Komatsu Utility SK714-5 Shop Manual Download Page 4

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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

00-2

Summary of Contents for SK714-5

Page 1: ...WEBM005500 ...

Page 2: ......

Page 3: ...SK714 5 SK815 5 SK815 5 turbo WEBM005500 00 1 ...

Page 4: ...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 00 2 ...

Page 5: ...16 10 17 10 18 10 19 10 20 10 21 10 22 10 23 10 24 10 25 10 26 10 27 10 28 10 29 10 30 10 31 10 32 10 33 10 34 10 35 10 36 10 37 10 38 10 39 10 40 10 41 10 42 10 43 10 44 10 45 10 46 10 47 10 48 10 49 10 50 10 51 10 52 10 53 10 54 10 55 10 56 10 57 10 58 10 59 10 60 10 61 10 62 10 63 10 64 10 65 10 66 10 67 10 68 10 69 10 70 10 71 10 72 10 73 10 74 10 75 10 76 10 77 10 78 10 79 10 80 10 81 10 82 1...

Page 6: ...rk Page Time of revision 30 34 30 35 30 36 30 37 30 38 30 39 30 40 30 41 30 42 30 43 30 44 30 45 30 46 30 47 30 48 30 49 30 50 30 51 30 52 30 53 30 54 30 55 30 56 30 57 30 58 30 59 30 60 30 61 30 62 40 1 40 2 40 3 40 4 40 5 40 6 40 7 40 8 40 9 40 10 40 11 40 12 40 13 40 14 40 15 40 16 40 17 40 18 40 19 40 20 40 21 40 22 REVISED PAGES 00 2 2 ...

Page 7: ...AIR 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 and removed parts Always keep the tools and parts in their correct places Always keep the work area clean and make sure that there is no dirt or oil on the floor Smoke only in the areas provided for smoking Nev er smoke while ...

Page 8: ...ause you to slip or can even start fires 18 As a general rule do not use gasoline to wash parts 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...

Page 9: ...ach component It serves not only to give an understanding 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 DISASS...

Page 10: ...and SAFETY page SYMBOLS In order to make the shop manual greatly chelpful im portant points about safety and quality are marked with the following symbols 10 3 Item number 10 Structure and Function Consecutive page number for each item 10 4 10 4 1 10 4 2 10 5 Added pages Symbol Item Remarks Safety Special safety precautions are necessary when performing the work Extra special safety precautions ar...

Page 11: ...ping of the rope from its original winding position on the load which can cause dangerous accidents 4 Do not sling a heavy load with ropes forming a wide hanging angle from the hook When hoisting a load with two or more ropes the force subjected to each rope will increase with the hanging angles The table below shows the variation of allowable load kg when hoisting is made with two ropes each of w...

Page 12: ... mm kgm Nm kgm Nm 6 8 10 12 14 1 1 25 1 5 1 75 2 10 13 17 19 22 8 6 8 10 12 0 96 0 1 2 3 0 2 4 6 0 5 7 8 0 8 12 5 1 9 5 1 23 2 45 4 9 77 8 122 13 1 3 0 15 3 2 0 3 6 5 0 6 11 1 17 5 2 13 5 1 5 32 2 3 5 63 6 5 108 11 172 18 16 18 20 22 24 2 2 5 2 5 2 5 3 24 27 30 32 36 14 14 17 17 19 19 5 2 27 3 38 4 52 6 66 7 191 21 262 28 372 40 511 57 644 70 27 3 37 4 53 6 73 8 92 10 268 29 366 36 524 57 719 80 9...

Page 13: ...2 6 0 5 4 0 5 6 7 2 8 2 9 7 3 17 3 20 5 8 2 20 5 25 5 4 9 39 2 4 9 65 7 19 6 78 5 19 6 95 15 29 4 166 7 29 4 196 2 49 78 5 19 6 196 2 49 Thread diameter of nut part mm Width across flats of nut part mm TIGHTENING TORQUE kgm Nm 9 16 18 11 16 16 13 16 16 1 14 1 3 16 12 1 7 16 12 1 11 16 12 2 12 17 22 24 30 36 41 50 57 2 3 2 5 3 4 3 9 5 2 5 8 8 2 9 2 12 2 13 3 15 3 17 3 18 4 20 4 20 4 24 4 23 25 33 3...

Page 14: ...hen the option of possible future dismantling is required Loctite 601 Used for high resistant locking of mechanical components that can be removed only after heating Loctite 675 Used to lock cylindrical couplings and for the permanent locking of threaded parts and also to lock shafts to bearings gears pulleys pins bushings etc Gasket sealant Loctite 542 Used by itself to seal grease fittings taper...

Page 15: ...2 5 35 0 30 2 47 3 80 20 4 56 0 30 3 95 4 60 28 6 84 0 30 5 93 5 20 37 Primary Auxiliary Code A A B A B A G A N A N A R A V A V Colour Light Blue Light Blue White Light Blue Yellow Light Blue Black Light Blue Red Light Blue Green Code B B G B N B N B R B R Colour White White Yellow White Black White Red Code C C B C B C L C N C N Colour Orange Orange White Orange Blue Orange Black Code G G N G N G...

Page 16: ...1 5 Engine hood 14 5 14 5 14 5 Cabin without seat 215 215 215 Seat standard witj suspension 10 16 10 16 10 16 Engine pump group 278 285 283 290 283 290 Piston pump standard High Flow 78 84 82 88 82 88 Wheel assy standard 43 44 44 Control valve 3 spool standard 4 spool High Flow 19 21 5 19 21 5 19 21 5 Work equipment without bucket Arm Work equipment support Bucket L 1460 mm Tilt cylinder Dump cyli...

Page 17: ...ctions First filling quantity total quantity of oil including the oil for the components and pipes Oil change quantity quantity of oil necessary to fill the system or unit during the normal inspection and maintenance operations ASTM American Society of Testing and Materials SAE Society of Automotive Engineers API American Petroleum Institute RESERVOIR KIND OF FLUID AMBIENT TEMPERATURE CAPACITY ᐉ 3...

Page 18: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 19: ...al point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 in 3 The original value 550 mm was divided by 10 so multiply 2 165 in by 10 move the decimal point one place to the right to return to the original value This gives 550 mm 21 65 in From millimeters to inches 1 mm 0 03937 in 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0 0 394...

Page 20: ... 1 102 1 496 1 890 2 283 2 677 3 071 3 465 3 858 0 354 0 748 1 142 1 536 1 929 2 323 2 717 3 110 3 504 3 898 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0 22 05 44 09 66 14 88 18 110 23 132 28 154 32 176 37 198 42 2 20 24 25 46 30 68 34 90 39 112 44 134 48 156 53 178 57 200 62 4 41 26 46 48 50 70 55 92 59 114 64 136 69 158 73 180 78 202 83 6 61 28 66 50 71 72 75 94 80 116 85 138 89 160 94 182...

Page 21: ...341 22 983 25 625 2 113 4 755 7 397 10 039 12 680 15 322 17 964 20 605 23 247 25 889 2 378 5 019 7 661 10 303 12 944 15 586 18 228 20 870 23 511 26 153 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 0 2 200 4 399 6 599 8 799 10 998 13 198 15 398 17 598 19 797 0 220 2 420 4 619 6 819 9 019 11 281 13 418 15 618 17 818 20 017 0 440 2 640 4 839 7 039 9 239 11 438 13 638 15 838 18 037 20 237 0 660 2 ...

Page 22: ...34 871 142 241 2 948 10 318 17 688 25 058 32 428 39 798 47 168 54 538 61 908 69 278 76 648 84 018 91 388 98 758 106 128 113 498 120 868 128 238 135 608 142 978 3 685 11 055 18 425 25 795 33 165 40 535 47 905 55 275 82 645 70 015 77 385 84 755 92 125 99 495 106 865 114 235 121 605 128 975 136 345 143 715 4 422 11 792 19 162 26 532 33 902 41 272 48 642 56 012 63 382 70 752 78 122 85 492 92 862 100 2...

Page 23: ...606 16 626 17 646 18 666 19 686 0 408 1 428 2 448 3 468 4 488 5 508 6 528 7 548 8 568 9 588 10 608 11 628 12 648 13 668 14 688 15 708 16 728 17 748 18 768 19 788 0 510 1 530 2 550 3 570 4 590 5 610 6 630 7 650 8 670 9 690 10 710 11 730 12 750 13 770 14 790 15 810 16 830 17 850 18 870 19 890 0 612 1 632 2 652 3 672 4 692 5 712 6 732 7 752 8 772 9 792 10 812 11 832 12 852 13 872 14 892 15 912 16 932...

Page 24: ... 3 1106 6 1179 0 1251 3 1323 6 1396 0 28 9 101 3 173 6 245 9 318 3 390 6 462 9 535 2 607 6 679 9 752 2 824 6 896 9 969 2 1041 5 1113 9 1186 2 1258 5 1330 9 1403 2 36 2 108 5 180 8 253 2 325 5 397 8 470 2 542 5 614 8 687 1 759 5 831 8 904 1 876 5 1048 8 1121 1 1193 4 1265 8 1338 1 1410 4 43 4 115 7 188 1 260 4 332 7 405 1 477 4 549 7 622 0 694 4 766 7 839 0 911 4 983 7 1056 0 1128 3 1200 7 1273 0 1...

Page 25: ...2 3524 2 58 0 203 0 348 1 493 1 638 1 783 2 928 2 1073 2 1218 2 1363 3 1508 3 1653 3 1798 4 1943 4 2088 4 2233 5 2378 5 2523 5 2668 5 2813 6 2958 6 3103 6 3248 7 3393 7 3538 7 72 5 217 5 362 6 507 6 652 6 797 7 942 7 1087 7 1232 7 1377 8 1522 8 1667 8 1812 9 1957 9 2102 9 2248 0 2393 0 2538 0 2683 0 2828 1 2973 1 3118 1 3263 2 3408 2 3553 2 87 0 232 0 377 1 522 1 667 1 812 2 957 2 1102 2 1247 2 13...

Page 26: ...3 7 8 7 2 6 7 6 1 5 6 5 0 4 4 3 9 3 3 2 8 2 2 1 7 1 1 0 6 0 0 0 6 1 1 1 7 2 2 2 8 3 3 3 9 4 4 5 0 5 6 6 1 6 7 7 2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 51 8 53 6 55 4 57 2 59 0 60 8 62 6 64 4 66 2 68 0 69 8 71 6 73 4 75 2 77 0 78 8 80 6 72 4 84 2 86 0 87 8 89 6 91 4 93 2 95 0 96 8 98 6 100 4 102 2 104 0 105 8 107 6 109 4 111 2 113 ...

Page 27: ... 43 Solenoid valve 51 Accumulator 53 Pattern change valve Optional 54 R H PPC Valve Standard 58 R H PPC Valve Pattern Change Optional 62 L H PPC Valve Standard 66 L H PPC VALVE Pattern Change Optional 70 Cylinders 74 Electrical diagram Engine line 75 Electrical diagram Frame line standard 79 Electrical diagram Frame line optional 83 Electrical diagram Cabin line standard 87 Electrical diagram Cabi...

Page 28: ...10 2 SK714 5 SK815 5 SK815 5 turbo P T O 1 Joint 2 Spring pin 3 Dumper 4 Flywheel cover 5 Hydraulic pump RKS01090 4 2 3 1 5 STRUCTURE AND FUNCTION P T O ...

Page 29: ...S00990 8 4 3 5 8 8 8 1 2 6 7 A B C STRUCTURE AND FUNCTION POWER TRAIN 1 Engine 2 Hydraulic pump 3 Control valve 4 Solenoid valve 4a Servocontrol 4b Speed increment 4c Parking brake 5 High flow solenoid valve 6 L H final drive 7 R H final drive 8 Axle ...

Page 30: ...4 5 SK815 5 SK815 5 turbo TRANSMISSION 1 L H final drive 2 Front trasmission chain 3 Rear trasmission chain 4 Master link RKS01001 1 X A A B B C C View X Section A A 2 3 2 3 4 STRUCTURE AND FUNCTION TRANSMISSION ...

Page 31: ...5 5 SK815 5 turbo 1 Front wheel 2 Axle housing 3 Sprocket 4 Shaft 5 Front trasmission chain 6 Rear wheel 7 Rear trasmission chain RKS01010 4 5 3 2 1 4 3 7 2 6 Section B B Section C C STRUCTURE AND FUNCTION TRANSMISSION ...

Page 32: ... PB2 port c PP1 Port From solenoid valve group ST1 A Port 2nd speed d PP2 Port From solenoid valve group ST1 C Port parking brake e DR Port To hydraulic tank R H FINAL DRIVE a A Port To hydraulic pump PB1 port b B Port To hydraulic pump PA1 port c PP1 Port From solenoid valve group ST1 A Port 2nd speed d PP2 Port From solenoid valve group ST1 C Port parking brake e DR Port To hydraulic tank ...

Page 33: ...25 24 23 26 STRUCTURE AND FUNCTION FINAL DRIVE 1 Shaft 2 Bearing 3 Bearing 4 Body 5 Pin 6 Gear 7 Shoe 8 Brake piston 9 Plate 10 Cylinder block 11 Bearing 12 Spring 13 Piston 14 Brake spring 15 Bushing 16 Retainer plate 17 Swash plate 18 Plate 19 Shaft 20 Flange 21 Collar 22 Gasket 23 Plug 24 Spring 25 Spool 26 Plug 27 Spool 28 Plug 29 Spring ...

Page 34: ...pump through port B Rotation in the opposite direction is achieved by sending the oil to port B instead of to port A Varying the displacement The swash plate 4 which has two surfaces A and B on the side opposite the sliding side for the shoes 6 is sup ported by two bearings 7 attached to the body of the motor 8 The position of the bearings is eccentric with respect to the axis of the shaft and whe...

Page 35: ... and 5 which are integrated with the housing and is thus blocked The drive shaft 6 can therefore no longer turn When the motor is running and the operator disengages the brake oil is sent under pressure to the chamber A The force exerted by the oil is greater than the force of the springs 2 and the piston 1 is therefore pushed to the right thus releasing the friction disk 3 and permitting rotation...

