Komatsu SKID-STEER LOADER SK815-8E0 Shop Manual WENBM00400 – PDF

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Komatsu SKID-STEER LOADER SK815-8E0 Shop Manual WENBM00400 – PDF DOWNLOAD

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Komatsu SKID-STEER LOADER SK815-8E0 Shop Manual WENBM00400 – PDF DOWNLOAD

Language : English
Pages :650
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu SKID-STEER LOADER SK815-8E0 Shop Manual WENBM00400 – PDF DOWNLOAD

SERIAL NUMBERS F30002 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
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.

TABLE OF CONTENTS:

Komatsu SKID-STEER LOADER SK815-8E0 Shop Manual WENBM00400 – PDF DOWNLOAD

SERIAL NUMBERS F30002 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
Cooling System 93
Layout Drawing of Cooling System 93
Control System 94
Layout Drawing of Control System 94
Machine Monitor System 95
System Diagram of Machine Monitor System 95
KOMTRAX System 96
System Diagram of KOMTRAX System 96
Function of KOMTRAX System 96
Component Parts of Control System 97
Machine Monitor 97
KOMTRAX Terminal106
Machine Controller108
Hydraulic System112
Layout Drawing of Hydraulic System112
CLSS113
Structure of CLSS113
Function of CLSS113
Component Parts of Hydraulic System115
Hydraulic Tank115
Hydraulic Pump116
Control Valve132
Work Equipment System146
Layout Drawing of Work Equipment System146
PPC Lock System147
System Diagram of PPC Lock147
Function of PPC Lock System147
Component Parts of Work Equipment System148
Work Equipment PPC Valve148
Attachment PPC Valve153
Solenoid Valve Group155
Super Flow Solenoid Valve156
Pilot Circuit Accumulator157
Travel System158
Layout Drawing of Travel System158
System Diagram of Travel Control System159
Function of Travel Control System159
Component Parts of Travel System160
Travel PPC Valve160
Final Drive164
Power Train170
Transmission171
Work Equipment173
Structure of Work Equipment173
Function of Work Equipment174
Work Equipment Clearance Adjustment Shim175
Function of Work Equipment Clearance Adjustment Shim175
20 Standard Value Table177
Table of Contents178
Standard Value Table for Engine179
Standard Value Table for Machine181
Machine Posture and Procedures to Measure Performance190
30 Testing and Adjusting193
Table of Contents194
Engine and Cooling System196
Examine Engine Speed196
How to Examine Engine High Idle Speed196
How to Examine Engine Low Idle Speed196
How to Examine Engine at Travel Relief196
How to Examine Engine at Travel and Work Equipment Relief197
Examine Exhaust Gas Color198
How to Examine Exhaust Gas Color with the Handy Smoke Checker198
How to Examine Exhaust Gas Color with Smoke Meter199
Examine and Adjust Valve Clearance200
How to Examine Valve Clearance200
How to Adjust Valve Clearance201
Examine Compression Pressure202
How to Examine Compression Pressure202
Examine Engine Oil Pressure204
How to Examine Engine Oil Pressure204
Bleed Air from Fuel System205
How to Bleed Air from Fuel System205
Examine Fuel Circuit for Leakage206
How to Examine Fuel Circuit for Leakage at Engine Stop206
How to Examine Fuel Circuit for Leakage at Engine Low Idle206
How to Examine Fuel Circuit for Leakage at Engine High Idle206
Handle Cylinder Cut-out Mode Operation207
Examine and Adjust Alternator Belt Tension208
How to Examine Alternator Belt Tension208
How to Adjust Alternator Belt Tension208
Frame210
Examine and Adjust Gear Chain Tension210
How to Examine Gear Chain Tension210
How to Adjust Gear Chain Tension210
Hydraulic System211
Release Remained Pressure in Hydraulic Circuit211
How to Release Remained Pressure from Hydraulic Tank211
How to Release Remained Pressure in PPC Accumulator Circuit211
How to Release Remained Pressure in Hydraulic Cylinder Circuit211
Examine Oil Pressure of Work Equipment212
How to Examine Unload Pressure212
How to Examine Oil Pressure of Work Equipment213
Adjust Oil Pressure of Work Equipment215
How to Adjust Unload Pressure215
How to Adjust Oil Pressure of Work Equipment Relief Pressure215
Examine Oil Pressure of Control Circuit217
How to Examine Oil Pressure of Control Circuit217
Examine and Adjust Oil Pressure of Pump Circuit219
How to Examine Oil Pressure of Travel Pump HST Charge Circuit219
How to Adjust Oil Pressure of Travel Pump HST Charge Circuit219
How to Examine Oil Pressure of Travel Pump AS Valve220
How to Adjust Oil Pressure of Travel Pump AS Valve at Low Idling221
