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Komatsu SK815-5N, SK815-5NA Skid Steer Loader Shop Manual – PDF DOWNLOAD
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Komatsu SK815-5N, SK815-5NA Skid Steer Loader Shop Manual
Book Code: CEBM015901
SERIAL NUMBERS :
SK815-5N A30001 and up
SK815-5NA A10001 and up
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Description
Komatsu SK815-5N, SK815-5NA Skid Steer Loader Shop Manual
FILE DETAILS:
Komatsu SK815-5N, SK815-5NA Skid Steer Loader Shop Manual
Brands: Komatsu
Equipment Type: Skid Steer Loader
Manuals Type: Shop Manual
Machine Model: SK815-5N, SK815-5NA
Serial Number: A30001 and up, A10001 and up
Book Code: CEBM015901
Language: English
Pages: 288
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu SK815-5N, SK815-5NA Skid Steer Loader Shop Manual
1 GENERAL :
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD:
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. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
TESTING AND ADJUSTING:
This section 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:
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
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.
DIAGRAMS AND SCHEMATICS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu SK815-5N, SK815-5NA Skid Steer Loader Shop Manual
COVER............................................................................. 1 FOREWORD.......................................................................... 2 CONTENTS...................................................................... 2 SAFETY........................................................................ 7 SAFETY NOTICE............................................................. 7 IMPORTANT SAFETY NOTICE............................................... 7 GENERAL PRECAUTIONS................................................... 7 PREPARATIONS FOR WORK................................................. 7 PRECAUTIONS DURING WORK............................................... 8 GENERAL....................................................................... 9 HOW TO READ THE SHOP MANUAL................................................... 10 VOLUMES................................................................... 10 DISTRIBUTION AND UPDATING................................................. 10 FILING METHOD............................................................. 10 REVISED EDITION MARK...................................................... 10 REVISIONS................................................................. 10 SYMBOLS................................................................... 10 HOISTING INSTRUCTIONS......................................................... 11 HOISTING.................................................................. 11 WIRE ROPES................................................................ 11 PUSH PULL COUPLER............................................................. 12 TYPE 1.................................................................... 12 DISCONNECTION......................................................... 12 CONNECTION............................................................ 12 TYPE 2.................................................................... 13 DISCONNECTION......................................................... 13 CONNECTION............................................................ 13 TYPE 3.................................................................... 14 DISCONNECTION......................................................... 14 CONNECTION............................................................ 14 COATING MATERIALS............................................................. 15 SPECIFIC DRIVING TORQUE....................................................... 17 STANDARD TIGHTENING TORQUE.................................................... 18 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.............................. 18 TIGHTENING TORQUE OF HOSE NUTS............................................ 19 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................... 19 TIGHTENING TORQUE FOR FLARED NUTS......................................... 19 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS................. 20 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS......................... 20 TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE).... 20 ELECTRIC WIRE CODE............................................................ 21 CLASSIFICATION BY THICKNESS............................................... 21 CLASSIFICATION BY COLOR AND CODE.......................................... 21 CONVERSION TABLES............................................................. 22 METHOD OF USING THE CONVERSION TABLE...................................... 22 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................... 29 PTO........................................................................... 31 Maintenance Standard...................................................... 32 POWER TRAIN................................................................... 33 Maintenance Standard...................................................... 34 FINAL DRIVE................................................................... 38 Maintenance Standard...................................................... 40 Description............................................................... 41 Hydraulic Motor........................................................... 41 Function.............................................................. 41 Operation............................................................. 41 Flushing Relief Valve..................................................... 44 Reduction Gearing......................................................... 45 Function.............................................................. 45 Operating Principle................................................... 45 HYDRAULIC PUMP................................................................ 46 HST Pump LPV40 + 40 (Standard Flow)....................................... 46 HST Pump LPV40 + 40 (High Flow)........................................... 48 HST Pump LPV40 + 40 (Standard Flow and High Flow)......................... 50 Operation................................................................. 51 Maintenance Standards..................................................... 54 SAFETY VALVES................................................................. 55 Suction Safety Valve Action............................................... 55 Charge Safety Valve Action................................................ 58 Charge Pump............................................................... 60 ANTI ENGINE-STALL VALVE (AS VALVE)............................................ 61 Maintenance Standards..................................................... 