Caterpillar 815K, 816K Compactors Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar 815K, 816K Compactors, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar 815K, 816K Compactors workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
M0067694 - Disassembly and Assembly (815K; 816K Compactor Engine Supplement).pdf
M0068544 - Disassembly and Assembly (815K; 816K Soil Compactor Machine Systems).pdf
M0068550 - Disassembly and Assembly (815K; 816K Compactor Power Train).pdf
M0072480 - Systems Operation (815K Soil Compactor and 814K and 816K Landfill Compactor VIMS Network Manager).pdf
M0072480 - Testing and Adjusting (815K Soil Compactor and 814K and 816K Landfill Compactor VIMS Network Manager).pdf
M0072480 - Troubleshooting (815K Soil Compactor and 814K and 816K Landfill Compactor VIMS Network Manager).pdf
UENR0313 - Specifications (815K Soil Compactor and 816K Landfill Compactor Systems).pdf
UENR0314 - Systems Operation (814; 814K Wheel Dozer; 815; 815K Soil Compactor and 816; 816K Landfill Compactor).pdf
UENR0314 - Testing and Adjusting (814; 814K Wheel Dozer; 815; 815K Soil Compactor and 816; 816K Landfill Compactor).pdf
UENR0315 - Troubleshooting (816K Landfill Compactor and 815K Soil Compactor Systems).pdf
UENR0328 - Schematic (815K Soil Compactor Hydraulic System).pdf
UENR0330 - Schematic (815K Soil Compactor and 816K Landfill Compactor Electrical System; Cab; Chassis; Pump Electronics Tank Unit Header).pdf
PRODUCT DETAILS:
Total Pages: 1,611 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
M0067694 - Disassembly and Assembly (815K; 816K Compactor Engine Supplement)....1
Steering Frame Lock - Separate and Connect....3
System Pressure - Release....7
Batteries - Remove and Install....11
Hood - Remove and Install....13
Engine Enclosure - Remove and Install....16
Alternator - Remove and Install....18
Electric Starting Motor - Remove and Install....20
Fuel Priming Pump and Primary Filter (Water Separator) - Remove and Install....22
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install....25
DEF Injector and Mounting - Remove and Install....27
Nitrogen Oxide Sensor - Remove and Install....29
Soot Sensor - Remove and Install....31
Temperature Sensor (DPF) - Remove and Install....32
Clean Emissions Module - Remove and Install....35
Fuel Tank - Remove and Install....41
Water Temperature Regulator - Remove and Install....45
Water Pump - Remove and Install....48
Refrigerant Condenser - Remove and Install....49
Fuel Cooler - Remove and Install....51
Hydraulic Oil Cooler - Remove and Install....53
Radiator Top Tank - Remove and Install....55
Radiator - Remove and Install....58
Cooling System Package (Radiator; Fan; Aftercooler; Oil Cooler) - Remove and Install....64
Fan Group - Remove and Install....71
Aftercooler Core - Remove and Install....84
Transmission Oil Cooler - Remove and Install....88
Engine Oil Filter and Oil Filter Base - Remove and Install....92
Turbocharger - Remove and Install....94
Air Cleaner - Remove and Install....97
Muffler - Remove and Install....100
Refrigerant Compressor - Remove and Install....102
Engine and Transmission - Remove and Install....105
Engine - Remove and Install....119
M0068544 - Disassembly and Assembly (815K; 816K Soil Compactor Machine Systems)....127
Steering Frame Lock - Separate and Connect....129
System Pressure - Release....133
Hydraulic Tank - Remove and Install....137
Hydraulic Tank - Disassemble....141
Hydraulic Tank - Assemble....144
Steering Control Valve - Remove and Install....147
Steering Control Valve - Disassemble....150
Steering Control Valve - Assemble....156
Steering Neutralizer Valve - Remove and Install....161
Steering Neutralizer Valve - Disassemble....163
Steering Neutralizer Valve - Assemble....165
Steering Cylinder - Remove and Install....167
Brake Accumulator - Remove and Install....172
Accumulator Charging Valve (Brake) - Remove and Install....174
Brake Control Valve (Service) - Remove and Install....176
