Komatsu SK815-5N SK815-5NA Skid Steer Loader Shop Manual PDF

Description

Komatsu SK815-5N SK815-5NA Skid Steer Loader Shop Manual CEBM015901 – PDF DOWNLOAD

FILE DETAILS:

Komatsu SK815-5N SK815-5NA Skid Steer Loader Shop Manual CEBM015901 – PDF DOWNLOAD 

Language : English
Pages : 288
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu SK815-5N SK815-5NA Skid Steer Loader Shop Manual CEBM015901 – PDF DOWNLOAD 

SERIAL NUMBERS

SK815-5N A30001 and up
SK815-5NA A10001 and up
ENGINES 4D88E-5
4D84E-5

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 thestructure, 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 CEBM015901 – PDF DOWNLOAD 

SERIAL NUMBERS

SK815-5N A30001 and up
SK815-5NA A10001 and up
ENGINES 4D88E-5
4D84E-5

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

S.V 15/12/24