Page 36: ...the B port and the oil gallery D which is connected to the over pressure limitation valve 2 If the pressure present at port B exceeds the calibration value of the overpressure limitation valve 2 this valve will open and discharge the excess oil into the reduction gears The valve also functions in the same way when the pressurised oil is sent to the B port The only difference is that the selector v...

Page 37: ...e motoristransmittedto the gear s1 andhence tothe bevel gears b1 whi ch are integrated with the planetary gear 1 Sincethegear a1 isfixedwithrespecttotheoutputshaftofthehydraulicmotor theplanetarygearisobligedtoturn mo ving with it the output shaft 2 of the reduction gearing connected to the planetary gear by means of grooved toothing The reduction ratio of the rotation speed is described by the fo...

Page 38: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 39: ...Jic P2 P4 P3 100 Mesh ø6 4L 1500 1 2 20 Jic ø 10L 1050 9 16 18 Jic A B C P T ø 6 4L 950 1 2 20 Jic ø 6 4L 850 1 2 20 Jic ø 6 4L 650 1 2 20 Jic ø 6 4L 650 1 2 20 Jic ø19 1L 1100 1 3 16 12 Orfs Engine 4D88E E1FD E 34 7km 2800rpm PA1 DA1 DB1 DB2 DA2 PA2 P4 PB1 T5 PB2 S3 S4 40cm3 rev 40cm3 rev E2 ø 25 4L 620 1 5 16 12 JIC ø9 5L 1000 9 16 18 Jic ø 25 4L 500 1 5 16 12 JIC ø19L 1450 1 5 16 12 JIC ø20 ø16...

Page 40: ...100 Mesh ø6 4L 1500 1 2 20 Jic ø 10L 1050 9 16 18 Jic A ø 10L 470 9 16 18 Jic B C P T ø9 5L 1000 9 16 18 Jic ø 9 5L 1050 9 16 18 Jic ø 6 4L 950 1 2 20 Jic ø 6 4L 850 1 2 20 Jic ø 6 4L 650 1 2 20 Jic ø 6 4L 650 1 2 20 Jic ø19 1L 1100 1 3 16 12 Orfs Engine 4D88E E1FD E 34 7km 2800rpm PA1 DA1 DB1 DB2 DA2 PA2 P4 PB1 T5 PB2 S3 S4 40cm3 rev 40cm3 rev E2 ø 25 4L 620 1 5 16 12 JIC ø10L 470 9 16 18 Jic ø 2...

Page 41: ...20 9 16 18 Jic P2 P4 P3 100 Mesh ø6 4L 1500 1 2 20 Jic ø 10L 1050 9 16 18 Jic A B C P T ø 6 4L 950 1 2 20 Jic ø 6 4L 850 1 2 20 Jic ø 6 4L 650 1 2 20 Jic ø 6 4L 650 1 2 20 Jic ø19 1L 1100 1 3 16 12 Orfs Engine 4D88E E1FD E 34 7km 2800rpm PA1 DA1 DB1 DB2 DA2 PA2 P4 PB1 T5 PB2 S3 S4 40cm3 rev 40cm3 rev ø 25 4L 620 1 5 16 12 JIC ø9 5L 1000 9 16 18 Jic ø 25 4L 500 1 5 16 12 JIC ø19L 1450 1 5 16 12 JIC...

Page 42: ...c P2 P4 P3 100 Mesh ø6 4L 1500 1 2 20 Jic ø 10L 1050 9 16 18 Jic A ø 10L 470 9 16 18 Jic B C P T ø9 5L 1000 9 16 18 Jic ø 9 5L 1050 9 16 18 Jic ø 6 4L 950 1 2 20 Jic ø 6 4L 850 1 2 20 Jic ø 6 4L 650 1 2 20 Jic ø 6 4L 650 1 2 20 Jic ø19 1L 1100 1 3 16 12 Orfs Engine 4D88E E1FD E 34 7km 2800rpm PA1 DA1 DB1 DB2 DA2 PA2 P4 PB1 T5 PB2 S3 S4 40cm3 rev 40cm3 rev ø 25 4L 620 1 5 16 12 JIC ø10L 470 9 16 18...

Page 43: ...ction safety valve 4 Charge safety valve 5 Charge pump 6 Work equipment pump 7 Adjustment screw Neutral position 8 Adjustment screw Max displacement 9 Adjustment screw Pump power control STRUCTURE This pump is composed of variable swash plate type tan dem piston pumps 1 control pistons 2 suction safety valves 3 charge safety valve 4 charge pump 5 work equipment gear pump 6 and adjustment screws 7 ...

Page 44: ...ty valve 4 Charge safety valve 5 Charge pump 6 Work equipment pump 7 Adjustment screw Neutral position 8 Adjustment screw Max displacement 9 Adjustment screw Pump power control STRUCTURE This pump is composed of variable swash plate type tan dem piston pumps 1 control pistons 2 suction safety valves 3 charge safety valve 4 charge pump 5 work equipment gear pump 6 and adjustment screws 7 8 9 ...

Page 45: ...safety valve 5 Charge pump 6 Work equipment pump 7 Adjustment screw Neutral position 8 Adjustment screw Max displacement 9 Adjustment screw Pump power control 10 AS valve 11 Shuttle valve STRUCTURE This pump is composed of variable swash plate type tan dem piston pumps 1 control pistons 2 suction safety valves 3 charge safety valves 4 charge pump 5 work equipment gear pump 6 and adjustment screws ...

Page 46: ...fety valve 5 Charge pump 6 Work equipment pump 7 Adjustment screw Neutral position 8 Adjustment screw Max displacement 9 Adjustment screw Pump power control 10 AS valve 11 Shuttle valve STRUCTURE This pump is composed of variable swash plate type tan dem piston pumps 1 control pistons 2 suction safety valves 3 charge safety valve 4 charge pump 5 work equipment gear pumps 6 and adjustment screws 7 ...

Page 47: ...r block 9 is supported to shaft 1 by a spline 12 and shaft 1 is supported by the front and rear bearings 11 13 The tip of piston 8 is a concave ball and shoe 7 is caulked to it to form one unit Piston 8 and shoe 7 form a spherical bearing Rocker cam 4 has flat surface A and shoe 7 is always pressed against this surface while sliding in a circular movement There is a cradle bearing 3 between cradle...

Page 48: ...ig 1 ii If center line X of rocker cam 4 is in line with the axial direction of cylinder block 9 swash plate angle 0 the difference between volu mes E and F inside cylinder block 9 beco mes 0 so the pump does not carry out any suction or discharge of oil Fig 2 iii Center line X of rocker cam 4 maintains swash plate angle αin relation to the axial di rection of cylinder block 9 and flat surface A m...

Page 49: ...urface to cradle slides in a rotating movement in direction On this pump maximum swash plate angle is 15 8 Screw A restricts to the maximum stroke of control piston i e maximum displacement of each pump When screw A is tightened maximum displacement decreases and when screw A is loosened maximum displacement in crease This screw should be adjusted when the machine doesn t travel straight or machin...

Page 50: ... balanced position by spring force and pressure PPA PPB If the relation of pressure dimension of PPA PPB is reversed i e PPA PPB control piston moves reversal di rection On SK714 5 AS valve is not installed so pressurized oil from PPC valve is directly inducted to control piston On SK815 5 and SK815 5 turbo AS valve is installed and lower pressure between AS valve output pressure and PPC pressure ...

Page 51: ...d to each HST pump and they have the following functions 1 High pressure safety valve The valve restricts the maximum pressure inside the HST circuit in order to protect the HST circuit 2 Suction safety valve The valve ensures the flow of the charge oil to the closed HST circuit and prevents the charge oil from flowing into the pump high pressure side delivery side RKS00110 4 3 1 3 5 2 RKS00090 3A...

Page 52: ... The pressurized oil at high pressure port A fills port D through groove b between body and valve Poppet 3A is in tight contact with valve seat 3C If abnormal pressure is generated in the circuit and the oil pressure at ports A and D reaches to the pressure set by spring 3D poppet 3A is pushed to direction and oil at port A is relieved to port B to reduce the oil pressure at port A RKS00050 3A 3B ...

Page 53: ...very is 0 The HST circuit is closed and the charge oil does not flow into the HST circuit Therefore the charge pressurized oil from the charge pump 1 all passes the charge safety valve 2 and is drained to the pump case RKS00121 PB PA Travel motor Travel pump 2 3 1 3 STRUCTURE AND FUNCTION HYDRAULIC PUMP ...

Page 54: ...use of the difference in area A1 A2 Thereforethe pressure oil from charge pump is prevented from flowing into HST pump 2 Valve at piston pump suction side Port PB is at low pressure because port PB is suction side And sleeve 3C is pushed to direction to open body seat portion because of the difference in area A1 A2 In this way the charge pressure oil at port B flows into port PB through this clear...

Page 55: ...oppet 2E Spring 2F Adjustment screw 3 Suction safety valve FUNCTION There is the charge safety valve installed to the HST pump The charge safety valve restricts the maximum pressure inside the charge circuit in order to protect the charge circuit RKS00140 2 3 1 3 RKS00040 2A 2B 2G 2C 2D 2E 2F STRUCTURE AND FUNCTION HYDRAULIC PUMP ...

Page 56: ...andC reaches the pressure set by spring 2E poppet 2D is pushed to direction and oil atCis relieved to port B and pressure of the oil at C reduce When the pressure of the oil at port C goes down a differential pressure is occured between ports A and C because of orifice a in valve 2A Valve 2A is pushed to direction by oil pressure at port A and oil at port A is relieved to port B In this way the pr...

Page 57: ...ing 5 Case 6 Inner roter 7 Outer roter FUNCTION HST charge pump is built inthe HST pump anddriven with HST pump at the same time Discharged oil is delivered to AS valve and charge sa fety valve AS valve is only installed SK815 5 and SK815 5 turbo Charge pump sucks oil from hydraulic tank SPECIFICATIONS Type trochoid pump Theoletical delivery 25 cm rev ...

Page 58: ...pling 2 so inner roter 6 and outer roter 7 rotate When inner roter 6 and outer roter 7 rotate capacity of A increase and oil is sucked and capacity of B decrease and oil discharge RKS00161 Suction port Discharge port Discharge side Suction side 7 6 B A A A 2 STRUCTURE AND FUNCTION HYDRAULIC PUMP ...

Page 59: ...DRAULIC PUMP 1 AS valve 1A Nut 1B Screw 1C Spring 1D Spring 1E Spring 1F Valve 1G Valve 1H Nut 1L Screw 2 Charge pump 3 Orifice 4 Charge safety valve 5 Engine FUNCTION The AS valve is attached on the main piston pump It reduces pressure for pump swash plate control from charge circuit The AS valve outputs pressure correspond with en gine revolution ...

Page 60: ...tial pressure is generated at port A and port B This differential pressure actuates the differential pressure sensing valve 1G and makes hydraulic force F By the hydraulic force F the differential pressure sensing valve 1G is moved direction That makes a change of spring 1D load In port C the AS valve output pressure that is balanced with spring 1C and 1D load is generated by reducing from charge ...

Page 61: ...to pump swash plate control pressure OPERATION Port C is connected to port A Travel PPC pressure inlet port And hydraulic force F1 by travel PPC pressure ac tuates the valve 1 And port D is connected to port B AS pressure inlet port Hydraulic force F2 by AS valve pressure actuates the val ve 1 Bythe hydraulicforceF1 andF2 the shuttle valveselectslower pressure either PPC pressure orAS valve pressu...

Page 62: ... E C C D D B B PB2 PB1 PB3 B3 A3 A2 A1 P1 B2 B1 T PA2 PA1 PA3 TS STRUCTURE AND FUNCTION CONTROL VALVE P1 from gear pump T to tank Ts to tank A1 to lift arm cylinder head side A2 to bucket cylinder head side A3 to attachment port B1 to lift arm cylinder bottom side B2 to bucket cylinder bottom side B3 to attachment port ...

Page 63: ...TROL VALVE 1 Main relief valve 2 Stop plug lift arm bottom side 3 Suction valve bucket bottom side 4 Stop plug for individual relief valve 5 Suction valve lift arm head side 6 Series parallel circuit switching valve 7 Spool lift arm 8 Spool bucket 9 Spool attachment 10 Flow divider 11 Check valve circulating circuit 12 Combination circulating valve 13 Leveling circulating valve ...

Page 64: ...ve F lift arm 3 Pressure compensation valve F bucket 4 Pressure compensation valve F attachment 5 Pressure compensation valve R attachment 6 Pressure compensation valve R bucket 7 Pressure compensation valve R lift arm 8 Spool lift arm 9 Suction valve 10 Shuttle valve 11 Spool bucket 12 Suction valve 13 Shuttle valve 14 Spool attachment 15 Stop plug for individual relief valve F Flow control valve...

Page 65: ...B B PA2 PA1 PA3 TS STRUCTURE AND FUNCTION CONTROL VALVE P1 from gear pump P2 from gear pump T to tank Ts to tank Pi2 From solenoid valve group ST2 S port A1 to lift arm cylinder head side A2 to bucket cylinder head side A3 to attachment port A4 to High Flow port B1 to lift arm cylinder bottom side B2 to bucket cylinder bottom side B3 to attachment port B4 to High Flow attachment port ...

Page 66: ...7 6 STRUCTURE AND FUNCTION CONTROL VALVE 1 Main relief valve 2 Stop plug lift arm bottom side 3 Suction valve bucket bottom side 4 Stop plug for individual relief valve 5 Float valve 6 Series parallel circuit switching valve 7 Spool lift arm 8 Spool bucket 9 Spool attachment 10 Spool High Flow ...

Page 67: ... F bucket 4 Pressure compensation valve F attachment 5 Pressure compensation valve F High Flow 6 Check valve for High Flow joining circuit 7 Pressure compensation valve R High Flow 8 Pressure compensation vavle R attachment 9 Pressure compensation valve R bucket 10 Pressure compensation valve R lift arm 11 Combination circulating valve 12 Leveling circulating valve 13 Flow divider 14 Check valve c...

