Caterpillar 815, 816 Compactors Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar 815, 816 Compactors, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar 815, 816 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.
M0113643 - Troubleshooting (815 Soil Compactor and 816 Landfill Compactor Systems).pdf
M0115139 - Schematic (815 Soil Compactor Hydraulic System).pdf
M0115147 - Schematic (814 Wheel Dozer;815 Soil Compactor and 816 Landfill Compactor Power Train System; 451-9808-00).pdf
M0115149 - Schematic (814 Wheel Dozer; 815 Soil Compactor; and 816 Landfill Compactor Electrical System; Cab; Chassis; Engine).pdf
M0117525 - Specifications (815 Soil Compactor and 816 Landfill Compactor Systems).pdf
M0122576 - Disassembly and Assembly (815; 816 Compactor Machine Systems).pdf
M0122580 - Disassembly and Assembly (815; 816 Compactor Power Train).pdf
REG00849 - Systems Operation (814-815-816 POWER TRAIN).pdf
REG00849 - Testing and Adjusting (814-815-816 POWER TRAIN).pdf
REG01162 - Disassembly and Assembly (814-815-816 ENGINE).pdf
REG01183 - Disassembly and Assembly (814-815-816 WHEEL TRACTOR & COMPACTOR POWER TRAIN).pdf
REG01184 - Disassembly and Assembly (814-815-816 VEHICLE SYSTEMS).pdf
SENR7337 - Specifications (814 TRACTOR; 815 & 816 COMPACOTRS; POWER TRAIN).pdf
SENR7526 - Systems Operation (815 & 816 COMPACTORS STEERING SYSTEM).pdf
SENR7526 - Testing and Adjusting (815 & 816 COMPACTORS STEERING SYSTEM).pdf
SENR7527 - Specifications (815 & 816 COMPACTORS STEERING SYSTEM).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
PRODUCT DETAILS:
Total Pages: 1,703 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
M0113643 - Troubleshooting (815 Soil Compactor and 816 Landfill Compactor Systems)....1
General Information....3
Service Tools....6
Connector Locations....10
Diagnostic Capabilities....11
Machine Preparation for Troubleshooting....16
Visual Inspection....21
Determining Diagnostic Trouble Codes....24
Diagnostic Trouble Codes....27
Event Codes....35
Symptom Troubleshooting....42
Emerging Symptom Information....44
Brake System....45
Differential and Final Drive....48
HVAC; Required Tools....52
HVAC; General Troubleshooting....55
HVAC; Visual Inspection....58
HVAC; Air Conditioning System....60
HVAC; Automatic Temperature Control System....77
HVAC; Condensate Drainage System....83
HVAC; Control System....84
HVAC; Heating System....93
Hydraulic System....99
Steering System....103
Torque Converter....109
Transmission....114
Alarm - Test....124
CAN Data Link - Test....130
Cat Data Link - Test....140
Charging System - Test....147
ECM Location Code - Test....148
Electrical Power Supply - Test....155
Parameter - Test....163
Relay - Test....167
Sensor Signal (Analog; Active) - Test....174
Sensor Signal (Analog; Passive) - Test....180
Sensor Signal (PWM) - Test....188
Sensor Supply - Test....199
Solenoid Valve - Test....207
Speed Sensor - Test....220
Switch Circuits - Test....225
Wiring Harness (Open Circuit) - Test....237
Wiring Harness (Short Circuit) - Test....238
ECM Software - Install....240
ECM - Configure....242
ECM - Replace....244
Connector Contact Description....248
System Schematic....257
M0115139 - Schematic (815 Soil Compactor Hydraulic System)....261
M0115147 - Schematic (814 Wheel Dozer;815 Soil Compactor and 816 Landfill Compactor Power Train System; 451-9808-00)....263