63 CONTROL VALVES................................................................ 65 Standard 3-Spool Valve Port Location...................................... 65 Valve Sectional Views..................................................... 66 Super High-Flow 4-Spool Valve Port Location............................... 68 Valve Sectional Views..................................................... 69 Maintenance Standards..................................................... 72 Standard 3-spool...................................................... 72 Super High Flow 4-Spool............................................... 76 CLSS (CLOSED CENTER LOAD SENSING SYSTEM)...................................... 83 Pressure Compensation Control............................................. 83 System Series Circuit Operation........................................... 86 Self Leveling Function.................................................... 87 System In Series-Parallel Circuit Operation............................... 88 Pressure Compensation Valve............................................... 90 Dividing Function......................................................... 91 SOLENOID VALVE................................................................ 92 Valve Group ST1........................................................... 92 Valve Group ST2........................................................... 93 ACCUMULATOR................................................................... 94 PATTERN CHANGE VALVE (OPTIONAL)............................................... 95 Operation................................................................. 97 Pattern ISO........................................................... 97 Pattern Optional...................................................... 97 Maintenance Standards..................................................... 98 R.H. PPC VALVE (STANDARD)..................................................... 99 Equipment Control......................................................... 99 Maintenance Standards.....................................................103 R.H. PPC VALVE (PATTERN CHANGE) (OPTIONAL)....................................105 Equipment and Travel Control..............................................105 L.H. PPC VALVE (STANDARD).....................................................109 Travel Control............................................................109 Maintenance Standards.....................................................113 L.H. PPC VALVE PATTERN CHANGE (OPTIONAL)......................................115 Equipment and Travel Control..............................................115 Maintenance Standards.....................................................119 PATTERN CHANGE VALVE (OPTIONAL)...............................................121 Maintenance Standard......................................................121 CYLINDERS.....................................................................122 Boom......................................................................122 Bucket....................................................................122 Maintenance Standards.....................................................123 WORKING EQUIPMENT.............................................................124 20 STANDARD VALUE TABLES..........................................................127 STANDARD SERVICE VALUE TABLE..................................................128 Standard Value Table......................................................129 Engine................................................................129 Chassis...............................................................130 30 TESTING AND ADJUSTING..........................................................135 SPECIAL TOOLS.................................................................137 T-ADAPTER PROCEDURES AND KITS.................................................138 ENGINE COMPONENTS.............................................................139 Measuring Exhaust Smoke...................................................139 Measuring Exhaust Temperature.............................................139 Measuring Crankcase Pressure..............................................139 Measuring Boost Pressure..................................................139 Measuring Fuel Pressure...................................................139 Bleeding Air From Fuel System.............................................139 Adjusting Engine Stop Solenoid............................................139 Checking The Engine Speed.................................................140 Adjusting Valve Clearance (SK815-5NA).....................................141 Adjusting Valve Clearance (SK815-5N)......................................142 Zero setting..........................................................142 Adjustment............................................................142 Measuring Compression Pressure (SK815-5NA)................................144 Measuring Compression Pressure (SK815-5N).................................145 Control and Adjustment of Fan Belt Tension................................146 Checking the Tension..................................................146 Adjusting the Belt Tension............................................146 Control and Adjustment of the Injection Timing............................147 Checking Engine Oil Pressure..............................................149 Adjusting the Stroke of Accelerator Cables................................150 ADJUSTING PPC VALVE DRIVE PRESSURES...........................................151 Disassembly and Regulation................................................151 Assembly..............................................................152 Adjustment of the PPC Valve Clearances....................................153 ADJUSTING SERVO-CONTROL SAFETY SENSOR.........................................154 GEAR CHAIN TENSION............................................................155 Test......................................................................155 Adjustment................................................................155 HYDRAULIC CIRCUITS............................................................156 HYDRAULIC PUMP................................................................157 VALVE CALIBRATION.............................................................158 HST Valve Calibration.....................................................158 AS Valve Calibration......................................................158 Pressure Adjustment at Low Idling.....................................158 Pressure Adjustment at Working Pressure...............................159 Travel Deviation Check....................................................160 Checking the Deviation................................................160 Adjusting the Deviation...............................................161 CONTROL VALVE.................................................................162 