How to Adjust Oil Pressure of Travel Pump AS Valve at High Idling221
Examine Outlet Pressure of Solenoid Valve223
How to Examine Outlet Pressure of Solenoid Valve223
Operating Condition of Solenoid Valve224
Examine PPC Valve Outlet Pressure225
How to Examine Outlet Pressure of PPC Valve225
How to Examine Outlet Pressure of PPC Valve for Travel System227
Examine Parking Brake Release Pressure229
How to Examine Parking Brake Release Pressure229
Examine and Adjust Travel Deviation230
How to Examine Travel Deviation at High Idling230
How to Examine Travel Deviation at Medium Idling230
How to Adjust Travel Deviation231
Adjust Play of Work Equipment and Travel PPC Valves233
How to Adjust Play of Work Equipment and Travel PPC Valves233
Examine Parts Which Cause Hydraulic Drift of Work Equipment234
How to Examine Parts Which Cause Hydraulic Drift of Arm Cylinder and Bucket Cylinder234
How to Examine Parts that Cause Hydraulic Drift of PPC Valve234
Bleed Air from Hydraulic System235
How to Bleed Air from Travel Pump235
How to Bleed Air from Cylinder236
Pressurize Hydraulic Tank237
How to Pressurize Hydraulic Tank237
Electrical System238
How to Set and Operate Machine Monitor238
Operator Mode240
Examine Function by LCD (Liquid Crystal Display)240
Examine Function of Service Meter241
Usage Limitation and Maintenance Password Change Function241
Service Mode241
How to Start Up KOMTRAX Terminal273
Handle Voltage Circuit of Engine Controller278
40 Troubleshooting279
Table of Contents280
Abbreviation List283
Related Information to Troubleshooting289
General Troubleshooting Points289
Sequence of Events in Troubleshooting290
Troubleshooting Points for Aftertreatment System292
Checks Before Troubleshooting300
Inspection Procedure Before Troubleshooting302
Walk-Around Check302
Test in Accordance with Testing Procedure304
Examine Fuel Level, Add Fuel304
Examine Water Separator, Drain Water and Sediment304
Replace Fuel Prefilter Element305
Replace Fuel Main Filter Cartridge307
Examine Oil Level in Engine Oil Pan, Add Oil309
Replace Oil in Engine Oil Pan and Engine Oil Filter Cartridge310
Examine Coolant Level, Add Coolant312
Examine Clogging of Air Cleaner312
Examine Oil Level in Hydraulic Tank, Add Oil317
Replace Hydraulic Oil Drain Filter318
Examine Gear Chains Tension319
Examine Oil Level in Final Transmission320
Bleed Air from Fuel System321
Bleed Air from Hydraulic System321
Examine Electric Equipment322
Procedure for Troubleshooting330
Information Shown in Troubleshooting Table333
Connector Contact Identification (For 4D88E-7 Engine)335
T-Branch Box and T-Branch Adapter Table339
Fuse Location Table345
Failure Code Table347
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 Operate413
When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing415
Engine Coolant Temperature Monitor Comes On in White While Engine Runs418
Charge Level Monitor Comes On in Red While Engine is in Operation419
Fuel Level Monitor Comes On in Red While Engine Runs420
Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation421
Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation422
Fuel Gauge Display Does Not Move from Minimum or Maximum423
Display of Fuel Gauge is Different from Actual Fuel Level425
Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum426
Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature427
Some Areas of Machine Monitor Screen are Not Shown428
Function Switch Does Not Operate429
Alarm Buzzer Does Not Sound430
Alarm Buzzer Cannot be Canceled432
Service Meter is Not Shown, While Starting Switch is in OFF Position433
Service Mode Cannot be Selected434
Alarm Does Not Sound During Travel435
Travel Alarm Does Not Stop When Machine Stops437
Horn Does Not Sound438
Horn Does Not Stop440
Front or Rear Working Lamps Do Not Light Up441
When Front Wiper Switch is Operated, Front Wiper Does Not Operate445
When Rear Wiper Switch is Operated, Rear Wiper Does Not Operate447
When Front Wiper Switch is Operated, Front Window Washer Does Not Operate449
When Rear Wiper Switch is Operated, Rear Window Washer Does Not Operate451
Travel Indicator is Not Shown Correctly with Monitoring Function453
Arm IN is Not Shown Normally in Monitoring Function454
KOMTRAX System Does Not Operate Normally455
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 Position457
S-2 Engine Cranks but No Exhaust Smoke Comes Out458
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)459