Brake Control Valve (Parking) - Remove and Install....177
Brake Control Valve (Parking) - Disassemble....178
Brake Control Valve (Parking) - Assemble....179
Parking Brake Actuator - Remove and Install....180
Piston Pump (Steering) - Remove and Install....186
Piston Pump (Steering) - Disassemble....188
Piston Pump (Steering) - Assemble....197
Piston Pump (Implement) - Remove and Install....206
Piston Pump (Implement) - Disassemble....208
Piston Pump (Implement) - Assemble....217
Gear Pump (Charge) - Remove and Install....228
STIC Control and Pilot Valve (Steering) - Remove and Install....230
Pressure Reducing Valve (Implement Pilot) (Steering Pilot) - Remove and Install....236
Pressure Reducing Valve (Implement Pilot) (Steering Pilot) - Assemble....237
Pressure Reducing Valve (Implement Pilot) (Steering Pilot) - Disassemble....239
Electrohydraulic Control - Remove and Install....241
Main Control Valve - Remove and Install....244
Main Control Valve - Disassemble....246
Main Control Valve - Assemble....248
Push Arms and Blade - Remove and Install....250
Stabilizer Link - Remove and Install....254
Lift Cylinder - Remove and Install....255
Tilt Cylinder - Remove and Install....257
Cab - Remove and Install....260
Operator Platform - Remove and Install....265
Instrument Panel (Lower) - Remove and Install....268
Instrument Panel (Upper) - Remove and Install....270
Window Wiper and Wiper Motor (Front) - Remove and Install....272
Window Wiper and Wiper Motor (Rear) - Remove and Install....276
Seat - Remove and Install....280
Blower Motor (Air Conditioner; Heater) - Remove and Install....282
Evaporator Coil and Heater Coil - Remove and Install....284
Refrigerant Condenser - Remove and Install....291
Front Frame from Rear Frame - Separate....293
Front Frame to Rear Frame - Connect....301
M0068550 - Disassembly and Assembly (815K; 816K Compactor Power Train)....312
Steering Frame Lock - Separate and Connect....314
System Pressure - Release....318
Crankcase Guard - Remove and Install....322
Power Train Guard (Transmission) - Remove and Install....324
Relief Valve (Torque Converter Outlet) - Remove and Install....326
Transmission Oil Pump - Remove and Install....333
Relief Valve (Transmission Hydraulic Control) - Remove and Install....343
Modulating Valve (Transmission Clutch) - Remove and Install....351
Torque Converter; Transmission and Output Transfer Gears - Remove....356
Torque Converter from Transmission; Output Transfer Gears - Separate....362
Torque Converter - Disassemble....366
Torque Converter - Assemble....373
Transmission from Output Transfer Gears - Separate....381
Transmission Planetary - Disassemble....383
Transmission Planetary - Assemble....409
Output Transfer Gears - Disassemble....437
Output Transfer Gears - Assemble....446
Transmission to Output Transfer Gears - Connect....457
Torque Converter to Transmission; Output Transfer Gears - Connect....459
Torque Converter; Transmission and Output Transfer Gears - Install....462
Parking Brake Actuator - Remove and Install....468
Parking Brake - Remove and Install....474
Drive Shaft (Front) - Remove and Install....485
Carrier Bearing (Drive Shaft) - Remove and Install....486
Drive Shaft (Center) - Remove and Install....492
Drive Shaft (Rear) - Remove and Install....495
Fixed Axle (Front) - Remove and Install....497
Oscillating Axle (Rear) - Remove and Install....500
Trunnion Support (Oscillating Axle; Front) - Remove and Install....503
Trunnion Support (Oscillating Axle; Rear) - Remove and Install....507
Axle Housing - Disassemble....513
Duo-Cone Conventional Seals - Install....523
Axle Housing - Assemble....530
Service Brakes - Remove and Install....538
Differential and Bevel Gear - Remove and Install....545
Differential Pinion - Disassemble....563
Differential Pinion - Assemble....566
Differential - Disassemble....570
Differential - Assemble....573
NoSPIN Differential - Disassemble....577
NoSPIN Differential - Assemble....580
Cleaner Bar - Remove and Install - Front Axle....583