SERVO-CONTROL POWER SUPPLY....................................................164 RELIEVING HYDRAULIC PRESSURE..................................................166 Elimination of Pressures From the Hydraulic Circuits......................166 Elimination of Pressure in the Tank.......................................166 Pressurizing the Tank.....................................................166 BLEEDING HYDRAULIC CIRCUITS...................................................167 Sequence for Bleeding the Air.............................................167 Bleeding Air From The Pump............................................167 Bleeding Air From The Cylinders.......................................168 Bleeding Air From Any Optional Equipment..............................168 50 DISASSEMBLY AND ASSEMBLY.......................................................169 HOW TO READ THIS MANUAL.......................................................172 Removal And Installation Of Assemblies....................................172 Special Tools.........................................................172 Removal...............................................................172 Installation..........................................................172 Disassembly and Assembly of Assemblies....................................174 Special Tools.........................................................174 Disassembly...........................................................174 Assembly..............................................................174 PRECAUTIONS DURING OPERATION..................................................175 Precautions for Disassembly Operation.....................................175 Precautions for Assembly Operation........................................176 Precautions for Completing Disassembly and Assembly Operations............176 Other Precautions.........................................................177 CONNECTOR REPAIR PROCEDURES...................................................178 Stripping Insulation......................................................178 Wire Inspection...........................................................178 Contact Terminal Removal (HD30 Type)......................................179 Crimping Contact Terminal (HD30 Type).....................................180 Insertion Of Contact Terminal (HD30 Type).................................181 Contact Terminal Removal (DT Type)........................................182 Striping Insulation.......................................................183 Crimping Contact Terminal (DT Type).......................................184 Insertion Of Contact Terminal (DT Type)...................................185 ENGINE HOOD ASSEMBLY..........................................................186 Removal...................................................................186 Installation..............................................................186 ENGINE ASSEMBLY...............................................................187 Removal...................................................................187 Installation..............................................................190 Valve Cover (SK815-5NA)...................................................191 Removal...............................................................191 Installation..........................................................191 Valve Cover (SK815-5N turbo)..............................................192 Removal...............................................................192 Installation..........................................................193 Nozzle (SK815-5NA)........................................................194 Removal...............................................................194 Installation..........................................................194 Nozzle (SK815-5N turbo)...................................................195 Removal...............................................................195 Installation..........................................................195 Injector Pump.............................................................196 Removal...............................................................196 Installation..........................................................198 Cylinder Head (SK815-5NA).................................................199 Removal...............................................................199 Installation..........................................................201 Cylinder Head (SK815-5N turbo)............................................202 Removal...............................................................202 Installation..........................................................204 Water Pump................................................................205 Removal...............................................................205 Installation..........................................................205 Starting Motor............................................................206 Removal...............................................................206 Installation..........................................................206 Turbocharger..............................................................207 Removal...............................................................207 Installation..........................................................208 Alternator................................................................209 Removal...............................................................209 Installation..........................................................209 CAB...........................................................................210 Tilting The Cab...........................................................210 Lowering The Cab..........................................................212 Removing the Cab..........................................................213 Installing the Cab........................................................215 BATTERY.......................................................................216 Removal...................................................................216 Installation..............................................................216 AIR CLEANER ASSEMBLY..........................................................217 Removal...................................................................217 Installation..............................................................217 MUFFLER (SK815-5NA)...........................................................218 Removal...................................................................218 Installation..............................................................218 MUFFLER (SK815-5N turbo)......................................................219 Removal...................................................................219 