S-4 Engine Startability is Unsatisfactory460
S-5 Engine Does Not Pick Up Smoothly462
S-6 Engine Stops During Operation464
S-7 Engine Runs Rough or is Not Stable466
S-8 Engine Lacks Power467
S-9 KDPF Becomes Clogged in a Short Time469
S-10 Engine Oil Consumption is Excessive471
S-11 Oil Becomes Dirty Quickly472
S-12 Fuel Consumption is Excessive473
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant474
S-14 Oil Pressure Drops475
S-15 Fuel Mixes Into Engine Oil477
S-16 Water Mixes Into Engine Oil (Milky)478
S-17 Coolant Temperature Increases Too High (Overheating)479
S-18 Unusual Noise is Heard480
S-19 Vibration is Excessive482
S-20 Air Cannot be Bled from Fuel Circuit483
50 Disassembly and Assembly485
Table of Contents486
Related Information on Disassembly and Assembly488
How to Read This Manual488
Coating Materials List490
Engine and Cooling System494
Remove and Install Starter Assembly494
How to Remove Starter Assembly494
How to Install Starter Assembly494
Remove and Install Radiator Assembly495
How to Remove Radiator Assembly495
How to Install Radiator Assembly499
Remove and Install Engine and Pump Assembly502
How to Remove Engine and Pump Assembly502
How to Install Engine and Pump Assembly508
Remove and Install Fuel Tank Assembly514
How to Remove Fuel Tank Assembly514
How to Install Fuel Tank Assembly516
Remove and Install Alternator Assembly518
How to Remove Alternator Assembly518
How to Install Alternator Assembly518
Remove and Install Air Cleaner Assembly519
How to Remove Air Cleaner Assembly519
How to Install Air Cleaner Assembly519
Frame521
Remove and Install Engine Hood521
How to Remove Engine Hood521
How to Install Engine Hood522
Remove and Install Heater Assembly523
How to Remove Heater Assembly523
How to Install Heater Assembly525
Raise Arm and Tilt Cab528
How to Raise Arm528
How to Tilt Cab529
Fully Tilt and Rest the Cab Assembly531
How to Tilt of Cab531
How to Rest of Cab535
Remove and Install Cab Assembly540
How to Remove Cab Assembly540
How to Install Cab Assembly544
Remove and Install Wheel Hub Assembly549
How to Remove Wheel Hub Assembly549
How to Install Wheel Hub Assembly551
Remove and Install Travel Motor Assembly553
How to Remove Travel Motor Assembly553
How to Install Travel Motor Assembly555
Hydraulic System558
Remove and Install Pump Assembly558
How to Remove Pump Assembly558
How to Install Pump Assembly560
Remove and Install Gear Pump Assembly562
How to Remove Gear Pump Assembly562
How to Install Gear Pump Assembly563
Remove and Install Pump Coupling564
How to Remove Pump Coupling564
How to Install Pump Coupling565
Remove and Install Control Valve567
How to Remove Control Valve567
How to Install Control Valve569
Remove and Install PPC Valve571
How to Remove PPC Valve571
How to Install PPC Valve572
Work Equipment574
Remove and Install Arm574
How to Remove Arm574
How to Install Arm576
Remove and Install Lift Cylinder578
How to Remove Lift Cylinder578
How to Install Lift Cylinder579
Remove and Install Bucket Cylinder580
How to Remove Bucket Cylinder580
How to Install Bucket Cylinder580
Remove and Install Equipment Support Frame582
How to Remove Equipment Support Frame582
How to Install Equipment Support Frame582
Electrical System584
Remove and Install Battery584
How to Remove Battery584
How to Install Battery584
60 Maintenance Standard587
Table of Contents588
Engine and Cooling System589
Maintenance Standard for PTO589
Hydraulic System590
Maintenance Standard for Control Valve (Standard Flow)590
Maintenance Standard for Control Valve (Super Flow)595
Maintenance Standard for Work Equipment PPC Valve600
Maintenance Standard for Travel PPC Valve603
Maintenance Standard for Attachment PPC Valve606
Power Train608
Maintenance Standard for Transmission608
Work Equipment610
Maintenance Standard for Work Equipment Linkage610
Maintenance Standard for Lift Cylinder612
Maintenance Standard for Tilt Cylinder613
90 Circuit Diagrams615
Table of Contents616
How to Read the Codes for Electric Cable617
Hydraulic Circuit Diagram621
Symbols Used in Hydraulic Circuit Diagram621
Hydraulic Circuit Diagram625
Electrical Circuit Diagram627
Symbols Used in Electric Circuit Diagram627
Electrical Circuit Diagram (1/6)631
Electrical Circuit Diagram (2/6)633
Electrical Circuit Diagram (3/6)635
Electrical Circuit Diagram (4/6)637
Electrical Circuit Diagram (5/6)639
Electrical Circuit Diagram (6/6)641
INDEX643

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24