Komatsu SK815-5N, SK815-5NA Skid Steer Loader Shop Manual CEBM015901

Description

• Model List:
  • SK815-5N Skid Steer Loader
  • SK815-5NA Skid Steer Loader

• 0.1. GENERAL
• 0.2. HOW TO READ THE SHOP MANUAL
• 0.2.1. VOLUMES
• 0.2.2. DISTRIBUTION AND UPDATING
• 0.2.3. FILING METHOD
• 0.2.4. REVISED EDITION MARK
• 0.2.5. REVISIONS
• 0.2.6. SYMBOLS
• 0.3. HOISTING INSTRUCTIONS
• 0.3.1. HOISTING
• 0.3.2. WIRE ROPES
• 0.4. PUSH PULL COUPLER
• 0.5. COATING MATERIALS
• 0.6. SPECIFIC DRIVING TORQUE
• 0.7. STANDARD TIGHTENING TORQUE
• 0.7.1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
• 0.7.2. TIGHTENING TORQUE OF HOSE NUTS
• 0.7.3. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
• 0.7.4. TIGHTENING TORQUE FOR FLARED NUTS
• 0.7.5. TABLE OF TIGHTENING TORQUES FOR ORING BOSS PIPING JOINTS
• 0.7.6. TABLE OF TIGHTENING TORQUES FOR ORING BOSS PLUGS
• 0.7.7. TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
• 0.8. ELECTRIC WIRE CODE
• 0.8.1. CLASSIFICATION BY THICKNESS
• 0.8.2. CLASSIFICATION BY COLOR AND CODE
• 0.9. CONVERSION TABLES
• 0.9.1. METHOD OF USING THE CONVERSION TABLE
• 1. STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
• 1.1.1. Maintenance Standard
• 1.2. POWER TRAIN
• 1.2.1. Maintenance Standard
• 1.3. FINAL DRIVE
• 1.3.1. Maintenance Standard
• 1.3.2. Description
• 1.3.3. Hydraulic Motor
• 1.3.4. Flushing Relief Valve
• 1.3.5. Reduction Gearing
• 1.4. HYDRAULIC PUMP
• 1.4.1. HST Pump LPV40 40 (Standard Flow)
• 1.4.2. HST Pump LPV40 40 (High Flow)
• 1.4.3. HST Pump LPV40 40 (Standard Flow and High Flow)
• 1.4.4. Operation
• 1.4.5. Maintenance Standards
• 1.5. SAFETY VALVES
• 1.5.1. Suction Safety Valve Action
• 1.5.2. Charge Safety Valve Action
• 1.5.3. Charge Pump
• 1.6. ANTI ENGINESTALL VALVE (AS VALVE)
• 1.6.1. Maintenance Standards
• 1.7. CONTROL VALVES
• 1.7.1. Standard 3Spool Valve Port Location
• 1.7.2. Valve Sectional Views
• 1.7.3. Super HighFlow 4Spool Valve Port Location
• 1.7.4. Valve Sectional Views
• 1.7.5. Maintenance Standards
• 1.8. CLSS (CLOSED CENTER LOAD SENSING SYSTEM)
• 1.8.1. Pressure Compensation Control
• 1.8.2. System Series Circuit Operation
• 1.8.3. Self Leveling Function
• 1.8.4. System In SeriesParallel Circuit Operation