Cleaner Bar - Remove and Install - Rear Axle....586
Compactor Wheel - Remove and Install....589
M0072480 - Systems Operation (815K Soil Compactor and 814K and 816K Landfill Compactor VIMS Network Manager)....592
General Information....593
Features....595
Electronic Control Module....598
Monitoring System....602
Display Modules....604
Menu Navigation....605
Service Tool Software....613
VIMSpc Software....614
VIMSpc Onboard Configuration....622
Trend Report....633
M0072480 - Testing and Adjusting (815K Soil Compactor and 814K and 816K Landfill Compactor VIMS Network Manager)....634
Self Test....635
Display Module - Replace....637
ECM Software - Install....638
ECM - Replace....640
ECM - Configure....642
Battery - Replace....646
Cable Connections....647
Off-Board Service Tool....648
Connector Contact Description....649
Glossary of Terms....654
System Schematic....660
M0072480 - Troubleshooting (815K Soil Compactor and 814K and 816K Landfill Compactor VIMS Network Manager)....662
General Information....663
Service Tools....664
Electrical Component and Connector Locations....667
Diagnostic Capabilities....669
Determining Diagnostic Trouble Codes....674
Diagnostic Trouble Codes....679
Event Codes....680
Symptom Troubleshooting....683
Emerging Symptom Information....685
Operating Hours Discrepancy....686
Electronic Service Tool Does Not Communicate....688
Reports and Messages Not Available....694
Data Link - Test....700
Data Link Configuration Status - Test....704
Electrical Connector - Inspect....709
External Antenna - Test....715
Wiring Harness (Open Circuit) - Test....717
Wiring Harness (Short Circuit) - Test....718
UENR0313 - Specifications (815K Soil Compactor and 816K Landfill Compactor Systems)....719
Hydraulic Tank....723
Breaker Relief Valve....725
Piston Pump (Implement)....726
Oil Filter (Hydraulic)....728
Electrohydraulic Control - Control Support Group....729
Electrohydraulic Control - Mounting....731
Hydraulic Oil Cooler....733
Main Control Valve....734
Accumulator....738
Accumulator Charging Valve....740
Solenoid Valve (Quick Coupler)....741
Solenoid Valve and Mounting (Hydraulic Lockout)....742
Pilot Valve....743
Accumulator (Pilot)....744
Pilot Lines....746
Shuttle Valve....748
Ride Control Accumulator....751
Lift Cylinder....754
Tilt Cylinder....756
Cylinder Mounting - Steering....758
Pressure Sensor....760
Fan Drive....763
Torque Converter....765
Torque Converter - Housing Group....767
Relief Valve (Torque Converter Outlet)....769
Modulating Valve (Torque Converter Lockup Clutch)....771
Speed Sensor (Torque Converter Output)....773
Modulating Valve (Transmission Clutch)....775
Pressure Switch (Filter Bypass) - Differential....779
Transmission Oil Pump....780
Transmission Hydraulic Control....783
Relief Valve (Transmission Hydraulic Control)....785
Modulating Valve (Transmission Hydraulic Control)....787
Oil Filter (Transmission)....790
Transmission Case....792
Transmission Planetary....794
Output Transfer Gears....799
Drive Shaft....802
Oscillating Axle Housing....804
Fixed Axle Housing....807
Differential....809
Bevel Gear and Pinion (Fixed and Oscillating Axles)....811
Axle Mounting....812
Rim Mounting....814
Piston Pump (Steering)....815
Steering Neutralizer Valve....817
Check Valve (Steering Quad)....818
Steering Control Valve....819
Relief Valve (Steering Cylinder Crossover)....821
Steering Cylinder....822
Brake Accumulator - Charged....826
Brake Accumulator - Uncharged....827
Position Sensor (Left Brake Pedal)....828
Solenoid Valve (Parking Brake)....829
Solenoid Valve....830
Parking Brake Control....832
Parking Brake....833
Fuel Tank - Front....835
Fuel Tank....837
Refrigerant Compressor....838
Pressure Switch (Air Conditioner)....840
Pressure Switch (Refrigerant)....842
Air Cleaner....843
Fuel Cooler....847
Diesel Exhaust Fluid Pump....848
Relief Valve (Pump Backup)....849
Coolant Temperature Sensor....850
Magnetic Switch....853
Refrigerant Condenser and Mounting....854
