		Technical Characteristics...............................................................................................212
OPTIONS, ATTACHMENTS............................................................................................................213
	AUTHORIZED OPTIONAL EQUIPMENT...............................................................................................214
		Precautions Regarding Safety............................................................................................214
		Precautions Regarding The Installation Of Equipment.....................................................................214
		Characteristics Of The Standard Machine Optional Equipment..............................................................215
		Characteristics Of The Optional Equipment Of The Machine Version With Super-flow Hydraulic System.......................216
	CHANGING THE AUTHORIZED EQUIPMENT...........................................................................................217
		Connecting The Excavator................................................................................................217
		Connecting The Hydraulic Circuit........................................................................................218
		Connecting The Return Circuit With Direct Drainage Into The Tank........................................................220
		Preparing The Machine For The Use Of The Excavator......................................................................221
		Using The Machine With The Excavator....................................................................................221
	PALLET FORKS................................................................................................................222
		Changing The Operating Pattern..........................................................................................223
		How To Change The Operating Pattern.....................................................................................225
	HAND & FOOT CONTROL SYSTEM..................................................................................................226
		Machine Controls........................................................................................................226
			Travel And Steering Control Levers..................................................................................227
			Work Equipment Control Pedals (Loader Arm And Bucket)...............................................................229
			Auxiliary Hydraulic Kit Control.....................................................................................232
		How To Move The Machine (Hand & Foot Control System)....................................................................235
			Steering (Changing Direction).......................................................................................236

PLEASE NOTE:

⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]