M0115149 - Schematic (814 Wheel Dozer; 815 Soil Compactor; and 816 Landfill Compactor Electrical System; Cab; Chassis; Engine)....265
M0117525 - Specifications (815 Soil Compactor and 816 Landfill Compactor Systems)....275
Hydraulic Tank and Filter....280
Breaker Relief Valve....282
Pressure Switch....283
Piston Pump (Implement)....284
Electrohydraulic Control - Control Adjuster Group....286
Electrohydraulic Control and Mounting....288
Oil Cooler Lines....293
Hydraulic Lines....295
Hydraulic Oil Cooler....296
Main Control Valve....297
Accumulator Charging Valve....301
Solenoid Valve and Mounting (Hydraulic Lockout)....302
Accumulator (Pilot) - Uncharged....303
Pilot Lines....304
Shuttle Valve....306
Ride Control Accumulator....307
Lift Cylinder....308
Tilt Cylinder....310
Cylinder Mounting - Steering....312
Pressure Sensor - Parking Brake....313
Pressure Sensor - Swing Drive Oil....314
Fan Drive....315
Torque Converter....317
Torque Converter - Housing Group....319
Relief Valve (Torque Converter Outlet)....321
Transmission Oil Pump....322
Transmission Hydraulic Control....325
Relief Valve (Transmission Hydraulic Control)....327
Modulating Valve (Transmission Hydraulic Control)....329
Temperature Sensor (Transmission Oil)....332
Oil Filter (Power Train)....333
Power Train Oil Lines....336
Transmission Planetary....337
Planetary Case and Parts....342
Output Transfer Gears....343
Speed Sensor (Transmission Output)....346
Drive Shaft....347
Oscillating Axle Housing....349
Fixed Axle Housing....352
Differential....354
Bevel Gear and Pinion (Fixed and Oscillating Axles)....356
Axle Mounting....357
Cleaner Bar....358
Brake and Planetary....366
Rim Mounting....369
Piston Pump (Steering)....370
Steering Neutralizer Valve....372
Steering Neutralizer Valve - Lines Group....373
Check Valve (Steering Quad)....374
Steering Control Valve....375
Steering Cylinder....377
Position Sensor (Left Brake Pedal)....379
Solenoid Valve....380
Brake Control Valve (Parking)....381
Parking Brake....383
Fuel Tank - Front....385
Flexible Exhaust Pipe....387
Exhaust Lines....389
Refrigerant Compressor....390
Pressure Switch (Refrigerant)....392
Oil Level Gauge....394
Air Cleaner....395
Air Cleaner - Precleaner....396
Fuel Cooler....398
Diesel Exhaust Fluid Tank....399
Diesel Exhaust Fluid Pump....401
Diesel Exhaust Fluid Lines....403
Temperature Sensor....405
Temperature Sensor - 2-Pin; Air Outlet....406
Liquid Level Sensor (Water Separator)....407
Position Sensor - Inclination Sensor....408
Radiator Guard....409
Radiator Guard - Compactor....411
Radiator - Grill....412
Aftercooler....413
Water Tank....414
Magnetic Switch....415
Refrigerant Condenser....416
Heater and Air Conditioner Lines....417
Valve - Expansion....419
Valve - Ether Starting Aid....420
Display Module....421
Steering Control Support....423
Electronic Control....429
Instrument Panel....431
Access Door....432
Governor Pedal....434
Position Sensor (Governor Pedal)....435
Rollover Protective Structure (ROPS)....436
Cab - Liner....441
Cab....443
Cab Mounting....445
Cab Mounting - ROOF....447
Cab Window....448
Cab Window - Rubber-Mounted Glass....449
Cab Door....451
Mirror....453
Rear View Mirror....455
Sound Suppression - Panel Group....456
Window Wiper and Washer....457
Window Wiper Motor....459
Antenna....462
Electric Horn....463
Flood Lighting....464
Flood Lamp....471
Communication Electronic Control Module (Product Link)....472
Communication Installation....476