• 1.8.5. Pressure Compensation Valve
• 1.8.6. Dividing Function
• 1.9. SOLENOID VALVE
• 1.9.1. Valve Group ST1
• 1.9.2. Valve Group ST2
• 1.10. ACCUMULATOR
• 1.11. PATTERN CHANGE VALVE (OPTIONAL)
• 1.11.1. Operation
• 1.11.2. Maintenance Standards
• 1.12. PPC VALVE (STANDARD)
• 1.12.1. Equipment Control
• 1.12.2. Maintenance Standards
• 1.13. PPC VALVE (PATTERN CHANGE) (OPTIONAL)
• 1.13.1. Equipment and Travel Control
• 1.14. PPC VALVE (STANDARD)
• 1.14.1. Travel Control
• 1.14.2. Maintenance Standards
• 1.15. PPC VALVE PATTERN CHANGE (OPTIONAL)
• 1.15.1. Equipment and Travel Control
• 1.15.2. Maintenance Standards
• 1.16. PATTERN CHANGE VALVE (OPTIONAL)
• 1.16.1. Maintenance Standard
• 1.17. CYLINDERS
• 1.17.1. Boom
• 1.17.2. Bucket
• 1.17.3. Maintenance Standards
• 1.18. WORKING EQUIPMENT
• 2. STANDARD VALUE TABLES
• 2.1. STANDARD SERVICE VALUE TABLE
• 2.1.1. Standard Value Table
• 3. TESTING AND ADJUSTING
• 3.1. SPECIAL TOOLS
• 3.2. TADAPTER PROCEDURES AND KITS
• 3.3. ENGINE COMPONENTS
• 3.3.1. Measuring Exhaust Smoke
• 3.3.2. Measuring Exhaust Temperature
• 3.3.3. Measuring Crankcase Pressure
• 3.3.4. Measuring Boost Pressure
• 3.3.5. Measuring Fuel Pressure
• 3.3.6. Bleeding Air From Fuel System
• 3.3.7. Adjusting Engine Stop Solenoid
• 3.3.8. Checking The Engine Speed
• 3.3.9. Adjusting Valve Clearance (SK8155NA)
• 3.3.10. Adjusting Valve Clearance (SK8155N)
• 3.3.11. Measuring Compression Pressure (SK8155NA)
• 3.3.12. Measuring Compression Pressure (SK8155N)
• 3.3.13. Control and Adjustment of Fan Belt Tension
• 3.3.14. Control and Adjustment of the Injection Timing
• 3.3.15. Checking Engine Oil Pressure
• 3.3.16. Adjusting the Stroke of Accelerator Cables
• 3.4. ADJUSTING PPC VALVE DRIVE PRESSURES
• 3.4.1. Disassembly and Regulation
• 3.4.2. Adjustment of the PPC Valve Clearances
• 3.5. ADJUSTING SERVOCONTROL SAFETY SENSOR
• 3.6. GEAR CHAIN TENSION
• 3.6.1. Test
• 3.6.2. Adjustment
• 3.7. HYDRAULIC CIRCUITS
• 3.8. HYDRAULIC PUMP
• 3.9. VALVE CALIBRATION
• 3.9.1. HST Valve Calibration
• 3.9.2. AS Valve Calibration
• 3.9.3. Travel Deviation Check
• 3.10. CONTROL VALVE
• 3.11. SERVOCONTROL POWER SUPPLY
• 3.12. RELIEVING HYDRAULIC PRESSURE
• 3.12.1. Elimination of Pressures From the Hydraulic Circuits.