Page 68: ...compensation valve F lift arm 8 Shuttle valve 9 Pressure compensation valve R bucket 10 Spool bucket 11 Suction valve 12 Pressure compensation valve R bucket 13 Shuttle valve 14 Pressure compensation valve F attachment 15 Spool attachment 16 Stop plug for individual relief valve 17 Pressure compensation valve R attachment 18 Pressure compensation valve F High Flow 19 Spool High Flow 20 Pressure co...

Page 69: ...valve pressure compensation valve is installed to the inlet port side of the control valve to balance the load When there is compound operation of the actuators this valve acts to make pressure difference P constant for the up stream flow inlet port and downstream flow outlet port of the notch of each spool In this way the flow of oil from the pump is divided in proportion to area of opening S1 an...

Page 70: ...te However during compound operations they are divided in the proportion of 1 to 9 and keep High flow section flow rate SK815 5 and SK815 5 turbo has only Super flow specification Hydraulic circuit diagram and names of valves RKS00751 Raise arm Dump bucket A4 B4 P1 P2 A3 B3 A2 B2 Pa3 Pa3 A1 B1 Pa2 Pa1 6 13 1 2 3 4 8 12 10 11 9 7 Pa1 Optional equipment High flow Ls Port Bucket cylinder 5 Pa2 Curl b...

Page 71: ...circulating valve 3 and the combination circulating valve 4 stroke fully Return flow rate from the lift arm cylinder passes through passage A Then it is divided to passage B and C by the leveling circulating valve 4 and the combination circulating valve 3 When this happens the flow divider 5 is operated as P1 P2 so flow rate Q1 Q2 is divided to passage B and C in proportion to the area of opening ...

Page 72: ...o all flow rate from pump supplies to the lift arm raise The lift arm raise PPC pressure is sent by passage E Then the leveling circulating valve strokes fully Return flow rate from the lift arm cylinder passes through passage A Then it is divided to passage B and C by the leveling circulating valve 3 When this happens the flow divider 5 is operated as P1 P2 so flow rate Q1 Q2 is divided to B and ...

Page 73: ...T Function 1 Low bucket load Series circuit 2 High bucket load Parallel circuit Depend on bucket load a circuit can change automatically as above Then the machine gets high speed and strong digging power RKS00730 5 6 2 1 3 4 P2 P1 Q1 Q2 P3 7 d F A D B C G b c a f e H E STRUCTURE AND FUNCTION CLSS ...

Page 74: ...ated as P1 P2 so flow rate Q1 Q2 is divided to passage B and C in proportion to the area of opening as below expression Q1 Q2 notch b notch d notch C Q1 flow rate flows to B Q2 flow rate flows to C If the bucket load becomes beyond a certain valve by influences of digging the series parallel switching valve 7 strokes to the right Then it passes thorough passage G by opening notch e And then the sp...

Page 75: ...er PLS1 and reducing valve 1 and flow control valve 2 are pushed to the left in the direction of the arrow Flow control valve 2 throttles the area of opening between pump circuit PP and spool upstream PPA and pressure loss is generated between PP and PPA Flow control valve 2 and reducing valve 1 are balanced in position where the difference in pressure between PLS and PA acting on both ends of red...

Page 76: ...ol 1 and High Flow spool 3 stroke fully and individually therefore they keep demand flow rate in dividually Attachment 60L min High Flow 100L min 2 When attachment and High Flow are operated at the same time High FlowattachmentPPCpressurepassesthroughpassageA issenttoretainer 2 andmakesretainer 2 stroke to the left When this happens attachment spool 1 can stroke by half As a result flow rate of at...

Page 77: ... 2nd SPEED View Z Z RKS01151 1 2 3 P T S A B C STRUCTURE AND FUNCTION SOLENOID VALVE FUNCTION 1 2nd speed 2 Servocontrol 3 Parking brake A Port To travel motors PP1 port B Port To PPC valve C Port To travel motors PP2 port P Port From hydraulic pump E1 port T Port To hydraulic tank S Port To accumulator ...

Page 78: ... turbo SOLENOID VALVE ST2 HIGH FLOW CONTROL T Port To hydraulic tank P1 Port From control valve PA3 port P2 Port From control valve PB3 port S Port To control valve Pi2 port RKS01140 P2 S T P2 STRUCTURE AND FUNCTION SOLENOID VALVE ...

Page 79: ...ntaining nitrogen is fitted inside the accumulator to maintain oil pressure in the circuit to which the accumulator is connected OPERATION When the engine is running the chamber A of the rub ber bag 1 containing nitrogen is compressed by oil under pressure coming from line B If the oil under in line B falls below the maximum ca libration pressure even after intensive use the rub ber bag 1 will exp...

Page 80: ... ISO Z 5 A A 1 B B 3 2 6 4 P in 1 P in 5 P in 6 P in 4 P in 3 P in 2 OPTIONAL PATTERN ISO PATTERN STRUCTURE AND FUNCTION PATTERN CHANGE VALVE OPTIONAL Pin 1 From L H PPC valve P4 port Pin 2 From L H PPC valve P1 port Pin 3 From L H PPC valve P3 port Pin 4 From L H PPC valve P2 port Pin 5 From R H PPC valve P1 port Pin 6 From R H PPC valve P2 port Pout 1 To hydraulic pump DA1 port Pout 2 To hydraul...

Page 81: ... D C Section F F Section G G Section C C Section D D Section B B Section A A Section E E Section F F Section G G 1 7 5 6 2 H H Section H H 3 7 4 3 STRUCTURE AND FUNCTION PATTERN CHANGE VALVE OPTIONAL 1 Lever 2 Rotor 3 Valce seat 4 Ball 5 Upper cover 6 Lower cover 7 Pin lock ...

Page 82: ... B1 A1 B2 A2 PA1 PB1 P out 4 P out 6 P out 3 P out 2 P out 1 P out 5 P in 4 P in 6 P in 3 P in 2 P in 1 P in 5 RKS00931 L H FORWARD ARM DOWN L H REVERSE R H FORWARD ARM RAISE R H REVERSE FRONT BUCKET DUMP BUCKET CURL P P2 P3 P4 P1 P P2 P3 P4 P1 T T B1 A1 B2 A2 PA1 PB1 P out 4 P out 6 P out 3 P out 2 P out 1 P out 5 P in 4 P in 6 P in 3 P in 2 P in 1 P in 5 STRUCTURE AND FUNCTION PATTERN CHANGE VAL...

Page 83: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 84: ... P3 STRUCTURE AND FUNCTION R H PPC VALVE STANDARD P1 port To control valve PA1 port P2 port To control valve PB1 port P3 port To control valve PA2 port P4 port To control valve PB2 port P port From solenoid valve group ST1 B port T port To hydraulic tank FUNCTION P1 Lower arm P2 Raise arm P3 Curl bucket P4 Dump bucket ...

Page 85: ... RKS00811 Section A A 4 6 5 7 8 9 10 1 3 2 Section B B Section C C Section D D Section E E STRUCTURE AND FUNCTION R H PPC VALVE STANDARD 1 Spool 2 Metering spring 3 Centering spring 4 Piston 5 Disc 6 Nut 7 Joint 8 Cover 9 Stopper 10 Body ...

Page 86: ...o ol 1 ispushed backandfinecontrolholefisshut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P1 When this happens spool 1 moves up or down so that the force of metering spring 2 is balanced with the pressure at port P1 The relationship in the po sition of spool 1 and body 10 fine control hole f is at a point midway betwe...

Page 87: ...hamber D and the pressure oil at port P1 is released If the pressure at port P1 drops too far spool 1 is pushed down by metering spring 2 and fine con trol hole f is shut off from drain chamber D At almost the same time it is connected to pump pressure chamber PP and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position Fig 3 RKS0...

Page 88: ...TIONAL Attacco P1 To pattern change valve Pin 5 port Attacco P2 To pattern change valve Pin 6 port P3 port To control valve PA2 port P4 port To control valve PB2 port P port From solenoid valve group ST1 B port T port To hydraulic tank FUNCTION ISO PATTERN P1 Lower arm P2 Raise arm P3 Curl bucket P4 Dump bucket OPTIONAL PATTERN P1 R H travel forward P2 R H travel reverse P3 Curl bucket P4 Dump buc...

Page 89: ...1 Section A A 4 6 5 7 8 9 10 1 3 2 Section B B Section C C Section D D Section E E STRUCTURE AND FUNCTION R H PPC VALVE PATTERN CHANGE OPTIONAL 1 Spool 2 Metering spring 3 Centering spring 4 Piston 5 Disc 6 Nut 7 Joint 8 Cover 9 Stopper 10 Body ...

Page 90: ...spushed backandfinecontrolholefisshut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P1 When this happens spool 1 moves up or down so that the force of metering spring 2 is balanced with the pressure at port P1 The relationship in the po sition of spool 1 and body 10 fine control hole f is at a point midway between drain...

Page 91: ...D and the pressure oil at port P1 is released If the pressure at port P1 drops too far spool 1 is pushed down by metering spring 2 and fine con trol hole f is shut off from drain chamber D At almost the same time it is connected to pump pressure chamber PP and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position Fig 3 RKS00840 1 ...

Page 92: ... pump DA2 port P2 port To hydraulic pump DB2 port P3 port To hydraulic pump DA1 port P4 port To hydraulic pump DB1 port P port From solenoid valve group ST1 T port To hydraulic tank FUNCTION P1 L H travel forward P2 L H travel reverse P3 R H travel forward P4 R H travel reverse When acting control lever two ports are pressurized contemporarily i e travel forward pressurize P1 and P3 ports ...

Page 93: ...ction B B Section C C Section D D Section E E Section F F Section G G 14 11 G G 12 13 STRUCTURE AND FUNCTION L H PPC VALVE STANDARD 1 Spool 2 Metering spring 3 Centering spring 4 Piston 5 Disc 6 Nut 7 Joint 8 Cover 9 Stopper 10 Body 11 Plug 12 Ball 13 Seat 14 Body for shuttle valve ...

Page 94: ...ushed backandfinecontrolholefisshut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P1 When this happens spool 1 moves up or down so that the force of metering spring 2 is balanced with the pressure at port P1 The relationship in the po sition of spool 1 and body 10 fine control hole f is at a point midway between drain h...

Page 95: ...chamber D and the pressure oil at port P1 is released If the pressure at port P1 drops too far spool 1 is pushed down by metering spring 2 and fine con trol hole f is shut off from drain chamber D At almost the same time it is connected to pump pressure chamber PP and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position Fig 3 RKS...

Page 96: ...ONAL P1 port To pattern change valve Pin 1 port P2 port To pattern change valve Pin 2 port P3 port To pattern change valve Pin 3 port P4 port To pattern change valve Pin 4 port P port From solenoid valve group ST1 T port To hydraulic tank FUNCTION ISO PATTERN P1 Travel forward P2 Travel reverse P3 L H travel P4 R H travel OPTIONAL PATTERN P1 L H travel forward P2 L H travel reverse P3 Raise arm P4...

Page 97: ...1 Section A A 4 6 5 7 8 9 10 1 3 2 Section B B Section C C Section D D Section E E STRUCTURE AND FUNCTION L H PPC VALVE PATTERN CHANGE OPTIONAL 1 Spool 2 Metering spring 3 Centering spring 4 Piston 5 Disc 6 Nut 7 Joint 8 Cover 9 Stopper 10 Body ...

Page 98: ...ispushed backandfinecontrolholefisshut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pressure at port P1 When this happens spool 1 moves up or down so that the force of metering spring 2 is balanced with the pressure at port P1 The relationship in the po sition of spool 1 and body 10 fine control hole f is at a point midway between drai...

Page 99: ...D and the pressure oil at port P1 is released If the pressure at port P1 drops too far spool 1 is pushed down by metering spring 2 and fine con trol hole f is shut off from drain chamber D At almost the same time it is connected to pump pressure chamber PP and the pump pressure is supplied until the pressure at port P1 recovers to a pressure that corresponds to the lever position Fig 3 RKS00840 1 ...

Page 100: ... 2 3 4 5 6 7 9 8 12 7 STRUCTURE AND FUNCTION CYLINDERS 1 Bushing 2 Dust 3 Gasket 4 Gasket 5 Rod 6 Gasket 7 Ring 8 Bushing 9 Nut 10 Piston 11 Cilinder 12 Gasket 13 Head Unit mm Cilinder Ø Rod Ø Piston Piston stroke Max cylinder length Min cylinder length Key size Bucket raise 35 55 678 1616 938 32 Bucket tilt 30 60 357 970 613 32 ...

Page 101: ...T PRESSURE SWITCH 2 A LINEA TELAIO TO FRAME CABLE DIODO DIODE TIMER ARRESTO MOTORE ENGINE STOP TIMER RELE SICUREZZA SAFETY RELAY STOP LIGHT PRESSURE SWITCH 2 PRESSOSTATO 1 LUCI STOP FILTRO ARIA AIR FILTER SWITCH PRERISCALDO PREHEATING PRESSOSTATO OLIO MOTORE ENGINE OIL PRESSURE SWITCH POOL STOP SOLENOIDE CARBURANTE FUEL POOL STOP SOLENOID SENSORE LIVELLO COMBUSTIBILE FUEL LEVEL SENDER SIRENA BACK ...

Page 102: ...X15 1 X14 X14 X13 1 X13 2 X13 3 X12 1 X10 13 X10 11 X10 12 X10 10 X10 9 X10 8 X10 7 X10 6 X10 5 X10 4 X10 3 X10 2 R G1 X10 1 S G1 X08 X08 X08 X06 X06 X05 X04 X04 X03 S G1 R N1 5 N1 R G1 M2 5 C L1 C N1 R V1 R N1 R N1 R N1 R N1 N1 N1 N1 M V1 S1 R G1 R G1 M V1 R1 Z N1 B1 R1 R V1 B1 S1 C N1 C L1 B N1 B G1 S N1 B2 5 B2 5 p S31 p S26 p S25 V1 SAFETY RELAY K02 p S27 p S30 p S29 p S28 t R3 R2 R1 K01 86 87...