STIC Control....477
STIC Lockout Control....479
Monitor and Mounting....481
Seat Adjuster....482
Suspension Seat....483
Foot Brake Control....485
Joystick Control....486
Electronic Control Module....488
Push Arm....489
Bulldozer Installation....491
Cutting Edge....495
Articulated Hitch....496
Stabilizer Link....499
Pressure Reducing Valve....501
Gear Pump....502
High Speed Oil Change Group....503
Engine and Transmission Mounting....505
Grease Lines - Front....507
Grease Lines - Rear....509
M0122576 - Disassembly and Assembly (815; 816 Compactor Machine Systems)....510
Steering Frame Lock - Separate and Connect....512
System Pressure - Release....516
Hydraulic Tank - Remove and Install....520
Hydraulic Tank - Disassemble....524
Hydraulic Tank - Assemble....527
Steering Control Valve - Remove and Install....530
Steering Control Valve - Disassemble....533
Steering Control Valve - Assemble....539
Steering Neutralizer Valve - Remove and Install....544
Steering Neutralizer Valve - Disassemble....546
Steering Neutralizer Valve - Assemble....548
Steering Cylinder - Remove and Install....550
Brake Accumulator - Remove and Install....555
Accumulator Charging Valve (Brake) - Remove and Install....557
Brake Control Valve (Service) - Remove and Install....560
Brake Control Valve (Parking) - Remove and Install....561
Brake Control Valve (Parking) - Disassemble....563
Brake Control Valve (Parking) - Assemble....564
Parking Brake Actuator - Remove and Install....565
Piston Pump (Steering) - Remove and Install....577
Piston Pump (Steering) - Disassemble....579
Piston Pump (Steering) - Assemble....588
Piston Pump (Implement) - Remove and Install....597
Piston Pump (Implement) - Disassemble....599
Piston Pump (Implement) - Assemble....608
Gear Pump (Charge) - Remove and Install....619
STIC Control and Pilot Valve (Steering) - Remove and Install....621
Pressure Reducing Valve (Implement Pilot) (Steering Pilot) - Remove and Install....632
Pressure Reducing Valve (Implement Pilot) (Steering Pilot) - Assemble....633
Pressure Reducing Valve (Implement Pilot) (Steering Pilot) - Disassemble....635
Electrohydraulic Control - Remove and Install....637
Main Control Valve - Remove and Install....640
Main Control Valve - Disassemble....644
Main Control Valve - Assemble....646
Push Arms and Blade - Remove and Install....648
Lift Cylinder - Remove and Install....653
Tilt Cylinder - Remove and Install....657
Operator Platform - Remove and Install....660
Instrument Panel (Lower) - Remove and Install....663
Instrument Panel (Upper) - Remove and Install....665
Window Wiper and Wiper Motor (Front) - Remove and Install....667
Window Wiper and Wiper Motor (Rear) - Remove and Install....670
Seat - Remove and Install....674
Blower Motor (Air Conditioner; Heater) - Remove and Install....677
Evaporator Coil and Heater Coil - Remove and Install....680
Front Frame from Rear Frame - Separate....688
Front Frame to Rear Frame - Connect....698
M0122580 - Disassembly and Assembly (815; 816 Compactor Power Train)....711
Steering Frame Lock - Separate and Connect....713
System Pressure - Release....717
Crankcase Guard - Remove and Install....721
Power Train Guard (Transmission) - Remove and Install....723
Relief Valve (Torque Converter Outlet) - Remove and Install....725
Transmission Oil Pump - Remove and Install....732
Relief Valve (Transmission Hydraulic Control) - Remove and Install....742