• 3.12.2. Elimination of Pressure in the Tank
• 3.12.3. Pressurizing the Tank
• 3.13. BLEEDING HYDRAULIC CIRCUITS
• 3.13.1. Sequence for Bleeding the Air
• 4. DISASSEMBLY AND ASSEMBLY
• 4.1. HOW TO READ THIS MANUAL
• 4.1.1. Removal And Installation Of Assemblies
• 4.1.2. Disassembly and Assembly of Assemblies
• 4.2. PRECAUTIONS DURING OPERATION
• 4.2.1. Precautions for Disassembly Operation
• 4.2.2. Precautions for Assembly Operation
• 4.2.3. Precautions for Completing Disassembly and Assembly Operations
• 4.2.4. Other Precautions
• 4.3. CONNECTOR REPAIR PROCEDURES
• 4.3.1. Stripping Insulation
• 4.3.2. Wire Inspection
• 4.3.3. Contact Terminal Removal (HD30 Type)
• 4.3.4. Crimping Contact Terminal (HD30 Type)
• 4.3.5. Insertion Of Contact Terminal (HD30 Type)
• 4.3.6. Contact Terminal Removal (DT Type)
• 4.3.7. Striping Insulation
• 4.3.8. Crimping Contact Terminal (DT Type)
• 4.3.9. Insertion Of Contact Terminal (DT Type)
• 4.4. ENGINE HOOD ASSEMBLY
• 4.4.1. Removal
• 4.4.2. Installation
• 4.5. ENGINE ASSEMBLY
• 4.5.1. Removal
• 4.5.2. Installation
• 4.5.3. Valve Cover (SK8155NA)
• 4.5.4. Valve Cover (SK8155N turbo)
• 4.5.5. Nozzle (SK8155NA)
• 4.5.6. Nozzle (SK8155N turbo)
• 4.5.7. Injector Pump
• 4.5.8. Cylinder Head (SK8155NA)
• 4.5.9. Cylinder Head (SK8155N turbo)
• 4.5.10. Tilting The Cab
• 4.5.11. Lowering The Cab
• 4.5.12. Removing the Cab
• 4.5.13. Installing the Cab
• 4.6. BATTERY
• 4.6.1. Removal
• 4.6.2. Installation
• 4.7. AIR CLEANER ASSEMBLY
• 4.7.1. Removal
• 4.7.2. Installation
• 4.8. MUFFLER (SK8155NA)
• 4.8.1. Removal
• 4.8.2. Installation
• 4.9. MUFFLER (SK8155N turbo)
• 4.9.1. Removal
• 4.9.2. Installation
• 4.10. RADIATOR ASSEMBLY
• 4.11. ENGINE PUMP COUPLING
• 4.12. FINAL DRIVE ASSEMBLY
• 4.12.1. Removal
• 4.12.2. Installation
• 4.13. CYLINDER ASSEMBLIES
• 4.13.1. Lift Cylinder Assembly
• 4.13.2. Bucket Cylinder Assembly
• 4.13.3. Disassembly of Cylinders
• 4.13.4. Assembly of the Cylinders
• 4.14. WORK EQUIPMENT SYSTEM
• 4.14.1. Removal
• 4.14.2. Installation
• 4.15. WORKING EQUIPMENT SUPPORT FRAME
• 4.15.1. Removal
• 4.15.2. Installation
• 5. DIAGRAMS AND SCHEMATICS
• 5.1. ELECTRICAL DIAGRAMS
• 5.1.1. Engine Line (1/2)
• 5.1.2. Engine Line (2/2)
• 5.1.3. Frame Line Standard (1/2)
• 5.1.4. Frame Line Standard (2/2)
• 5.1.5. Frame Line Optional (1/2)
• 5.1.6. Frame Line Optional (2/2)
• 5.1.7. Cabin Line Standard (1/4)
• 5.1.8. Cabin Line Standard (2/4)
• 5.1.9. Cabin Line Standard (3/4)
• 5.1.10. Cabin Line Standard (4/4)
• 5.1.11. Cabin Line Optional (1/6)
• 5.1.12. Cabin Line Optional (2/6)
• 5.1.13. Cabin Line Optional (3/6)
• 5.1.14. Cabin Line Optional (4/6)
• 5.1.15. Cabin Line Optional (5/6)
• 5.1.16. Cabin Line Optional (6/6)
• 5.1.17. TopCabin Light Line Standard (1/2)
• 5.1.18. TopCabin Light Line Standard (2/2)
• 5.1.19. TopCabin Light Line Homologation (1/2)
• 5.1.20. TopCabin Light Line Homologation (2/2)
• 5.2. HYDRAULIC DIAGRAMS
• 5.2.1. Standard
• 5.2.2. HighFlow
• 5.2.3. Road Homologation