Page 103: ...ector X05 Pool solenoid relay 1 way connector X06 By pass diode 2 way connector X07 Pool solenoid timer 4 way connector X08 Safety relay 4 way connector X09 C5 generator terminal X10 Frame line mark 13 way connector X11 Generator 2 way connector X12 Generator frequency signal 1 way connector X13 Fuel pool stop solenoid 3 way connector solenoid 3 way connector X14 Fuel pump 2 way connector X15 Preh...

Page 104: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 105: ...OSTATO FRENO BRAKE PRESSURE SWITCH E V FLOTTANTE Y2 FLOAT VALVE Y2 X33 X35 X36 GND 2 X46 X37 X34 A LINEA CABINA TO CABIN CABLE X47 A LINEA CABINA TO CABIN CABLE X45 A LINEA CABINA TO CABIN CABLE X48 A LINEA CABINA TO CABIN CABLE X01 1 A LINEA CABINA TO CABIN CABLE X02 1 A LINEA CABINA TO CABIN CABLE X10 1 PRESS PPC SAFETY PPC SAFETY PRESSURE SWITCH X32A PRESS PPC SAFETY PPC SAFETY PRESSURE SWITCH ...

Page 106: ...9 X45 8 X45 7 X45 6 X45 5 X45 4 X45 3 X45 2 X45 1 X47 1 TO CABIN LINE EURO USA STD FROM ENGINE LINE STD OPT R N2 5 R4 R N2 5 R4 R N1 5 M V1 X37 1 M1 M B1 M B1 X36 2 X36 1 X35 2 X35 1 N1 N1 N1 N1 M N1 M N1 X34 2 X34 1 X33 2 X33 1 V N1 R1 L G1 X32 1 X32A 1 R V1 R N1 5 B1 S1 C N1 C L1 S G1 R N1 R G1 R G1 B G1 B G1 M2 5 M2 5 V N1 R1 R V1 B1 S1 C N1 C L1 S G1 B N1 p S32 p S33 Y6 Y3 Y2 Y1 N2 5 X47 2 2 1...

Page 107: ...ressure switch 1 way connector X32A PPC safety pressure switch 1 way connector X33 PPC valve 2 way connector X34 Float valve 2 way connector X35 Brake valve 2 way connector X36 Second speed valve 2 way connector X37 Brake pressure switch 1 way connector X45 Cabin line 13 way connector X46 Cabin line 4 way connector X47 Ground 2 way connector X48 Cabin line 5 way connector Y1 PPC valve Y2 Float val...

Page 108: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 109: ...AKE PRESSURE SWITCH E V FLOTTANTE Y2 FLOAT VALVE Y2 X33 X35 X36 X40 X39 GND 2 X46 X37 X34 A LINEA CABINA TO CABIN CABLE X47 A LINEA CABINA TO CABIN CABLE X45 A LINEA CABINA TO CABIN CABLE X48 A LINEA CABINA TO CABIN CABLE X49 A LINEA CABINA TO CABIN CABLE X41 A LINEA CABINA TO CABIN CABLE X43 A LINEA CABINA TO CABIN CABLE X42 A LINEA CABINA TO CABIN CABLE X01 1 A LINEA CABINA TO CABIN CABLE X02 1 ...

Page 110: ...49 7 X49 6 X49 5 X49 4 X49 3 X49 2 X49 1 X45 13 X45 11 X45 10 X45 12 X45 9 X45 8 X45 6 X45 7 X45 4 X45 2 X45 3 X45 5 X45 1 X41 4 X41 3 X41 2 X41 1 A G1 A G1 C B1 C1 V B1 V1 A N1 A B1 POWER BOX ATTACH LINE TO CABIN LINE EURO USA OPT FROM ENGINE LINE STD OPT A N1 A V1 Z N1 N1 N1 X40 2 X40 1 X39 2 X39 1 Y4 Y5 A B1 Z N1 A V1 V B1 V1 C B1 C1 R N2 5 R4 R N1 5 M V1 X37 1 M B1 X36 2 X36 1 X35 2 X35 1 N1 N...

Page 111: ...onnector X35 Brake valve 2 way connector X36 Second speed valve 2 way connector X37 Brake pressure switch 1 way connector X39 High flow detent valve 2 way connector X40 High flow momentary valve 2 way connector X41 Stabilizer 5 way connector X42 Attachement 5 way connector X43 ENPI valve 1 way connector X45 Cabin line 13 way connector X46 Cabin line 4 way connector X47 Ground cabin line 2 way conn...

Page 112: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 113: ...TO STARTING SWITCH MANIPOLATORE DX RIGHT LEVER PRESA DI CORRENTE CURRENT INTAKE SCATOLA FUSIBILI FUSES BOX PULSANTE FRENO S8 BRAKE BUTTON S8 INT GIROFARO S7 BEACON LIGHT SWITCH S7 SENSORE BRACCIOLO PROXIMITY BAR 3 WAY MANIPOLATORE SX LEFT LEVER RELE FLOAT FLOAT RELAY RELE PARKING PARKING RELAY MASSE GROUND X82 X80 X85 X55 X86 X45 1 X46 1 X48 1 X52 X53 X78 79 S10 X84 X87 X88 K04 X54 X83 K14 X47 1 X...

Page 114: ...1 3 X45 1 2 X45 1 1 X47 1 N4 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 K06 P1 FROM FRAME LINE STD N4 M V1 M V1 G N1 R N1 G R1 A R1 5 G R1 H R1 R N2 5 R G1 M B1 B G1 M B1 B N1 L R1 5 H R1 H R1 C B1 H R1 N1 C N1 X77 X76 1 X75 X74 1 X73 X72 1 X71 X70 1 X69 X68 1 X67 X66 1 X65 X64 1 X63 X62 1 X61 X60 1 X59 X58 1 X57 X56 1 X55 2 X55 1 X54 C X54 B X54 A X53 1 X52 1 H R1 B R1 H R1 5 S1 C L1 ...

Page 115: ...B R1 C1 S N1 L G1 L B1 S N1 H0 5 L G0 5 V B0 5 LEFT LEVER TO TOP CABIN LINE STD X89 87 X89 30 X89 86 X88 10 X88 5 1 9 7 2 X87 3 X87 6 X86 10 X86 2 X86 3 X86 1 X86 8 X86 9 N1 G R1 L B1 1 0 S08 15 1 30 3 L 6 49 4 30b 2 R 7 N1 N1 H R1 N1 5 A R1 5 H R1 H G1 H G1 H N1 H N1 H N1 A G1 5 G1 5 G R1 G R1 X85 10 X85 5 X85 1 X85 9 B R1 A B1 X83 3 X83 2 X83 1 C1 B R1 1 0 S01 1 9 5 10 H R1 G1 5 1 0 S07 1 9 5 10...

Page 116: ...OUR B N1 M N1 GROUND GROUND X80 5 X80 6 X80 7 X80 8 POWER SUPPLY 12V X81 2 X81 1 PIN FLOAT LAMP SAFETY BAR OPEN LED FUNCTION START SIGNAL X80 4 50 L2 B1 X80 16 X80 15 X80 13 X80 14 X80 12 X80 10 X80 11 NEGATIVE NEGATIVE M B1 G N1 X81 8 X81 7 SEAT LED WARNING LED DL2 DL1 POSITIVE NEGATIVE M V1 M B1 X81 3 X81 4 SECOND SPEED LAMP PARKING BRAKE LAMP POS C3 C2 GND GND 15 L8 DL3 POS 50 L7 L6 L5 L3 L4 DL...

Page 117: ...47 1 From frame line 2 way ground connector X48 1 From frame line 5 way connector X50 Electronic unit 23 way connector X52 Buzzer 1 way connector X53 Buzzer 1 way connector X54 Proximity bar 3 way connector X55 Safety seat switch 2 way connector X56 Fuse 1 way connector X57 Fuse 1 way connector X58 Fuse 1 way connector X59 Fuse 1 way connector X60 Fuse 1 way connector X61 Fuse 1 way connector X62 ...

Page 118: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 119: ...ROXIMITY BAR 3 WAY MANIPOLATORE SX LEFT LEVER RELE FLOAT FLOAT RELAY RELE PARKING PARKING RELAY MASSE GROUND X82 X80 X85 X55 X86 X45 1 X46 1 X48 1 X52 X53 X78 79 S10 X84 X50 X87 X88 K04 X54 X83 K14 X47 1 X56 X77 GND3 PANNELLO DI CONTROLLO CONTROL PANEL X81 DA LINEA TELAIO FROM FRAME LINE X49 1 INT LUCI DIREZIONE S3 DIRECTION LIGHTS SWITCH S3 X104 INT STAB DX S6 RIGHT STAB SWITCH S6 X107 INT STAB S...

Page 120: ...1 4 X46 1 3 X46 1 1 X45 1 13 X45 1 12 X45 1 11 X45 1 10 X45 1 9 X45 1 8 X45 1 7 X45 1 6 X45 1 5 X45 1 4 X45 1 3 X45 1 2 X45 1 1 X47 1 1 N4 X81 8 X81 7 X81 6 X81 5 X81 4 X81 3 X81 2 X81 1 X80 16 X80 15 X80 14 X80 13 X80 12 X80 11 X80 10 X80 9 X80 8 X80 7 X80 6 X80 5 X80 4 X80 3 X80 2 X80 1 K06 P1 FROM FRAME LINE OPT N4 M V1 M V1 G N1 R N1 G R1 A R1 5 G R1 H R1 R N2 5 R G1 M B1 B G1 M B1 B N1 H R1 H...

Page 121: ... X82 1 Parts not included in the wiring H N1 H R1 TO TOP CABIN LINE OMOLOG STD N1 5 C1 H N1 H N1 R N1 G N1 G1 L1 A1 B R1 L1 A1 L N1 B R1 R V1 C1 A R1 5 G R1 N1 5 N1 R N1 B R1 L R1 5 A B1 L R1 5 L G1 H R1 G N1 X88 X88 X88 X88 X87 X87 X87 X87 X86 X86 X86 1 8 9 N1 G R1 1 0 S08 15 1 30 3 L 6 49 4 30b 2 R 7 N1 N1 H R1 5 A R1 5 H G1 H R1 G N1 5 G1 5 G R1 G R1 10 5 1 9 1 0 S01 1 9 5 10 1 0 S07 1 9 5 10 N...

Page 122: ...C1 C B1 LEFT LEVER RIGHT LEVER X84 11 X84 9 X84 8 X84 7 X84 6 X84 5 X84 4 X84 3 X84 2 X84 1 HL5 X83 11 X83 6 X83 5 X83 4 X83 3 X83 2 X83 1 A V1 L R1 5 G R1 L R1 5 V1 V B1 V B1 G R1 L1 A N1 L R1 G R1 H R1 A1 A1 N1 N1 A N1 A G1 Z N1 L N1 C B1 X107 10 X107 3 X107 1 X107 7 X107 9 X106 10 X106 3 X106 1 X106 7 X106 9 X105 1 X105 3 X105 4 X105 2 X105 8 X105 10 X104 54 X104 1 X104 2 H R1 FROM FRAME LINE O...

Page 123: ...90 1 14 X90 1 13 X90 1 12 X90 1 11 X90 1 10 X90 1 9 X90 1 8 X90 1 7 X90 1 6 X90 1 5 X90 1 4 X90 1 3 X90 1 2 X90 1 1 K10 53M 31 T 15 53S K05 RELAYS UNIT K09 85 30 86 87 K11 86 87 85 30 K07 85 30 86 87 K12 86 87A 87 85 30 K13 R CL T 53S 1 2 3 4 5 6 7 8 9 10 12 11 13 14 15 16 17 18 19 20 RKS00790 STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM CABIN LINE OPTIONAL 5 7 ...

Page 124: ... SAFETY BAR OPEN LED START SIGNAL X80 4 50 L2 B1 X80 16 X80 15 X80 13 X80 14 X80 12 X80 10 X80 11 NEGATIVE NEGATIVE M B1 G N1 X81 8 X81 7 SEAT LED WARNING LED DL2 DL1 POSITIVE NEGATIVE M V1 M B1 X81 3 X81 4 SECOND SPEED LAMP PARKING BRAKE LAMP POS C3 C2 GND GND 15 L8 DL3 50 L7 L6 L5 L3 L4 DL2 DL3 DL1 L9 L10 L2 L1 WATER TEMP INDICATOR L8 L6 L7 C3 X80 15 X80 16 X80 12 X80 14 X80 11 FUEL LEVEL C2 C1 ...

Page 125: ...tent push button S38 C way push button S39 A way push button S40 B way push button X44 Parking brake relay connector X45 1 From frame line mark 13 way connector X46 1 From frame line 4 way connector X47 1 Ground 2 way connector X48 1 From frame line mark 5 way connector X49 1 From frame line mark 11 way connector X50 Safety control box 23 way connector X52 Buzzer 1 way connector X53 Buzzer 1 way c...

Page 126: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 127: ...NT INTAKE 12V FARO DI LAVORO ANTERIORE DX FRONT RIGHT WORKING LIGHT AVV ACUSTICO HORN LINEA CRUSCOTTO FROM DASHBOARD CABLE MASSE GROUND FARO DI LAVORO ANTERIORE SX FRONT LEFT WORKING LIGHT X82 1 HA2 H6 GND4 XP1 H4 ø6 A B 1 2 3 4 5 8 7 9 10 11 12 13 14 15 16 6 STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM TOP CABIN LIGHT LINE STANDARD 1 2 ...

Page 128: ... X108 2 X108 1 H6 H4 FROM CABIN LINE H G1 C1 HA2 M H1 1 2 3 4 5 6 7 8 9 10 RKS00500 STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM TOP CABIN LIGHT LINE STANDARD 2 2 COMPONENTS GND4 C6 ground terminal H1 Beacon light H4 Left front work lamp H6 Right front work lamp HA2 Horn X82 1 From cabin line 11 way connector X108 Left front light 2 way connector X109 Right front light 2 way connector X113 Horn 1 way...