Installation..............................................................219 RADIATOR ASSEMBLY.............................................................220 Removal...................................................................220 Installation..............................................................221 FUEL TANK.....................................................................222 Removal...................................................................222 Installation..............................................................223 HYDRAULIC PUMP................................................................224 Removal...................................................................224 Installation..............................................................226 GEAR PUMP.....................................................................227 Removal...................................................................227 Installation..............................................................227 ENGINE PUMP COUPLING..........................................................228 Removal...................................................................228 Installation..............................................................228 CONTROL VALVE.................................................................229 Removal...................................................................229 Installation..............................................................229 PPC VALVES....................................................................230 Removal...................................................................230 Installation..............................................................230 WHEEL HUB.....................................................................231 Removal...................................................................231 Installation..............................................................232 Disassembly...............................................................233 Assembly..................................................................234 FINAL DRIVE ASSEMBLY..........................................................235 Removal...................................................................235 Installation..............................................................236 CYLINDER ASSEMBLIES...........................................................237 Lift Cylinder Assembly....................................................237 Removal...............................................................237 Installation..........................................................237 Bucket Cylinder Assembly..................................................238 Removal...............................................................238 Installation..........................................................239 Disassembly of Cylinders..................................................240 Assembly of the Cylinders.................................................242 Assembly of the Cylinder Head.........................................242 Piston Assembly.......................................................243 Piston Rod Assembly...................................................243 Cylinder Assembly.....................................................244 WORK EQUIPMENT SYSTEM.........................................................246 Removal...................................................................246 Installation..............................................................248 WORKING EQUIPMENT SUPPORT FRAME...............................................249 Removal...................................................................249 Installation..............................................................249 90 DIAGRAMS AND SCHEMATICS........................................................251 ELECTRICAL DIAGRAMS...........................................................253 Engine Line (1/2).........................................................253 Engine Line (2/2).........................................................254 Frame Line Standard (1/2).................................................255 Frame Line Standard (2/2).................................................256 Frame Line Optional (1/2).................................................257 Frame Line Optional (2/2).................................................258 Cabin Line Standard (1/4).................................................259 Cabin Line Standard (2/4).................................................260 Cabin Line Standard (3/4).................................................261 Cabin Line Standard (4/4).................................................262 Cabin Line Optional (1/6).................................................263 Cabin Line Optional (2/6).................................................264 Cabin Line Optional (3/6).................................................265 Cabin Line Optional (4/6).................................................266 Cabin Line Optional (5/6).................................................267 Cabin Line Optional (6/6).................................................268 Top-Cabin Light Line Standard (1/2).......................................269 Top-Cabin Light Line Standard (2/2).......................................270 Top-Cabin Light Line Homologation (1/2)...................................271 Top-Cabin Light Line Homologation (2/2)...................................272 Standard (1/5)............................................................273 Standard (2/5)............................................................274 Standard (3/5)............................................................275 Standard (4/5)............................................................276 Standard (5/5)............................................................277 Optional (1/7)............................................................278 Optional (2/7)............................................................279 Optional (3/7)............................................................280 Optional (4/7)............................................................282 Optional (5/7)............................................................283 Optional (6/7)............................................................284 Optional (7/7)............................................................285 HYDRAULIC DIAGRAMS............................................................286 Standard..................................................................286 High-Flow.................................................................287 Road Homologation.........................................................288
KOMATSU SK815-5N, SK815-5NA SKID STEER LOADER SHOP MANUAL – PDF DOWNLOAD:
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- 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]