Modulating Valve (Transmission Clutch) - Remove and Install....744
Torque Converter; Transmission and Output Transfer Gears - Remove....749
Torque Converter from Transmission; Output Transfer Gears - Separate....755
Torque Converter - Disassemble....759
Torque Converter - Assemble....766
Transmission from Output Transfer Gears - Separate....774
Transmission Planetary - Disassemble....776
Transmission Planetary - Assemble....802
Output Transfer Gears - Disassemble....830
Output Transfer Gears - Assemble....839
Transmission to Output Transfer Gears - Connect....850
Torque Converter to Transmission; Output Transfer Gears - Connect....852
Torque Converter; Transmission and Output Transfer Gears - Install....855
Parking Brake Actuator - Remove and Install....861
Parking Brake - Remove and Install....867
Drive Shaft (Front) - Remove and Install....878
Carrier Bearing (Drive Shaft) - Remove and Install....879
Drive Shaft (Center) - Remove and Install....885
Drive Shaft (Rear) - Remove and Install....888
Fixed Axle (Front) - Remove and Install....890
Oscillating Axle (Rear) - Remove and Install....894
Trunnion Support (Oscillating Axle; Front) - Remove and Install....898
Trunnion Support (Oscillating Axle; Rear) - Remove and Install....902
Axle Housing - Disassemble....908
Duo-Cone Conventional Seals - Install....918
Axle Housing - Assemble....925
Service Brakes - Remove and Install....933
Differential Pinion - Disassemble....940
Differential Pinion - Assemble....943
Differential - Disassemble....947
Differential - Assemble....950
NoSPIN Differential - Disassemble....954
NoSPIN Differential - Assemble....957
Cleaner Bar - Remove and Install....960
REG00849 - Systems Operation (814-815-816 POWER TRAIN)....963
REG00849 - Testing and Adjusting (814-815-816 POWER TRAIN)....979
REG01162 - Disassembly and Assembly (814-815-816 ENGINE)....983
Fuel Transfer Pump SMCS - 1256-15; 1256-16; 1256-11; 1256-12; 1453-11; 1453-12....985
Fuel Injection Pump Housing And Governor SMCS - 1286-11; 1286-12....990
Governor SMCS - 1264-15; 1264-16....996
Fuel Injection Pump Housing SMCS - 1253-15; 1253-16....1000
Fuel Priming Pump SMCS - 1258-11; 1258-12....1009
Fuel Filter Housing And Base SMCS - 1262-11; 1262-12....1010
Alternator SMCS - 1405-11; 1405-12....1011
Transmission Oil Cooler SMCS - 1375-11; 1375-12....1013
Oil Filter Base SMCS - 1306-11; 1306-12; 1306-15; 1306-16....1015
Engine Oil Cooler SMCS - 1378-11; 1378-12....1019
Water Pump SMCS - 1361-11; 1361-12; 1361-15; 1361-16....1021
Air Compressor SMCS - 1065-11; 1065-12....1025
Air Tank Guard SMCS - 7151-11; 7151-12....1027
Air Tank SMCS - 4272-11; 4272-12....1028
Oil Pan SMCS - 1302-11; 1302-12....1030
Oil Pump SMCS - 1304-11; 1304-12; 1304-15; 1304-16....1032
Oil Pan Plate SMCS - 1302-11; 1302-12....1037
Connecting Rod Bearings SMCS - 1218-10....1038
Crankshaft Main Bearings SMCS - 1203-10....1040
Air Cleaner SMCS - 1051-11; 1051-12....1042
Water Temperature Regulator SMCS - 1355-11; 1355-12....1043
Injection Lines SMCS - 1252-11; 1252-12....1045
Fuel Injection Valves SMCS - 1254-11; 1254-12....1046
Precombustion Chambers SMCS - 1106-11; 1106-12....1048
Turbocharger SMCS - 1052-11; 1052-12....1050
Exhaust Manifold SMCS - 1059-11; 1059-12....1052
Valve Cover SMCS - 1107-11; 1107-12....1054
Rocker Shaft Assembly And Push Rods SMCS - 1102-11; 1102-12; 1208....1056
Rocker Shaft Assembly SMCS - 1102-15; 1102-16....1058