Page 129: ...O FROM DASHBOARD CABLE FANALE POSTERIORE DX REAR RIGHT LIGHT FARO DI LAVORO POSTERIORE DX REAR RIGHT WORKING LIGHT LUCE TARGA NUMBER PLATE LIGHT FARO DI LAVORO POSTERIORE SX REAR LEFT WORKING LIGHT MASSE GROUND FANALE POSTERIORE SX REAR LEFT LIGHT FANALE ANTERIORE SX FRONT LEFT LIGHT FARO ANABBAGLIANTE SX RONT LEFT MAIN BEAM X82 1 HA2 H6 H7 H9 H11 H12 H10 GND4 XP1 H8 H5 H4 MASSA AVV ACUSTICO HORN ...

Page 130: ... 1 6 X82 1 7 X82 1 8 X82 1 9 X82 1 10 X82 1 11 X111 A X111 B 1 XP1A 1 H12 GND4 X125 1 X128 1 X129 1 X130 1 X110 A X110 B G1 R N1 N1 N1 N1 N1 H N1 H N1 H N1 A G1 A G1 A G1 X113 1 FROM CABIN LINE XP1 GND6 1 2 3 4 5 6 7 8 9 10 12 11 13 14 15 16 17 18 19 20 RKS02700 STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM TOP CABIN LIGHT LINE OMOLOGATION 2 2 COMPONENTS D1 Horn ground GND4 C6 ground terminal H4 Left ...

Page 131: ...IANTE DX FRONT RIGHT MAIN BEAM AVV ACUSTICO HORN LINEA CRUSCOTTO FROM DASHBOARD CABLE FARO DI LAVORO POSTERIORE DX REAR RIGHT WORKING LIGHT FARO DI LAVORO POSTERIORE SX REAR LEFT WORKING LIGHT MASSE GROUND FARO ANABBAGLIANTE SX RONT LEFT MAIN BEAM X82 1 HA2 H6 H11 H10 GND4 XP1 H4 MASSA AVV ACUSTICO HORN GROUND D1 A B A B RKS02800 STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM TOP CABIN LIGHT LINE OPTIO...

Page 132: ...X109 2 X109 1 X108 2 X108 1 H6 H4 FROM CABIN LINE H G1 C1 HA2 M H1 A G1 N1 N1 X109 2 X109 1 X108 2 X108 1 H11 H10 GND6 X113 1 A G1 A G1 1 2 3 4 5 6 7 8 9 10 RKS02690 STRUCTURE AND FUNCTION ELECTRICAL DIAGRAM TOP CABIN LIGHT LINE OPTIONAL 2 2 COMPONENTS D1 Horn ground GND4 C6 ground terminal H4 Left front work lamp H6 Right front work lamp H10 Left rear work light H11 Right rear work light HA2 Horn...

Page 133: ...calibration 30 Checking the travel deviation 32 Control valve 34 Control and regulation of the servo control power supply 35 Elimination of residual pressures pressurisation of the tank 37 Bleeding air from the hydraulic circuits 38 When carrying out controls adjustments or analyses for troubleshooting park the machine on firm level ground Apply all the machine safety devices and use blocks to pre...

Page 134: ...aust valve 20 C mm mm 0 20 0 20 0 15 0 25 0 15 0 25 Compression pressure SAE30 oil Oil temperature 40 60 C Engine speed kg cm rpm 35 1 250 28 1 250 Blow by pressure oil SAE30 Water temperature in operating range At high idling speed mm H2O Engine oil pressure Max idling in cold state At set speed At low idling kg cm kg cm 3 3 4 8 Oil temperature Entire speed range C Max 120 Max 120 Fuel injection ...

Page 135: ...ndard value Permissible value 3000 1100 2950 3050 1050 1150 3000 1100 2950 3050 1050 1150 0 20 0 20 0 15 0 25 0 15 0 25 0 20 0 20 0 15 0 25 0 15 0 25 35 1 250 28 1 250 35 1 250 28 1 250 3 3 4 8 3 3 4 8 Max 120 Max 120 Max 120 Max 120 12 11 13 12 11 13 10 10 15 10 10 15 TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA ...

Page 136: ... Dump 65 58 5 71 5 Curled bucket Neutral Curled 65 58 5 71 5 Attachment pedal Neutral Right 20 15 25 Neutral Left Travel speed lever Min Max 105 100 110 Accelerator pedal Min Max 40 30 50 Operating force for control of levers and pedals Travel forward Engine speed min Oil temperature 45 55 C Instrument coupling at centre of control lever knob Instrument coupling on outside edge for pedal control m...

Page 137: ...71 5 65 58 5 71 5 65 58 5 71 5 65 58 5 71 5 65 58 5 71 5 65 58 5 71 5 65 58 5 71 5 20 15 25 20 15 25 110 105 115 110 105 115 40 37 43 40 37 43 2 0 1 8 2 2 2 0 1 8 2 2 2 0 1 8 2 2 2 0 1 8 2 2 2 0 1 8 2 2 2 0 1 8 2 2 2 0 1 8 2 2 2 0 1 8 2 2 1 8 1 5 2 1 1 8 1 5 2 1 1 8 1 5 2 1 1 8 1 5 2 1 1 8 1 5 2 1 1 8 1 5 2 1 1 8 1 5 2 1 1 8 1 5 2 1 5 0 4 0 6 0 5 0 4 0 6 0 5 0 4 0 6 0 5 0 4 0 6 0 7 5 5 0 10 7 5 5 ...

Page 138: ...il temperature 45 55 C Machine raised from the ground Pressure of wheels start rotation bar 5 5 4 0 7 0 Pilot system travel maximum 14 46 13 7 15 2 Pilot system travel reverse start up 5 5 4 0 7 0 Pilot system travel reverse maximum 14 46 13 7 15 2 Pilot system travel to right or left start up 5 5 4 0 7 0 Pilot system travel to right or left maximum 14 46 13 7 15 2 Pilot system with parking brake ...

Page 139: ...274 316 309 274 316 26 25 29 5 26 25 29 5 12 7 12 7 15 2 15 2 5 5 4 0 7 0 5 5 4 0 7 0 14 46 13 7 15 2 14 46 13 7 15 2 5 5 4 0 7 0 5 5 4 0 7 0 14 46 13 7 15 2 14 46 13 7 15 2 5 5 4 0 7 0 5 5 4 0 7 0 14 46 13 7 15 2 14 46 13 7 15 2 15 15 22 15 15 22 2800 2800 2950 2800 2800 2950 2400 2250 2500 2400 2250 2500 TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA ...

Page 140: ...n of each cylinder and any leakages occurring when a load is applied to the tips of the bucket teeth Horizontal and level ground Bucket rated load SK714 5 650 kg SK815 5 SK815 5 turbo 700 kg Engine switched off Oil temperature 45 55 C Take measurements as soon as the engine stops Measurethe variationsevery5minutesandcheck the total variation after 15 mins mm Max 250 Max 375 Raising cylinder Retrac...

Page 141: ...MACHINE SK815 5 SK815 5 turbo Standard value Permissible value Standard value Permissible value Max 250 Max 275 Max 250 Max 275 Max 21 Max 30 Max 21 Max 30 Max 15 Max 22 Max 15 Max 22 TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA ...

Page 142: ...lly extended Cylinder fully retracted Measuring posture Engine speed max Oil temperature 45 55 C Dump 2 0 1 8 2 4 Curl 2 2 2 0 2 6 Pattern change version optional Arm Arm on the ground Cylinder fully extended Measuring posture Engine speed max Oil temperature 45 55 C Raise 3 4 3 1 4 0 Lower 2 2 2 0 2 6 Bucket Cylinder fully extended Cylinder fully retracted Measuring posture Engine speed max Oil t...

Page 143: ...ible value Standard value Permissible value 3 2 2 9 3 8 3 2 2 9 3 8 2 0 1 8 2 4 2 0 1 8 2 4 2 0 1 8 2 4 2 0 1 8 2 4 2 2 2 0 2 6 2 2 2 0 2 6 3 4 3 1 4 0 3 4 3 1 4 0 2 2 2 0 2 6 2 2 2 0 2 6 2 2 2 0 2 6 2 2 2 0 2 6 2 4 2 2 2 9 2 4 2 2 2 9 TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA ...

Page 144: ...el speed Measuring posture Travel for 25 meters and then check on the time needed for cover 25 meters Normal km h 10 5 9 5 11 6 With increment 16 0 14 4 17 6 Travel deviation Measuring posture Engine speed max Oil temperature 45 55 C Travel 20 metres on flat ground and measure the deviation Check all the direction The surface must be firm and horizontal Value with speed increment mm Max 250 Max 25...

Page 145: ... value Permissible value Standard value Permissible value 76 68 84 76 68 84 118 106 130 118 106 130 10 5 9 5 11 6 10 5 9 5 11 6 16 0 14 4 17 6 16 0 14 4 17 6 Max 250 Max 250 Max 375 Max 375 Max 250 Max 250 Max 375 Max 375 TESTING AND ADJUSTMENTS NORMAL OR STANDARD TECHNICAL DATA ...

Page 146: ...it Yanmar TOL 97190080 2 Adapter 1 Engine oil pressure D 1 Commercially available Pressure adapter 1 Thread 1 8 2 Commercially available Compression gauge 1 Scale 10 bar Hydraulic pressure E 1 Commercially available Compression gauge 2 Scale 60 bar 2 Commercially available Compression gauge 1 Scale 400 bar 1 Scale 600 bar 3 Commercially available Compression gauge 1 Scale 10 bar 4 Commercially ava...

Page 147: ...minimum and maximum speeds do not fall within permissible limits when the engine is without load check the position locks of the accelerator le ver and the sheathing of the accelerator well be fore carrying out any tests under load See ADJUSTMENT OF THE ACCELERATOR LEVER Engine rpm with the pumps under load Only for Pattern Change version Check that the Patternchangevalveisin ISO mo de Max speed w...

Page 148: ... them with new ones 2 Make sure that the valve caps fit perfectly and are lying flat on the valve stem 4 Insert the feeler gauge B1 between the rocker 6 and the valve cap 5 Rotate the adjusting screw 4 until it rubs against the fe eler gauge B1 Secure this position with the nut 3 Lock nut 25 5 2 5 Nm After locking the nut 3 check the valve clearance again 5 After adjusting the No 1 cylinder rotate...

Page 149: ...C1 Check that the seal is mounted in the adapter and that it is undamaged 7 Turn the engine using the starting motor and read the compression value Read the compression value when the pressure gauge has stabilised While reading the compression also check the en gine rpm using the tachometer A1 or A2 If the spe ed does not correspond with the control value check it against the diagram Compression v...

Page 150: ...und adjust the belt tension With a new belt the flexion should be 7 9 mm 2 Adjusting the belt tension 1 Loosen the screws 4 that secure the alternator 2 2 Rotate the alternator 2 to give the belt 1 the correct tension and tighten the screw 4 3 Check the belt 1 tension If the belt has been replaced with a new one check the tension again after about 20 hours of operation Screw 25 32 Nm RKSA0070 2 4 ...

Page 151: ...C Check that the cylinder is in a compression stroke i e that both valves are closed Once the B T D C has been ascertained rotate the drive shaft in a clockwise direction seen from the flywheel side for about 25 teeth 3 Take off the clamp 3 and disconnect all the fuel deli very tubes 4 from the injection pump 5 4 Rotate the flywheel slowly in a counter clockwise direc tion seenfromtheflywheelside ...

Page 152: ...tethepump 5 towards the cylinder block Check the extent of the movement on the scale 7 7 Lock the nuts 6 that fasten the pump to its block Pump fastening nuts 25 35 Nm After adjustment of the fuel injection timing 8 Connect the fuel delivery tubes 4 to the pump and re place the clamp 3 Delivery tube couplings 31 85 2 45 Nm 9 Bleed any air from the fuel circuit RKSA0090 5 6 7 TESTING AND ADJUSTMENT...

Page 153: ...tempe rature Working temperature Coolant liquid 90 C Engine oil 110 C 2 Stop the engine and remove the oil pressure sensor 1 3 Mount the adapter D1 and connect the pressure gauge D2 4 Start the engine and check the oil pressure at low idling accelerator lever in low idling position and at high idling accelerator lever in high idling position Low idling pressure min 1 kg cm2 High idling pressure 3 ...

Page 154: ...tive sheath 2 in an inter mediate position and block the retainer 3 at approx 1 mm from the injection pump lever 4 3 Put the accelerator command lever 1 into the high idling position 4 Use the nuts 7 and 8 to reset the position of the injec tion pump lever 5 to approx 0 5 mm from the high idling adjustment screw 6 5 Bring the accelerator command lever back to the low idling position and check that...

Page 155: ...position and re move the ignition key Gently loosen the oil fill cap to eliminate any resid ual pressure Disassembly and regulation 1 Remove the complete PPC VALVE For details please refer to section 30 REMOVAL OF PPC VALVES 2 Lift the boot 1 and mark the position of the lever 2 in relation to the PPC valve body 3 3 Loosen the screw 4 remove the washer 5 and pull out the complete handle 6 4 Remove...

Page 156: ... in pressure of about 0 6 bar For details ple ase refer to TECHNICAL DATA Assembly Toassemble performthedisassemblyprocedureinthe reverse order Thoroughly clean all parts Cleaner Loctite 7063 Screw 64 74 Nm Press down on the stoppers 13 to ease setting into place tighten the retainer plate 8 until it is pro perlyseatedandadjustclearance Fordetails ple ase refer to PPC VALVE CLEARANCE ADJUSTMENT Jo...

Page 157: ...lic circuits Return the ignition key to the O OFF position and re move it Slowly loosen the oil tank refuelling cap to eliminate re sidual pressure 1 Remove cap 1 2 Loosen the nut 2 that retains the disc 3 3 Tighten the disc 3 until it makes light contact with the 4 push rods 4 During this adjustment take care not to activate any of the push rods 4 individually 4 Secure this position by tightening...