Heater and Air Conditioner Lines....855
Display Module....857
Steering Control Support....859
Instrument Panel....867
Cab Mounting....868
Cab Mounting - ROOF....870
Cab Window....872
Cab Door....873
Window Wiper and Washer....875
Window Wiper Motor....878
Antenna - Soot monitor....883
Antenna....885
Electric Horn....886
Flood Lighting....887
Flood Lamp....889
Communication Electronic Control Module (Product Link)....892
Communication Electronic Control Module (Product Link) - PL631e Satellite Radio....897
STIC Control....899
STIC Lockout Control....903
Handle Control....905
Disconnect Switch....906
Push Button Switch....907
Toggle Switch (Ground Level Shutdown)....909
Monitor and Mounting....910
Suspension Seat....912
Foot Brake Control....914
Joystick Control....916
Electronic Control Module....918
Push Arm - Left Hand....919
Push Arm - Right Hand....920
Bulldozer Installation....921
Cutting Edge....925
Articulated Hitch....926
Pressure Reducing Valve....929
Gear Pump....930
UENR0314 - Systems Operation (814; 814K Wheel Dozer; 815; 815K Soil Compactor and 816; 816K Landfill Compactor)....931
General Information (Hydraulic System)....933
Location of Components (Hydraulic System)....936
Electronic Control (Hydraulic System)....937
Hydraulic System....947
Hydraulic Tank....957
Accumulator....960
Piston Pump (Implement)....961
Main Control Valve....967
Oil Filter (Hydraulic)....970
Hydraulic Oil Cooler....973
General Information (Power Train System)....976
Location of Components (Power Train System)....980
Electronic Control (Power Train System)....981
Transmission Hydraulic System....996
Torque Converter and Pump Drive Housing....999
Transmission Oil Pump....1002
Oil Filter (Power Train)....1005
Transmission Lubrication....1009
Transmission Hydraulic Control....1012
Modulating Valve (Transmission Clutch)....1014
Transmission Hydraulic Control Operation....1017
Transmission Planetary....1025
Output Transfer Gears....1034
Differential....1037
NoSPIN Differential....1040
General Information (Steering System)....1049
Location of Components (Steering System)....1054
Electronic Control (Steering System)....1055
Monitoring System (Steering Functions)....1063
Steering Pilot System....1066
Pilot Valve (STIC Steering)....1068
Steering Neutralizer Valve....1072
Steering Control Valve....1074
Piston Pump (Steering)....1079
General Information (Brake System)....1083
Location of Components (Brake System)....1089
Electronic Control (Brake System)....1090
Monitoring System (Brake Functions)....1102
Brake Accumulator....1104
Gear Pump (Brake and Pilot)....1107
Brake Control Valve (Service)....1109
Brake Control Valve (Parking)....1115
Service Brakes....1119
Parking Brake....1121
General Information (HVAC System)....1124
Location of Components (HVAC System)....1128
Electronic Control (HVAC System)....1129
UENR0314 - Testing and Adjusting (814; 814K Wheel Dozer; 815; 815K Soil Compactor and 816; 816K Landfill Compactor)....1142
Calibration Error Codes....1144
Calibration....1154
Machine Preparation....1163
System Pressure - Release....1168
Hydraulic Oil Contamination - Test....1169
Lift and Tilt Cylinder Drift - Check....1173
Accumulator (Pilot) - Test and Charge....1176
Implement Cycle Time - Check....1184
Piston Pump (Implement) - Test and Adjust....1187
Speed Sensor - Adjust....1197
Torque Converter Stall and Implement Pump Double Stall - Test....1199
Torque Converter Stall - Test....1202
Fill Time for the Transmission Clutch (Electronic Technician) - Calibrate....1205
Transmission Pressures - Test and Adjust....1211
Piston Pump (Steering) - Test and Adjust....1229
Relief Valve (Steering Cylinder Crossover) - Test and Adjust....1239
Relief Valve (Steering) - Test and Adjust - Backup....1247
STIC Control (Steering Deadband) - Adjust....1255
Steering Neutralizer Valve - Check and Adjust....1258
Steering Time - Check and Adjust....1263
Articulated Hitch - Adjust....1267
Brake System Air - Purge....1275
Service Brake System Pressure - Test....1278