Valve Lifters SMCS - 1209-11; 1209-12....1060
Cylinder Head SMCS - 1100-11; 1100-12....1061
Pistons SMCS - 1214-11; 1214-12....1064
Cylinder Liners SMCS - 1216-11; 1216-12....1067
Fan SMCS - 1356-11; 1356-12....1070
Fan Drive SMCS - 1359-11; 1359-12; 1359-15; 1359-16....1071
Radiator And Guard SMCS - 1381-11; 1381-12....1074
Vibration Damper And Crankshaft Pulley SMCS - 1205-11; 1205-12....1077
Crankshaft Front Seal SMCS - 1160-11; 1160-12....1079
Timing Gear Cover SMCS - 1166-11; 1166-12....1082
Camshaft SMCS - 1210-11; 1210-12....1084
Accessory Drive Shaft SMCS - 1207-11; 1207-12....1086
Timing Gears And Plate SMCS - 1162; 1206-11; 1206-12....1089
Engine SMCS - 1000-11; 1000-12....1093
Flywheel SMCS - 1156-11; 1156-12....1097
Crankshaft Rear Seal SMCS - 1161-11; 1161-12....1099
Flywheel Housing SMCS - 1157-11; 1157-12....1102
Pump Drive SMCS - 3108-11; 3108-12....1104
Camshaft Bearings SMCS - 1211-11; 1211-12....1108
Crankshaft SMCS - 1201-12; 1202-11....1110
REG01183 - Disassembly and Assembly (814-815-816 WHEEL TRACTOR & COMPACTOR POWER TRAIN)....1113
Transmission Oil Pump....1114
Axles....1115
Planetary Carrier Assemblies....1117
Final Drive Ring Gears And Hubs....1119
Wheels; Bearings; And Duo-Cone Seals....1122
Brake Shoes....1125
Spindle Housings....1127
Rear Differential And Carrier Assembly....1130
Front Differential And Carrier Assembly....1136
Differential And Carrier Assembly....1140
Engine; Torque Converter; And Transmission....1154
Torque Converter And Transmission....1161
Torque Converter....1163
Transmission....1174
REG01184 - Disassembly and Assembly (814-815-816 VEHICLE SYSTEMS)....1209
Air Tank Guard SMCS - 3066-11; 3066-12....1210
Air Tank SMCS - 4272-11; 4272-12....1211
Brake Rotochambers SMCS - 4262-11; 4262-12....1213
Quick Release And Holding Valves SMCS - 4262-11; 4262-12....1215
Steering Pump SMCS - 4306-11; 4306-12....1217
Steering Cylinders SMCS - 4303-11; 4303-12....1219
Steering Control Valve SMCS - 4307-11; 4307-12....1221
Steering Gear SMCS - 4301-11; 4301-12; 4301-15; 4301-16....1223
Main Frames SMCS - 7051-11; 7051-12....1232
Lower Pivot Pin Bearings SMCS - 7057-11; 7057-12....1238
SENR7337 - Specifications (814 TRACTOR; 815 & 816 COMPACOTRS; POWER TRAIN)....1242
Introduction....1243
Torque Converter....1244
Drive Shaft And Universal Joints....1248
Torque Converter; Transfer Gears And Pump Drive....1249
Transmission....1250
Transmission Hydraulic Controls....1252
Pressure Control Valve....1254
Relief Valve For Lubrication....1266
Oil Filter For The Transmission....1267
Transmission Pump....1269
Differential Group....1272
Front Axle....1273
Rear Axle....1275
Differential And Bevel Gear....1277
Torque Proportioning Differential....1285
Final Drive....1286
Rim....1294
Tamping Wheel Group....1295
Wheel Assembly....1296
SENR7526 - Systems Operation (815 & 816 COMPACTORS STEERING SYSTEM)....1297
SENR7526 - Testing and Adjusting (815 & 816 COMPACTORS STEERING SYSTEM)....1303
SENR7527 - Specifications (815 & 816 COMPACTORS STEERING SYSTEM)....1309
Introduction SMCS - 1201-12; 1202-11....1310
Hydraulic Pump (9J5067)....1311
Steering Cylinders SMCS - 1201-12; 1202-11....1314
Steering Control Valve SMCS - 1201-12; 1202-11....1315
Steering Control Wheel SMCS - 1201-12; 1202-11....1317
Hitch Group SMCS - 1201-12; 1202-11....1319
UENR0314 - Systems Operation (814; 814K Wheel Dozer; 815; 815K Soil Compactor and 816; 816K Landfill Compactor)....1321