Page 158: ... to the ground stop the engine and remove starter key 1 Lowerthe LHsafetybar 1 andadjust the positionofthe sensor 2 by loosening and tightening the adjustment nuts 3 Distance between safety bar and sensor 1 mm RKSA0140 1 2 RKS01260 2 3 1 1mm TESTING AND ADJUSTMENTS ADJUSTING THE POSITION OF THE SERVO CONTROL ENGAGEMENT SAFETY SENSOR ...

Page 159: ...n per missible limits Standard displacement 2 6 mm 2 Adjustment For greater clarity the photo opposite shows the adju stment operations with the tire removed It is not necessary to remove the tires for this adjust ment 1 Screw a screw A M10x50 fully threaded into the hole provided onthe frame until it makes firm contact with the wheel hub 2 Loosen the retaining screws 1 of the wheel hub until it c...

Page 160: ...asure the pressures release the residual pressures in the cir cuits see ELIMINATION OF THE RESIDUAL PRESSURES IN THE CIRCUITS AND IN THE TANK and place the safety engagement levers into their locked positions After having connected the pressure gauges pres surise the tank For details see PRESSURISATION OF THE TANK RKS01291 L H TRAVEL MOTOR CONTROL VALVE P1 P2 P3 P4 P5 R H TRAVEL MOTOR ENGINE The c...

Page 161: ...ers andtightentheplugs 1 and 2 Plugs 19 6 27 4 Nm 2 Check the working pressure of the AS valve Only for SK815 5 and SK815 5 turbo Test conditions Engine high idling Hydraulic oil temperature 45 55 C Safety bar lowered Machine raised from the ground 1 Remove the plug 1 and mount a pressure adapter E5 2 Connect a pressure gauge E1 60 bar and start the en gine at low idling 1100 rpm 3 Push the travel...

Page 162: ...hin permissible limits Nut 58 8 78 5 Nm 2 AS valve calibration only for SK815 5 and SK815 5 turbo Pressure adjustment at low idling 1 Loosen the nut 1 and adjust the working pressure of the AS valve with the engine at low idling proceeding as follows To INCREASE pressure turn the screw 2 in a CLOCKWISE direction To REDUCE pressure turn the screw 2 in a COUNTER CLOCKWISE direction One complete turn...

Page 163: ...ding as follows To INCREASE pressure turn the screw 4 in a CLOCKWISE direction To REDUCE pressure turn the screw 4 in a COUNTER CLOCKWISE direction One complete turn of the screw 4 varies the pres sure by 1 96 bar 3 Tighten the nut 3 and check that the working pressure remains within permissible limits Nut 34 3 58 8 Nm RKS01361 3 4 Section A A TESTING AND ADJUSTMENTS VALVE CALIBRATION ...

Page 164: ...velling posi tions Boom lowered and bucket fully curled 2 Bring the engine up to maximum rpm 3 Push the travel lever to full stroke forwards 4 Travel for 10 metres then measure the deviation of the machine over the next 20 metres 5 Check the deviation also in reverse gear and while ac celerating in both directions RKS01270 RKS01281 10 m 10 m 10 m Theoretical line of travel Measure the of the devia...

Page 165: ...the screw 2 A 60 turn of the screw 2 will reduce the deviation by about 500 mm 3 Tighten the nut 1 Nut 26 5 32 4 Nm Travel Deviation Screw Forwards Left A1 Forwards Right A2 Reverse Left B1 Reverse Right B2 RKS01370 1 2 SK714 5 RKS01380 1 2 SK815 5 SK815 5 turbo RKS01390 A1 A2 B2 B1 TESTING AND ADJUSTMENTS CHECKING THE TRAVEL DEVIATION ...

Page 166: ...vement with the com mand lever at the end of its stroke and with the pressure stabilised To check the pressure of the working equipment push the piston to the end of its stroke Valve adjustment The unloading valve cannot be re adjusted only sub stituted 1 Adjustment of the main relief valve If the pressures measured for the working equipment and machine travel do not fall within normal values adju...

Page 167: ...elivery pipe 1 and install a tee and a adapter riconnect the pipe 1 2 Connect the pressure gauge E1 60 bar 3 Start the engine and bring it up to 2800 rpm with all leers in neutral position 4 Lower the safety bars and check the pressure Normal pressure 25 28 bar 2 Test the pressure of the travel pilot system Test conditions Machine raised from the ground 1 Disconnect the pipe 1 of the actuator to b...

Page 168: ...rmal pressures when the wheels start to turn 4 0 7 0 bar with levers at full stroke 13 7 15 2 bar 3 Parking brake system pressure check 1 Disconnect the brake control hose 1 connect a T fit ting and a pressure tap and reconnect the hose 2 Connect a manometer E1 60 bar 3 Lower the cabin and sit down on the driver s seat 4 Start the engine and rev it up to operating speed 2800 rpm with all the lever...

Page 169: ...connected for con trols or repairs or when caps are removed tank pres sure must be eliminated using the following method 1 Rest the working equipment on the ground and stop the engine 2 Slowly loosen the oil refuelling cap 1 in order to rele ase residual pressure 3 Pressurising the tank This operation should be performed every time the oil refuelling cap is moved for removal of the tubes or other ...

Page 170: ...dling for about 10 minutes before pro ceding to bleed the air from the circuits Procedures for bleeding ai 1 2 3 4 5 Bleeding air from pumps Starting engine Bleeding air from cylinders Pressurising tank Starting tasks Substitution of hydraulic oil Cleaning tank filter Substitution filter Repair substitution pump Removal of suction tube Substitution repair control valve Repair Substitution cylinder...

Page 171: ... in point 2 Return the engine to low idling and pout the piston through its entire stroke until it reaches max pressure in both directions 4 Repeat the operation starting from point 2 for bucket cylinder 3 Bleeding air from any optional equipment This method must be used for all the optional working equipment unless otherwise indicated 1 Each time an item of optional working equipment is in stalle...

Page 172: ......

Page 173: ...bo Removal 23 Installation 24 COOLANT LIQUID PUMP Removal and installation 25 RADIATOR GROUP Removal 26 Installation 27 FUEL TANK SK714 5 SK815 5 Removal and installation 28 FUEL TANK SK815 5 turbo Removal 29 Installation 30 CAB Removal 31 Installation 33 ENGINE PUMP GROUP Removal 34 Installation 37 COMPLETE HYDRAULIC PUMP Removal 38 Installation 40 GEAR PUMP Removal and installation 41 ENGINE PUM...

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Page 175: ...hnique to be used for installation Technique or important point to remember when removing 2 Addition of water or oil Step in removal procedure Point to remember when adding water or oil 2 To the precautions to be taken during the removal or installation of the groups must be added the specific PRE CAUTIONS TO BE TAKEN DURING THE OPERATIONS Always make sure that these precautions are taken 3 List o...

Page 176: ...clean the piece to remove oil and grease then apply just enough ad hesive to cover the threading in a uniform manner When applying a liquid sealant clean the surface involved remove residual oil and grease check that there are no dents or dirt then apply the liquid sealant in a uniform manner Clean all the parts remove dirt rust burrs or dents Apply a film of engine oil over all the moving parts A...

Page 177: ...1 Remove the retainer screws 1 from hinges 2 and 3 2 While keeping the hood lifted remove the retainer nut 4 from the shock absorber 5 Engine hood 15 kg INSTALLATION OF ENGINE HOOD To replace reverse removal procedure Check the centre and the lock engagement adjust ment RKSA1800 1 2 3 4 5 1 1 1 REMOVAL AND INSTALLATION ENGINE HOOD ...

Page 178: ...close the front door 5 Loosen the screws 5 two to each side and raise the cab as far as the safety cables allow 6 Insert the safety pin If the engine or pump are to be removed proceed as follows 7 Disconnect the four pipes 6 on the RH side the two servo control supply pipes 7 and the four pipes 8 on the LH side To disconnect the pipes remove the retainer 9 push the pipe 6 completely inside the uni...

Page 179: ...he washer tank 10 Attach the cab 15 to some hoisting tackle 11 Remove the safety cotter pin 16 and the washers 17 12 Remove the safety cotter pin 13 Push the cab 15 gently towards its at rest position to relieve the tension on the safety cables 18 and dis connect them from the pins 19 Apply a slight tension to the hoisting tackle chains to prevent the cab from moving unexpectedly RKSA0132 11 12 RK...

Page 180: ...that the connecting cables between the cab and the engine are not being strained LOWERING THE CAB To lower the cab back into position reverse the tilting procedure Screws 110 Nm Connect the pipes by pushing them fully home in their seatings Check correct connection by trying to extract them Adjust the stroke of the accelerator lever cable For details see 20 TESTING AND ADJUST MENTS 1 Fill up the c...

Page 181: ...hat secure the battery clamp 5 a release the tie rods 6 of the battery support Disconnect the temperature sensor connector 7 from the battery clamp 5 3 Tilt the battery clamp 5 towards the front of the ma chine and lift out the battery INSTALLATION OF THE BATTERY To replace reverse removal procedure RKSA0310 1 2 3 RKSA0320 4 5 6 7 RKSA0330 5 REMOVAL AND INSTALLATION BATTERY ...

Page 182: ...ion 2 Remove the battery 1 For details see REMOVAL OF THE BATTERY 3 Disconnect the cables 2 and 3 4 Loosen the screws 4 and take out the starting motor 5 INSTALLATION OF THE STARTING MOTOR To install reverse removal procedure Screws 78 4 98 Nm RKSA0311 1 RKSA0340 5 2 3 4 1 1 REMOVAL AND INSTALLATION STARTING MOTOR ...

Page 183: ...onnectors 2 and 3 4 Loosen the screws 4 and 5 to leave the alternator free to turn 5 Free the pulley 6 from the fan belt and take out the al ternator 7 INSTALLATION OF THE ALTERNATOR To install reverse removal procedure Adjust the tension of the fan belt For details see 20 TESTING AND ADJUSTMENTS Adjustment of the fan belt tension RKSA0350 1 2 3 4 RKSA0360 5 6 7 1 1 REMOVAL AND INSTALLATION ALTERN...

Page 184: ... 4 ofmufflersupport 5 andremove it 3 Loosenthescrews 6 ofmufflersupport 7 andremove it 4 Loosen nut 8 and remove muffler 9 A new seal 10 should be fitted each time the muf fler is removed INSTALLATION OF THE MUFFLER To install reverse removal procedure RKSA1870 5 1 2 3 4 RKSA0381 6 7 9 RKSA1880 8 RKS01721 10 REMOVAL AND INSTALLATION MUFFLER SK714 5 SK815 5 ...

Page 185: ...Mark the position of bracket 5 Remove the four nuts 6 fixing the muffler 4 to the tur bocharger 7 4 Loose the screws 8 5 Remove the muffler 4 A new seal 9 should be fitted each time the muffler is removed INSTALLATION OF THE MUFFLER To install reverse removal procedure RKSA2490 1 1 2 RKSA2500 4 3 RKSA2510 5 6 4 5 7 RKSA2330 4 8 7 9 4 REMOVAL AND INSTALLATION MUFFLER SK815 5 turbo ...

Page 186: ...mps 2 3 and disconnect the intake hose 5 and supply hose 6 from the turbocharger 4 4 Loosen the fitting 7 and disconnect the upper lubrica tion pipe 8 from the turbocharger 4 Seals 9 must be replaced at each disassembly 5 Loosen the clamp 10 and remove the lower lubrication pipe 11 RKSA2460 1 RKSA2470 3 6 2 5 4 RKSA2350 9 7 8 4 8 7 4 RKSA2480 10 11 REMOVAL AND INSTALLATION TURBOCHARGER SK815 5 tur...

Page 187: ... Loosen the nuts 12 and remove the turbocharger 4 The seal 13 must be replaced at each disassem bly INSTALLATION OF TURBOCHARGER To install reverse removal procedure RKSA2340 4 12 13 12 4 REMOVAL AND INSTALLATION TURBOCHARGER SK815 5 turbo ...

Page 188: ...e washer tank 1 3 Loosen the clamp 4 and disconnect the connector 5 from the air filter clogging sensor 4 Loosenthescrews 6 andremovethecompleteairfilter 7 INSTALLATION OF AIR INTAKE FILTER To install reverse removal procedure RKSA1900 1 3 2 RKSA2520 2 RKSA1890 6 4 5 7 RKSA2530 7 5 4 6 REMOVAL AND INSTALLATION AIR INTAKE FILTER SK714 5 SK815 5 SK815 5 turbo SK714 5 SK815 5 SK815 5 turbo ...

Page 189: ... 2 and the fuel return tubes 3 3 Loosen nuts 4 and remove clips 5 4 Remove the complete injection nozzles 6 INSTALLATION OF THE NOZZLE HOLDER To install reverse the removal procedure High pressure pipe union 31 85 2 45 Nm Nuts 78 4 0 98 Nm RKSA1891 1 RKSA2531 1 RKSA0042 3 2 1 RKSA0401 5 6 4 2 1 2 REMOVAL AND INSTALLATION NOZZLE HOLDER SK714 5 SK815 5 SK815 5 turbo ...

Page 190: ...able 2 3 Remove the air filter 3 For details see REMOVAL OF AIR FILTER 4 Only for SK714 5 SK815 5 Disconnect from head cylinder the fuel filter support 4 with level oil rod 5 Disconnect from injection pump 5 fuel feeding pipes 6 and return pipes 7 6 Disconnect injection pump 5 lubricating pipe 8 7 Disconnect high pressure pipes 9 from injection pump 5 RKSA0770 1 2 1 RKSA1892 3 4 RKSA2532 3 RKSA041...

Page 191: ...ar 13 Before removing pump driving gear mark position compared to idling gear For removal use a puller X1 and tighten its screws X2 directly in the gear 13 During removal be careful not let key drop 14 in the housing 11 Disconnect spring 15 loosen nuts 16 No 3 and re move injection pump 5 with O rings 17 RKSA1200 10 11 3 RKSA0420 12 13 4 RKS01730 X2 X1 X2 13 17 14 RKSA0430 16 15 5 REMOVAL AND INST...

