Komatsu Utility SK815-5 turbo Install guide

WEBM005500

SK714-5 SK815-5 SK815-5 turbo
WEBM005500
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SK714-5 SK815-5 SK815-5 turbo
CONTENTS
Page
10 STRUCTURE AND FUNCTION........................................................................................10-1
20 TESTING AND ADJUSTING.............................................................................................20-1
30 DISASSEMBLY AND ASSEMBLY..................................................................................30-1
40 MAINTENANCE STANDARD...........................................................................................40-1
CONTENTS
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SK714-5 SK815-5 SK815-5 turbo
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SK714-5 SK815-5 SK815-5 turbo
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SK714-5 SK815-5 SK815-5 turbo
SAFETY
00-3
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine.
TheserviceandrepairtechniquesrecommendedbyKomatsuUtilityanddescribeinthismanualarebothef-
fectiveandsafemethodsof operation.Some ofthese operationsrequire theuse oftoolsspecially designed
by Komatsu Utility for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual.
Thecautionsaccompanyingthesesymbolsshouldalwaysbecarefullyfollowed.Ifanydangerarisesormay
possibly arise, first consider safety, and take necessary steps to face.
SAFETY
GENERAL PRECAUTIONS
Mistakes in operation extremely dangerous.
Read all the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Beforecarryingout anygreasingorrepairs,readall
theprecautionswrittenonthedecalswhicharesuck
on the machine.
2. Whencarryingoutanyoperation,alwayswearsafe-
ty shoes and helmet. Do not wear loose work
clothes, or clothes with buttons missing.
• Always wear safety glasses when hitting parts
with a hammer.
• Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
Whencarryingoutweldingwork,alwayswearweld-
ing gloves, apron,glasses, cap and other clothes
suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on the
controls in the operator’s compartment.
5. Keepalltoolsingoodconditionandlearnthecorrect
way to use them.
6. Decide a place in the repair workshop to keep tools
andremovedparts.Alwayskeepthetoolsandparts
in their correct places. Always keep the work area
cleanandmakesurethatthereisnodirtoroilonthe
floor.
Smokeonlyintheareasprovidedforsmoking.Nev-
er smoke while working.
PREPARATIONS FOR WORK
7. Before adding or making any repairs, park the ma-
chineonhard,levelground,andblockthewheelsto
prevent the machine from moving.
8. Beforestarting work,lower outrigger,bucket orany
other work equipment to the ground. If this is not
possible,useblocks to preventthework equipment
from falling down. In addition, be sure to lock all the
control levers and hang warning sign on them.
9. When disassembling or assembling, support the
machinewithblocks,jacksorstandsbeforestarting
work.
10. Removeallmudandoilfromthestepsorotherplac-
es used to get on and off the machine. Always use
thehandrails,laddersorstepswhengettingonoroff
the machine.
Never jump on or off the machine.
If it is impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hy-
draulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
Before disconnecting or removing components of
the hydraulic circuit and engine cooling circuit, first
remove the pressure completely from the circuit.
12. Thewaterandoilinthecircuitsarenothotwhenthe
engine in stopped, so be careful not to get burned.
Waitfor theoil waterto coolbeforecarrying outany
work on the cooling water circuits.
13. Beforestartingwork,removetheleadsfromthebat-
tery.Alwaysremove thelead fromthe negative(– )
terminal first.

SK714-5 SK815-5 SK815-5 turbo
SAFETY
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14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment whichhas ample ca-
pacity. Install the lifting equipment at the correct
places.
Use a hoist or crane and operate slowly to prevent
the component from hitting any other part.
Do not work with any part still raised by the hoist or
crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leavetwoboltsinpositiononoppositesides.Slowly
releasethepressure,thenslowlyloosentheboltsto
remove.
16. When removing components, be careful not to
break or damage the wiring.
Damage wiring may cause electrical fires.
17. Whenremovingpiping,stopthefueloroilfromspill-
ingout.Ifanyfueloroildripsontothefloor,wipeitup
immediately.
Fuel or oil on the floor can cause you to slip, or can
even start fires.
18. Asageneralrule,donotusegasolinetowashparts.
In particular, use only the minimum of gasoline
when washing electrical parts.
19. Be sure to assemble all parts again in their original
places. Replace any damage parts with new parts.
When installing hoses and wires, be sure that they
will not be damaged by contact with other parts
when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are dan-
gerous, so be extremely careful when installing
tubes for high pressure circuits. Also, check that
connecting parts are correctly tightened.
21. When assembling or installing parts, always use
specified tightening torques.
When installing the parts which vibrate violently or
rotateat highspeed, beparticularycareful tocheck
that they are correctly installed.
22. When aligning two holes, never insert your fingers
or hand.
23. Whenmeasuringhydraulicpressure,checkthatthe
measuringtooliscorrectlyassembledbeforetaking
any measurement.
24. Take sure when removing or installing wheels.

SK714-5 SK815-5 SK815-5 turbo
FOREWORD
Thisshop manualhas beenpreparedas anaid toimprovethe qualityof repairsby givingthe operatoranaccurate
understandingof theproduct andby showing himthecorrect wayto performrepairsand makejudgements. Makesure
you understand the contents of this manual and use it to full effect at every opportunity.
Thisshopmanual mainlycontainsthe necessarytechnical informationfor operations performedin aservicework-
shop.
Themanualis dividedintochaptersoneachmaingroupof components; thesechaptersarefurtherdividedintothe
following sections.
STRUCTURE AND FUNCTION
Thissectionexplainsthestructureandfunctionofeachcomponent.Itservesnotonlytogiveanunderstanding
of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This sections 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 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.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
FOREWORD
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NOTE
The specifications contained in this shop manual are subject to change at anytime and without any no-
tice.
Contact your Komatsu Utility distributor for the latest information.

SK714-5 SK815-5 SK815-5 turbo
HOW TO READ THE SHOP MANUAL
VOLUMES
Shop manual are issued as a guide to carry out repairs.
These various volumes are designed to avoid duplicat-
ing the same information.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be
sent to Komatsu Utility distributors.
Getthemostup-to-dateinformationbeforeyoustartany
work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Followingexamplesshowyouhowtoreadthepage
number.
Example:
3. Additionalpages:additional pagesare indicatedby
a hyphen (–) and number after the page number.
Fle as in the example.
Example:
REVISED EDITION MARK
(➀➁➂....)
When a manual is revised, an edition mark is recorded
on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown on the LIST OF REVISED
PAGES between the title page and SAFETY page.
SYMBOLS
In order to make the shop manual greatly chelpful, im-
portant points about safety and quality are markedwith
the following symbols.
10 3
Item number (10. Structure and
Function)
Consecutive page number for each
item
-
10-4
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10-5
Added pages
Symbol Item Remarks
Safety
Special safety precautions
are necessary when
performing the work.
Extra special safety precautions
are necessary when performing
the work because it is under in-
ternal pressure.
★Caution
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Weight
Weight of parts or systems.
Caution necessary when select-
ing hoisting wire, or when work-
ing posture is important, etc.
Tightening
torque
Parts that require special atten-
tion for the tightening torque dur-
ing assembly.
Coat
Parts to be coated with adhe-
sives and lubricants etc.
Oil, water Places where oil, water or fuel must be added, and their quan-
tity.
Drain Places where oil or water must be drained, and quantity to be
drained.
HOW TO READ THE SHOP MANUAL
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