Accumulator (Brake) - Test and Charge....1283
Service Brakes - Test....1288
Service Brake Discs - Check....1291
Limit Switch (Stop Light) - Test and Adjust....1295
Limit Switch (Throttle Lock Deactivation) (Electronic Technician) - Adjust....1299
Parking Brake Actuator - Adjust....1305
Parking Brake - Manual Release....1311
Parking Brake - Test....1313
Glossary of Terms....1315
UENR0315 - Troubleshooting (816K Landfill Compactor and 815K Soil Compactor Systems)....1321
General Information....1323
Service Tools....1326
Connector Locations....1329
Diagnostic Capabilities....1330
Machine Preparation for Troubleshooting....1335
Visual Inspection....1340
Determining Diagnostic Trouble Codes....1343
Diagnostic Trouble Codes....1346
Event Codes....1354
Symptom Troubleshooting....1360
Emerging Symptom Information....1362
Brake System....1363
Differential and Final Drive....1366
HVAC; Required Tools....1370
HVAC; General Troubleshooting....1373
HVAC; Visual Inspection....1376
HVAC; Air Conditioning System....1378
HVAC; Automatic Temperature Control System....1395
HVAC; Condensate Drainage System....1401
HVAC; Control System....1402
HVAC; Heating System....1411
Hydraulic System....1417
Steering System....1421
Torque Converter....1427
Transmission....1431
Alarm - Test....1441
CAN Data Link - Test....1447
Cat Data Link - Test....1451
Charging System - Test....1458
ECM Location Code - Test....1459
Electrical Connector - Inspect....1463
Electrical Power Supply - Test....1470
Operator Control Switch (Switch to Ground) - Test....1475
Parameter - Test....1483
Relay - Test....1486
Sensor Signal (Analog; Active) - Test....1491
Sensor Signal (Analog; Passive) - Test....1497
Sensor Signal (PWM) - Test....1504
Sensor Supply - Test....1515
Solenoid Valve - Test....1522
Speed Sensor - Test....1536
Switch Circuits - Test....1540
Wiring Harness (Open Circuit) - Test....1548
Wiring Harness (Short Circuit) - Test....1549
ECM Software - Install....1551
ECM - Configure....1553
ECM - Replace....1555
Connector Contact Description....1559
System Schematic....1570
UENR0328 - Schematic (815K Soil Compactor Hydraulic System)....1574
Features....1574
Cover page....1576
Tables....0
Components....1577
Connector-Tap....1578
Schematic....1579
Machine Views....0
Hydraulic Oil Filter - Under Cab....1580
Operator Control....1581
Hydraulic Tank....1582
Hydraulic Oil Cooler....1583
Front Frame....1584
Chassis - Top View....1585
UENR0330 - Schematic (815K Soil Compactor and 816K Landfill Compactor Electrical System; Cab; Chassis; Pump Electronics Tank Unit Header)....1586
Feature....1586
Cover Page....1587
Information....0
Component Location....0
Volume 1 of 4 - Cab....1589
Volume 2 of 4 - Chassis....1590
Volume 3 of 4 - Cab Attachment....1591
Volume 4 of 4 - Pump Electronics Tank Unit Header (If Equipped)....1592
Connector Location....0
Volume 1 of 4 - Cab....1593
Volume 2 of 4 - Chassis....1594
Volume 3 of 4 - Cab Attachment....1595
Volume 4 of 4 - Pump Electronics Tank Unit Header (If Equipped)....1596
Specifications and Related Manuals....0
Volume 1 of 4 - Cab....1597
Volume 2 of 4 - Chassis....1598
Volume 3 of 4 - Cab Attachment....1599
Schematics....0
Volume 1 of 4 - Cab....1600
Volume 2 of 4 - Chassis....1601
Volume 3 of 4 - Cab Attachment....1602
Volume 4 of 4 - Pump Electronics Tank Unit Header (If Equipped)....1603
Machine Views....0
Volume 1 of 4 - Cab....0
Cab Rear View....1604
Front Right of Cab....1605
Volume 2 of 4 - Chassis....0
Engine Left Side View....1606
Engine Right Side View....1607
Engine Top View....1608
Front and Implement Valve Harness View....1609
Machine Left Rear View....1610
Radiator View....1611
Transmission View....1612
Volume 3 of 4 - Cab Attachment....0
Cab Top View....1613
HVAC Cab Right Side View....1614
Right Hand and Left Hand Pods....1615
Volume 4 of 4 - Pump Electronics Tank Unit Header (If Equipped)....0
DEF Tank....1616
PETU Header....1617
Caterpillar 815K, 816K Compactors Repair Service Manual