Page 192: ... details see 20 CONTROLS AND ADJUST MENTS Feed and return pipes 31 85 2 45 Nm Cover surface liquid gasket Screw 44 1 53 9 Nm Align marks among gears before to install pump and nut Nut 59 69 Nm Pump lock nuts 22 5 28 5 Nm Check fuel injection timing For details see 20 CONTROLS AND ADJUST MENTS 1 2 3 4 5 REMOVAL AND INSTALLATION INJECTION PUMP ...

Page 193: ... details see REMOVAL OF THE NOZZLE HOLD ER 6 Remove the valves cover 6 7 Disconnect the pre heater cable 7 8 Remove the rocker arm shaft 8 Loosen the lock nuts and unscrew the valve tap pets by 2 3 turns 9 Take out the rocker arm control rods 9 10 Take out the screws 10 in the sequence indicated and remove the complete cylinder head 11 The cylinder head gasket 12 must be substituted every time it ...

Page 194: ...s For details see 20 CONTROLS AND ADJUST MENTS Nut 22 5 27 5 Nm Screw 196 225 Nm Adjust valve clearance For details see 20 CON TROLS AND ADJUSTMENTS Adjusting valve clear ance Raisethecylinderhead keeping ithorizontal andplace it on the gasket without shifting anything Lubricate the screw threadings with engine oil Tighten the screws in the sequence indicated See fig ure Screw 88 2 2 94 Nm 1 2 3 4...

Page 195: ...nect the pre heater cable 3 5 Remove nozzle holder 4 For details see REMOVAL OF THE NOZZLE HOLD ER 6 Remove the valves cover 5 7 Remove the rocker arm shaft 6 Loosen the lock nuts and unscrew the valve tap pets by 2 3 turns 8 Remove the rocker arm shaft 7 9 Take out the screws 8 in the sequence indicated and remove the complete cylinder head 9 The cylinder head gasket 10 must be substituted every ...

Page 196: ...s For details see 20 CONTROLS AND ADJUST MENTS Nut 22 5 27 5 Nm Screw 196 225 Nm Adjust valve clearance For details see 20 CON TROLS AND ADJUSTMENTS Adjusting valve clear ance Raisethecylinderhead keeping ithorizontal andplace it on the gasket without shifting anything Lubricate the screw threadings with engine oil Tighten the screws in the sequence indicated See figure Screw 88 2 2 94 Nm 1 2 3 4 ...

Page 197: ...d the O ring 8 INSTALLATION OF THE COOLANT LIQUID PUMP To install reverse removal procedure 1 Fill up the coolant liquid circuit 2 Start the engine to circulate the liquid and oil in all cir cuits Stop the engine and check the levels 3 Pressurise the tank and bleed the air from all circuits For details see 20 TESTING AND ADJUST MENTS Adjust the belt tension For details see 20 TESTING AND ADJUSTMEN...

Page 198: ... filter 4 Loosen the clamp 5 and disconnect the coolant liquid delivery pipe 6 5 Disconnect the coolant liquid return pipe 7 6 Attach the radiator group 8 to some hoisting tackle and apply a slight tension to the cables Radiator oil cooler group 62 kg 7 Loosen the screws 9 raise the radiator group 8 until the lower supports can be released and move it a little way away from the frame 8 Disconnect ...

Page 199: ... up the coolant liquid circuit to maximum level Coolant liquid approx 9 3 Start the engine to circulate the oil and the coolant and check that there are no leaks 4 Stop the engine check the levels and if necessary top them up Screws 190 Nm 5 Pressurise the tank and bleed the air from all circuits For details see 20 TESTING AND ADJUST MENTS 1 2 REMOVAL AND INSTALLATION RADIATOR GROUP ...

Page 200: ...nuts 7 that secure the tank 4 Loosen the screws 8 that secure the bracket 9 5 Raise the tank 10 and move it towards the front of the machine 6 Disconnect the level sensor connector 11 7 Remove the complete tank INSTALLATION OF THE FUEL TANK To install reverse removal procedure Screws 190 Nm Tighten the nuts by hand until the tank is tight against the frame Nut 6 Nm RKSA0451 1 2 2 1 1 RKSA0500 3 6 ...

Page 201: ... them in place 2 Disconnect the connector 3 from the level sensor and disconnect the connector from the reverse gear chime if installed 3 Disconnect the supply 6 and return 7 hoses from the pre filter 4 4 Loosen the screw 8 and remove the support 9 RKSA0451 1 2 2 1 1 RKSA2420 3 RKSA2430 7 5 4 6 RKSA2440 9 8 REMOVAL AND INSTALLATION FUEL TANK SK815 5 turbo ...

Page 202: ...5 turbo 5 Loosen the screws 10 and remove the support 11 6 Remove the complete tank INSTALLATION OF THE FUEL TANK To install reverse removal procedure Screws 190 Nm RKSA2450 10 11 1 REMOVAL AND INSTALLATION FUEL TANK SK815 5 turbo ...

Page 203: ...ling 5 from its retaining clamps 4 Tilt the cab For details see TILTING THE CAB 5 Disconnect the four pipes 6 on the RH side the two servo control feed pipes 7 and the four pipes 8 on the LH side To disconnect the pipes remove the retainer 9 push the pipe 6 completely inside the union 10 and extract the pipe 6 Mark thetubes toavoidexchanging them during re assembly 6 Pull out the cab cabling 5 RKS...

Page 204: ...ny engine cool ant from the hoses Mark the hoses to avoid mixing them during instal lation 8 Disconnect the hose 14 from the washer tank 13 9 Disconnect the accelerator command lever cable 16 from the engine 15 10 Connect the cab 17 to some hoisting tackle RKSA1545 11 12 RKSA1901 13 14 RKSA0133 15 16 2 RKSA0272 17 REMOVAL AND INSTALLATION CAB ...

Page 205: ...e the pins 21 from the dumper fixing hooks 22 15 Loosen the nuts 23 and remove the screws 24 and washers 25 16 Remove the complete cab 17 INSTALLATION OF THE CAB To install reverse removal procedure Fill up the coolant liquid circuit to maximum level Start the engine to circulate the coolant and check that there are no leaks Stop the engine check the levels and if necessary top them up Mount the n...

Page 206: ...n the fuel Fuel SK714 5 SK815 5 max 38 SK815 5 turbo max 50 3 Remove the radiator group For details see REMOV ING THE RADIATOR GROUP 4 Remove the cover of the control unit 1 and disconnect the connectors 2 3 and 4 that connect the control unit 1 to the frame wiring harness 5 5 Loosen the nuts 6 and disconnect the control unit from the frame 6 Disconnect the fuel level sensor connector 8 RKSA0301 1...

Page 207: ...t the delivery 16 and return 17 pipes from the prefilter 14 and the filter 15 10 Disconnect the pipes 19 20 and 21 from the pump 18 Mark thetubes toavoidexchanging them during re assembly 11 Disconnect the pipes 22 23 24 and 25 from the pump Mark thetubes toavoidexchanging them during re assembly RKSA0600 10 11 12 13 RKSA0501 14 15 16 17 RKSA0610 21 18 20 19 RKSA0230 24 23 22 25 REMOVAL AND INSTAL...

Page 208: ... engine and drain any engine cool ant from the hoses 13 Attach the engine pump group to some hoisting tackle and apply a slight tension to the cables 14 Loosen the four nuts 28 that secure the engine and re move the complete group Engine pump group 290 kg RKSA1546 27 26 RKSA0622 28 3 REMOVAL AND INSTALLATION ENGINE PUMP GROUP ...

Page 209: ...3 Fill the fuel tank and bleed the air from the system For details see 20 TESTING AND ADJUSTMENTS Fuel SK714 5 SK815 5 max 38 SK815 5 turbo max 50 4 Starttheenginetocirculatetheoilandcoolantliquidand check that there are no leaks 5 Stop the engine check the levels and if necessary top them up 6 Bleed the air from the hydraulic circuits and pressurise the tank For details see 20 TESTING AND AD JUST...

Page 210: ...Disconnect the pipes 2 3 and 4 from the pump 1 Markthe tubes toavoid exchangingthemduringre assembly 2 Disconnectthepipes 5 6 7 and 8 fromthepump Markthe tubes toavoid exchangingthemduringre assembly 3 Disconnect the servo control pressure sensor connec tors 9 and disconnect the support 10 from the en gine RKSA0611 1 2 3 4 RKSA0231 5 6 7 8 RKSA0601 10 11 9 REMOVAL AND INSTALLATION COMPLETE HYDRAUL...

Page 211: ...oses to avoid mixing them during instal lation 5 Attach the pump 1 to some hoisting tackle and apply a slight tension to the cables 6 Loosen the eight screws 14 and remove the pump 1 complete with the flange 15 Pump 88 kg 7 Loosen the screws 16 and disconnect the pump 1 from the flange 15 RKSA1547 13 12 RKSA0640 1 RKSA0651 1 14 15 16 1 2 REMOVAL AND INSTALLATION COMPLETE HYDRAULIC PUMP ...

Page 212: ...1 Fill the tank up to maximum level Hydraulic oil max 39 Bleed the air from the pump For details see 20 TESTING AND ADJUST MENTS 2 Start the engine to circulate the oil and check that there are no leaks 3 Stop the engine check the levels and if necessary top them up 4 Bleed the air from the hydraulic circuits and pressurise the tank For details see 20 TESTING AND ADJUST MENTS 1 2 REMOVAL AND INSTA...

Page 213: ...l Hydraulic oil max 39 1 Disconnect from the pump 1 the suction pipe 2 and the pipe 3 one for the normal version two for the HIGHFLOW version 2 Loosen the two screws 4 and remove the pump 1 complete with the O ring 5 INSTALLATION OF THE GEAR PUMP To install reverse removal procedure Screws 59 74 Nm RKSA0660 1 2 3 4 5 4 RKS01740 1 1 REMOVAL AND INSTALLATION GEAR PUMP ...

Page 214: ...ils see TILTING THE CAB 1 Remove the pump For details see REMOVAL OF THE PUMP 2 Take out the screws 1 and remove the coupling 2 Replace screws 1 every dismantling INSTALLATION OF THE ENGINE PUMP COUPLING To install reverse the removal procedure Coupling screws 80 Nm RKSA0670 1 2 1 1 REMOVAL AND INSTALLATION ENGINE PUMP COUPLING ...

Page 215: ...s and thede livery and return pipes 3 Mark thetubes toavoidexchanging them during re assembly 2 Loosen the three screws 4 and remove the control valve 1 Control valve max 21 5 kg INSTALLATION OF THE CONTROL VALVE To install reverse removal procedure Control valve screws 35 Nm 1 Fill the hydraulic oil tank up to maximum level Hydraulic oil max 39 2 Start the engine at low idling to circulate the oi...

Page 216: ...C valve 8 from the support 9 6 Disconnect the six pipes 10 from the PPC valve and plug the tubes to prevent entry of impurities Check the marks on the tubes to avoid exchanging them during re assembly INSTALLATION OF THE PPC VALVES To install reverse removal procedure Check very carefully the positions for the pipe con nections LEFT HAND PPC VALVE RIGHT HAND PPC VALVE If the union pieces are disma...

Page 217: ...en the nuts 1 and take off the tire 2 3 Loosen the drainage plug 3 in order to drain the chain gearing lubrication oil Gear box oil max 14 4 To facilitate oil drainage remove the vent plug 4 4 Loosen the nuts 5 and take off the cover 6 Check the condition of the seal 7 and install a new one if necessary RKS01750 RKSA0730 1 2 1 RKSA1190 4 3 RKSA0740 7 5 6 5 2 REMOVAL AND INSTALLATION HUB WHEEL ...

Page 218: ...on to the cables 9 Loosen the nuts 12 and remove the hub 11 Check the condition of the O ring and put in a new one if necessary Hub 55 kg INSTALLATION OF THE WHEEL HUB To install reverse removal procedure Nuts 186 Nm Nuts 29 Nm Make sure that the master link is in the correct position with respect to the pinion 1 Adjust the tension of the chains For details see 20 TESTING AND ADJUST MENTS 2 Fill t...

Page 219: ... ring bevel gear 5 Make a note of which way the ring bevel gear 5 is facing with respect to the hub 1 5 Position the wheel hub 1 beneath a press and slowly extracttheaxleshaft 6 untilit isreleasedfromtheinner ring 7 Place the wheel hub 1 on two supports A about 520 mm high 6 Remove the inner ring 7 7 Proceed with the extraction of the axle shaft 6 until it is released from the bearing 8 RKSA0761 1...

Page 220: ...alculate the thickness of shim that should be inserted between the disc 3 and the ring bevel gear 5 using the following formula Z X S S the shim pack X the measurement taken Z residual clearance 0 05 0 125 For example clearance measured X 0 570 Addition of two shims of 0 2 and one of 0 1 3 Check that the measurement X lies within the permis sible limits Grease the bearings 7 and 8 Bearings Lithium...

Page 221: ...nal drive 2 the supply pipes 3 the speed increment pipe 4 and the drainage pipe 5 Plug the tubes to prevent entry of impurities 4 Attach the final drive 2 to some hoisting tackle and ap ply a slight tension to the ropes 5 Loosenthe10screws 6 andtakeoutthecompletefinal drive 2 Check the condition of the O ring 7 and substitute a new one if necessary Final drive 54 kg RKSA0820 1 2 RKSA0830 2 3 4 5 R...

Page 222: ...14 5 SK815 5 SK815 5 turbo INSTALLATION OF THE FINAL DRIVE To install reverse removal procedure Grease the O ring O ring Lithium EP NLGI 2 Screws 120 Nm Screws Loctite 270 1 REMOVAL AND INSTALLATION FINAL DRIVE ...

Page 223: ...Disconnect the pipe 8 Plug the tube 8 and the union to prevent entry of impurities 5 Loosen the screw 9 and remove the pin 10 INSTALLATION OF THE RAISING CYLINDER To install reverse removal procedure Inside the bushings Lithium EP MS2 NLGI 2 Pin screws 49 Nm When aligning the positions between the hole and the pin run the engine at low idling Do not insert fingers into the holes to check align men...