General Information (Hydraulic System)....1323
Location of Components (Hydraulic System)....1326
Electronic Control (Hydraulic System)....1327
Hydraulic System....1337
Hydraulic Tank....1347
Accumulator....1350
Piston Pump (Implement)....1351
Main Control Valve....1357
Oil Filter (Hydraulic)....1360
Hydraulic Oil Cooler....1363
General Information (Power Train System)....1366
Location of Components (Power Train System)....1370
Electronic Control (Power Train System)....1371
Transmission Hydraulic System....1386
Torque Converter and Pump Drive Housing....1389
Transmission Oil Pump....1392
Oil Filter (Power Train)....1395
Transmission Lubrication....1399
Transmission Hydraulic Control....1402
Modulating Valve (Transmission Clutch)....1404
Transmission Hydraulic Control Operation....1407
Transmission Planetary....1415
Output Transfer Gears....1424
Differential....1427
NoSPIN Differential....1430
General Information (Steering System)....1439
Location of Components (Steering System)....1444
Electronic Control (Steering System)....1445
Monitoring System (Steering Functions)....1453
Steering Pilot System....1456
Pilot Valve (STIC Steering)....1458
Steering Neutralizer Valve....1462
Steering Control Valve....1464
Piston Pump (Steering)....1469
General Information (Brake System)....1473
Location of Components (Brake System)....1479
Electronic Control (Brake System)....1480
Monitoring System (Brake Functions)....1492
Brake Accumulator....1494
Gear Pump (Brake and Pilot)....1497
Brake Control Valve (Service)....1499
Brake Control Valve (Parking)....1505
Service Brakes....1509
Parking Brake....1511
General Information (HVAC System)....1514
Location of Components (HVAC System)....1518
Electronic Control (HVAC System)....1519
UENR0314 - Testing and Adjusting (814; 814K Wheel Dozer; 815; 815K Soil Compactor and 816; 816K Landfill Compactor)....1532
Calibration Error Codes....1534
Calibration....1544
Machine Preparation....1553
System Pressure - Release....1558
Hydraulic Oil Contamination - Test....1559
Lift and Tilt Cylinder Drift - Check....1563
Accumulator (Pilot) - Test and Charge....1566
Implement Cycle Time - Check....1574
Piston Pump (Implement) - Test and Adjust....1577
Speed Sensor - Adjust....1587
Torque Converter Stall and Implement Pump Double Stall - Test....1589
Torque Converter Stall - Test....1592
Fill Time for the Transmission Clutch (Electronic Technician) - Calibrate....1595
Transmission Pressures - Test and Adjust....1601
Piston Pump (Steering) - Test and Adjust....1619
Relief Valve (Steering Cylinder Crossover) - Test and Adjust....1629
Relief Valve (Steering) - Test and Adjust - Backup....1637
STIC Control (Steering Deadband) - Adjust....1645
Steering Neutralizer Valve - Check and Adjust....1648
Steering Time - Check and Adjust....1653
Articulated Hitch - Adjust....1657
Brake System Air - Purge....1665
Service Brake System Pressure - Test....1668
Accumulator (Brake) - Test and Charge....1673
Service Brakes - Test....1678
Service Brake Discs - Check....1681
Limit Switch (Stop Light) - Test and Adjust....1685
Limit Switch (Throttle Lock Deactivation) (Electronic Technician) - Adjust....1689
Parking Brake Actuator - Adjust....1695
Parking Brake - Manual Release....1701
Parking Brake - Test....1703
Glossary of Terms....1705
Caterpillar 815, 816 Compactors Repair Service Manual