Page 224: ...e position of the ad justments to a given clearance 2 Disconnect the pipes 4 and 5 from the cylinder 3 Plug the tubes to prevent entry of impurities Markthe tubes toavoid exchangingthemduringre assembly 3 Remove the pin 6 and take away the cylinder 3 Check and make a note of the position of the ad justments to a given clearance RKSA0900 RKSA0910 1 2 1 2 RKSA0920 3 4 5 RKSA0930 3 6 1 3 REMOVAL AND ...

Page 225: ... MS2 NLGI 2 Pin screws 49 Nm Insert the removed shims and if necessary add more until the residual clearance is about 1 mm Insert the removed shims and if necessary add more until the residual clearance is about 1 mm 1 Start the engine and bleed the air from the cylinder For details see 20 TESTING AND ADJUSTMENTS After bleeding the air check the level of oil in the tank 1 2 RKS01780 MAX 1mm 3 RKS0...

Page 226: ...not plugged 2 Place the cylinder 2 on the apparatus A Engage the cylinder in the tools B having the same bushing diam eter 3 Attach the special wrench C adjusted to fit the cylinder to the head 3 and apply the dynamometric tool D 4 Unscrew the head 3 and extract it completely from the cylinder 2 RKS01660 1 1 RKSA1060 2 A B RKSA1070 3 D C RKSA1080 3 2 REMOVAL AND INSTALLATION WORK EQUIPMENT CYLINDE...

Page 227: ...lete piston rod 4 onto the apparatus A 9 Attach the socket wrench E to the lock nut 5 of the pis ton 6 and using the dynamometric tool with a multi plier D remove the nut Socket wrench measurement 32 mm 10 Take all the groups to pieces and remove all the seals guard rings and guide rings The seals guard rings and guide rings cannot be used again RKSA1090 2 4 A RKSA1100 4 5 6 D E REMOVAL AND INSTAL...

Page 228: ...er head 1 Position the guard ring 7 and using a press and the push rod F press it home in the head 3 Check the orientation carefully 2 Mount the snap ring 8 3 Using the tool G mount the lip seal 9 Check that the lips face into the cylinder 4 Mount the O ring 10 the anti extrusion ring 11 and the O ring 12 onto the cylinder head 3 RKSA1110 3 7 3 F RKSA1120 8 9 G RKS01800 3 7 9 10 11 12 8 REMOVAL AN...

Page 229: ... adapted to fit the piston diameter 3 Piston rod group assembly 1 Using a press and the tool B adapted to the diameter in sert the bushing 17 into the piston rod 4 2 Insert the support K beneath the piston rod 3 Mount the pilot boss L adapted to the diameter onto the extremity of the piston rod 4 Slide the head 3 onto the piston rod 4 5 Remove the pilot boss L from the extremity of the piston rod ...

Page 230: ...r assembly 1 Mount the tools A onto the apparatus B 2 Position the bushing 20 and mount it onto the cylinder 2 Leave the cylinder in position ready for the next as sembly operation 3 Lubricate the threading and the first part of the cylinder 2 Cylinder Lithium EP NLGI 2 4 Mount the two halves of the tool M adapted to the di ameter onto the mouthpiece of the cylinder 2 RKSA1170 6 RKSA1101 5 E D RKS...

Page 231: ...the cylinder and then lower the apparatus A even further until the head 3 and the pis ton rod approach the cylinder 9 Placethecylinder 2 inpositionforscrewinginthehead 3 10 Insert the head into the cylinder and screw it in by hand for a few turns 11 Attach the special wrench C to the dynamometric tool D and screw the head 3 fully home Head Raising cylinder 412 41 Nm Bucket cylinder 441 44 Nm 12 Mo...

Page 232: ...crews 1 and remove the pins 2 and 3 Only for the RH cylinder Disconnect the safety rod 4 from the boom 5 Only for the HIGH FLOW version 2 Disconnect the electrical outlet 6 and its wiring from the boom 5 3 Attach the complete boom to some hoisting tackle and raise it until the hoses 7 connected to the frame be come easily accessible RKSA1210 1 2 3 1 RKSA0871 4 5 RKSA0970 5 6 RKSA0940 7 REMOVAL AND...

Page 233: ...verse removal procedure When aligning the positions between the hole and the pin run the engine at low idling Do not insert fingers into the holes to check align ment Inside the bushings Lithium EP MS2 NLGI 2 Insert shims between the boom and the frame until the residual clearance is less than 1 mm 1 Start the engine to circulate the oil and bleed the air from the circuits After bleeding the air s...

Page 234: ...ete working equipment support frame 4 Equipment support frame 57 kg INSTALLATION OF THE WORK ING EQUIPMENT SUPPORT FRAME To install reverse removal procedure Insert the removed shims and if necessary add more until the residual clearance is less than 3 mm When aligning the positions between the hole and the pin run the engine at low idling ATTENTION Do not insert fingers into the holes to check al...

Page 235: ... SK815 5 SK815 5 turbo STANDARD MAINTENANCE P T O 2 Transmission 3 Final drive 4 Hydraulic pump 5 Control valve 8 R H PPC valve 14 L H PPC valve 15 Pattern change valve Optional 17 Cylinders 18 Working equipment 20 ...

Page 236: ...40 2 SK714 5 SK815 SK815 5 turbo5 P T O RKS01091 195 Nm 80 Nm 80 Nm STANDARD MAINTENANCE P T O ...

Page 237: ...40 3 SK714 5 SK815 5 SK815 5 turbo TRANSMISSION Sectione A A RKS01440 A A 118 Nm 294 Nm 200 Nm with Loctite 270 29 Nm 186 Nm STANDARD MAINTENANCE TRANSMISSION ...

Page 238: ...40 4 SK714 5 SK815 SK815 5 turbo5 FINAL DRIVE RKS01480 61 8 75 5 Nm 46 51 Nm 167 196 Nm 28 4 31 4 Nm 28 4 31 4 Nm 28 4 31 4 Nm 28 4 31 4 Nm 51 0 64 7 Nm STANDARD MAINTENANCE FINAL DRIVE ...

Page 239: ...40 5 SK714 5 SK815 5 SK815 5 turbo HYDRAULIC PUMP SK714 5 RKS00330 19 6 27 4 Nm 147 186 2 Nm 19 6 27 4 Nm 147 186 2 Nm 58 8 73 5 Nm 49 58 8 Nm STANDARD MAINTENANCE HYDRAULIC PUMP ...

Page 240: ...40 6 SK714 5 SK815 SK815 5 turbo5 SK815 5 SK815 5 turbo RKS00340 19 6 27 4 Nm 147 186 2 Nm 19 6 27 4 Nm 147 186 2 Nm 58 8 73 5 Nm 49 58 8 Nm 19 6 27 4 Nm 58 8 73 5 Nm STANDARD MAINTENANCE HYDRAULIC PUMP ...

Page 241: ...epair limit Free length Installed length Installed load Free length Installed load 1 Spring 38 1 30 52 N 41 1 N Replace 2 Spring 25 9 23 16 7 N 13 7 N 3 Spring 40 2 34 5 73 5 N 58 8 N RKS01451 Section A A 3 1 2 34 3 58 8 Nm 44 1 53 9 Nm 34 3 58 8 Nm 58 8 78 4 Nm STANDARD MAINTENANCE HYDRAULIC PUMP ...

Page 242: ...5 CONTROL VALVE SK815 5 SK815 5 turbo SUPER HIGH FLOW VERSION A View Z RKS00371 A A C C B B D J H D J H 23 5 3 9 Nm 11 3 1 5 Nm 11 3 1 5 Nm 11 3 1 5 Nm 11 3 1 5 Nm 31 9 2 5 Nm 31 9 2 5 Nm 31 9 2 5 Nm STANDARD MAINTENANCE CONTROL VALVE ...

Page 243: ... 5 SK815 5 turbo SK714 5 SK815 5 SK815 5 turbo STANDARD RKS00251 Z View Z K K D D M M L L 23 5 3 9 Nm 11 3 1 5 Nm 11 3 1 5 Nm 11 3 1 5 Nm 11 3 1 5 Nm 31 9 2 5 Nm 31 9 2 5 Nm 31 9 2 5 Nm STANDARD MAINTENANCE CONTROL VALVE ...

Page 244: ...rn spring bucket 26 3x17 7 18 5 176 5 N 141 1N 3 Spool return spring bucket 21 6x14 8 10 38 7 N 31 0 N 4 Spool return spring ATT 28x11 5 24 5 137 3 N 109 8 N 5 Spool return spring High Flow 29x17 6 25 5 131 4 N 105 1 N 6 Spool return spring float 14 7x4 4 9 5 4 9 N 3 9 N 7 Spring of series parallel circuit switching valve 38 3x15 2 24 161 8 N 129 5 N RKS00383 Section B B Section A A 5 7 4 2 3 1 2 ...

Page 245: ... compensation valve 15 4x6 13 2 5 N 2 0 N 4 Spring of pressure compensation valve 20x8 4 12 6 9 N 5 5 N 5 Spring of combination circulating valve 37 5x16 6 22 5 177 5 N 142 0 N 6 Spring of leveling circulating valve 37 5x15 4 22 5 66 7 N 53 4 N 7 Spring of flow divider 30 2x9 4 23 2 9 N 2 4 N 8 Spring of check valve 18 5x3 8 15 5 1 1 N 0 9 N RKS00703 Section D D Section AA AA Section BB BB Section...

Page 246: ... load 1 Spring of check valve 13x6 5 9 5 2 0 N 1 6 N Change springs If there are damage or deformation 2 Spool return spring High Flow joining circuit 25 7x11 1 22 66 7 N 53 4 N Section K K RKS00761 Section J J Section H H 2 1 44 1 4 9 Nm 11 3 1 5 Nm 11 3 1 5 Nm 31 9 2 5 Nm 77 9 12 3 Nm 22 0 2 5 Nm 34 3 4 9 Nm 44 1 4 9 Nm 44 1 4 9 Nm STANDARD MAINTENANCE CONTROL VALVE ...

Page 247: ...urn spring bucket 21 6x14 8 10 38 7 N 31 0 N 4 Spool return spring ATT 29x17 5 25 180 4 N 144 4 N 5 Spring of series parallel circuit switching valve 38 3x15 2 24 161 8 N 129 5 N 6 Spring of unload valve 32 9x18 2 18 74 0 N 59 2 N 7 Spring of unload valve 18 7x9 3 16 3 4 N 2 7 N 8 Spring of pressure compensation valve 15 4x6 13 2 5 N 2 0 N 9 Spring of pressure compensation valve 20x8 4 12 6 9 N 5 ...

Page 248: ...e length Installed load 1 Centering spring for P3 and P4 42 4x15 5 34 9 8 N 9 2 N 2 Centering spring for P1 and P2 36 6x15 5 34 17 6 N 16 5 N 3 Metering spring for P3 and P4 32 7x8 2 25 6 40 8 N 39 4 N 4 Metering spring for P1 and P2 26 2x8 2 25 3 5 3 N 4 3 N Section A A Section B B Section C C Section D D Section E E RKS00852 1 3 2 4 112 8 14 7 Nm 44 1 4 9 Nm 13 2 1 5 Nm 39 2 4 9 Nm STANDARD MAIN...

Page 249: ...talled load Free length Installed load 1 Centering spring for Pout3 and Pout4 35 5x15 5 34 9 8 N 9 2 N 2 Centering spring for Pout1 and Pout2 26 2x15 5 34 17 6 N 16 5 N 3 Metering spring for P3 and P4 32 7x8 2 25 3 5 3 N 52 4 N RKS00911 Section A A Section B B Section C C Section D D Section E E Section F F Section G G 1 3 2 3 G G 112 8 14 7 Nm 44 1 4 9 Nm 13 2 1 5 Nm 13 7 1 Nm STANDARD MAINTENANC...

Page 250: ...Installed length Installed load Free length Installed load 1 Centering spring for Pout3 and Pout4 35 5x15 5 34 9 8 N 9 2 N 2 Centering spring for Pout1 and Pout2 36 6x15 5 34 17 6 N 16 5 N 3 Metering spring for P3 and P4 26 2x8 2 25 3 5 3 N 52 4 N Section A A Section B B Section C C Section D D Section E E RKS00853 1 3 2 3 112 8 14 7 Nm 44 1 4 9 Nm 13 2 1 5 Nm 39 2 4 9 Nm STANDARD MAINTENANCE L H ...

Page 251: ...40 17 SK714 5 SK815 5 SK815 5 turbo PATTERN CHANGE VALVE OPTIONAL RKS00941 Section B B Section A A 5 1 3 2 6 4 27 5 34 3 Nm 11 8 14 7 Nm 27 5 34 3 Nm STANDARD MAINTENANCE PATTERN CHANGE VALVE OPTIONAL ...

Page 252: ...82 0 184 1 0 2 Tolerance between bushing and cylinder mounting pin Lifting bucket 35 0 01 0 05 0 072 0 134 0 082 0 184 1 0 Tilt bucket 35 0 01 0 05 0 072 0 134 0 082 0 184 1 0 3 Tolerance between piston rod and cylinder head Lifting bucket 35 0 025 0 087 0 039 0 0 025 0 126 0 426 Replace head Tilt bucket 30 0 020 0 072 0 033 0 0 020 0 105 0 426 RKS01500 3 1 2 Lifting bucket 412 41 Nm Tilt bucket 4...

Page 253: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 254: ...40 20 SK714 5 SK815 SK815 5 turbo5 WORKING EQUIPMENT RKS01121 Section B B Section A A C C D E D E A A B B Section C C 1 STANDARD MAINTENANCE WORKING EQUIPMENT ...

Page 255: ...earance limit Shaft Hole 1 Clearance between bushing and mounting pin of arm and support frame 35 0 01 0 05 0 072 0 134 0 082 0 184 1 0 Replace bushing 2 Clearance between bushing and mounting pin of arm 35 0 01 0 05 0 072 0 134 0 082 0 184 1 0 Section E E RKS01161 Section D D 2 STANDARD MAINTENANCE WORKING EQUIPMENT ...

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Komatsu Utility SK714-5, Shop Manual

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