KOBELCO COMPACT LOADER WITH ACCESSORIES SL35B – SL40B HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD

Description

KOBELCO COMPACT LOADER WITH ACCESSORIES SL35B – SL40B HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD

DESCRIPTION:

KOBELCO COMPACT LOADER WITH ACCESSORIES SL35B – SL40B HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD

TO THE READER

• This manual has been written for a skilled technician, in order to give him the information necessary to repair this machine. –
• Read this manual carefully for correct information about repair procedures. –
• For any question or comment, or in case you notice a mistake in this manual

ADDITIONAL REFERENCE MANUALS

•  In addition to this Workshop Manual, refer also to the following: –
• Operation and maintenance instruction manual –
• Spare parts catalog

DESCRIPTION OF THE COMPLETE WORKSHOP MANUAL

• The complete repair manual consists of one volume:

SL45B-SL55BH – Workshop Manual “Compact loader with accessories”

• “Compact loader with accessories” Workshop Manual contains the technical information necessary for machine/engine service and repair, service equipment, information on maintenance standards, remove and install procedures, disassembly and assembly procedures.

• The complete Workshop Manual for the compact loader with accessories model SL45B-SL55BH consists of the following volume identified by print number as shown here below

AVOID ACCIDENTS

• Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of some individuals to follow simple and fundamental safety rules or precautions.
• For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs. Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation. Carefully read indications, cautions and safety warning quoted in the “SAFETY RULES” section.
• A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many thousand serious injuries each year. That rule is: Never attempt to clean, oil or adjust a machine while it is in motion.

ATTENTION

• On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing.
• If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment.

INTRODUCTION

• This service manual provides the technical information needed to properly service and maintain the Models SL45B and SL55BH skid steers. Use it in conjunction with the operator’s manual which is supplied with the skid steer. Keep both manuals available for ready reference.
• The SL45B and SL55BH have many similarities with the major differences being engine horsepower and lifting capacity. Whenever working on equipment, left and right sides of the machine are determined by standing behind the unit, looking in the direction of travel.
• The easiest and least time-consuming removal, disassembly, and reassembly procedures are detailed in the manual. Modifying these procedures is not recommended. Skid steers are designed with emphasis on safety for operator protection.
• However, careless and negligent operation can still result in serious injury to persons or damage to property. Be sure to read follow all safety instructions in this manual. Your dealer is interested in your obtaining the most from your investment and will be glad to answer any questions you may have about your skid steer. When major service is required, your dealer’s staff of trained service technicians is ready to serve you.
• When in need of parts, always order genuine parts from your dealer. Be prepared to give your dealer the model and serial number of the engine and skid steer (the location of these numbers is described later in this section).
• Record the serial numbers here. Skid Steer Model Skid Steer Serial Number Engine Model Engine Serial Number CAUTION This symbol is used throughout this book whenever your own personal safety is involved.
• Take time to be careful! ABOUT IMPROVEMENTS Your dealer is continually striving to improve its products. We must, therefore, reserve the right to make improvements or changes when it becomes practical and possible to do so, without incurring any obligation to make changes or additions to the equipment sold previously.
• ALL SPECIFICATIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE

TABLE OF CONTENTS:

KOBELCO COMPACT LOADER WITH ACCESSORIES SL35B – SL40B HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD

COMPACT LOADER WITH ACCESSORIES SL35B – SL40B……………………………………. 1
SECTION 00 – GENERAL INFORMATION……………………………………………….. 4
SECTION 00 – GENERAL INFORMATION……………………………………………. 20
INTRODUCTION………………………………………………………….. 21
ABOUT IMPROVEMENTS…………………………………………………….. 21
COMPANY POLICY………………………………………………………… 22
PARTS AND ACCESSORIES………………………………………………….. 22
MODEL CODES…………………………………………………………… 22
PRECAUTIONARY STATEMENTS……………………………………………….. 23
SAFETY PRECAUTION INFORMATION…………………………………………… 24
GENERAL SAFETY INFORMATION……………………………………………… 26
MACHINE MODEL AND SERIAL NUMBER LOCATION…………………………………. 28
ENGINE MODEL AND SERIAL NUMBER LOCATION………………………………….. 28
MINIMUM HARDWARE TIGHTENING TORQUES……………………………………… 29
INSTALLATION OF ADJUSTABLE FITTINGS IN STRAIGHT THREAD O RING BOSSES………… 31
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS……………………… 31
PIPE THREAD FITTING TORQUE……………………………………………… 32
LUBRICANTS AND COOLANTS………………………………………………… 32
SEALANTS……………………………………………………………… 32
PROPERLY SUPPORT A RAISED MACHINE……………………………………….. 33
PROPERLY SUPPORT BOOM ON BOOM LOCK PINS………………………………….. 33
RAISING BOOM WITHOUT HYDRAULIC OIL FLOW………………………………….. 33
RAISING BOOM WITHOUT BATTERY VOLTAGE (12 VOLTS)…………………………… 34
REATTACHING CYLINDERS AFTER REPAIR WITH BOOM RESTING ON BOOM LOCK PINS………. 36
MAJOR UNIT OVERHAUL……………………………………………………. 37
CAB AND BOOM TILT PROCEDURE…………………………………………….. 38
CRANING THE SKID STEER…………………………………………………. 45
SPECIAL TOOLS…………………………………………………………. 48
SPECIFICATIONS………………………………………………………… 49
DIMENSIONS……………………………………………………………. 52
SECTION 10 – ENGINE…………………………………………………………… 5
SECTION 10 – ENGINE……………………………………………………….. 54
GENERAL ENGINE INFORMATION……………………………………………… 56
GENERAL DESCRIPTION………………………………………………… 56
ENGINE COMPONENT DESCRIPTIONS……………………………………….. 56
ENGINE MODEL AND SERIAL NUMBER LOCATION………………………………. 58
SAFETY PRECAUTIONS…………………………………………………. 59
GENERAL ENGINE SPECIFICATIONS……………………………………….. 60
TROUBLESHOOTING……………………………………………………. 62
SPECIFICATIONS…………………………………………………….. 65
TORQUE SPECIFICATIONS………………………………………………. 70
ENGINE COMPONENTS ELECTRICAL DIAGRAM…………………………………. 71
ENGINE REMOVAL………………………………………………………… 72
ENGINE DISASSEMBLY SEQUENCE…………………………………………. 78
ENGINE COMPONENT MAINTENANCE………………………………………… 86
VALVE SEAT……………………………………………………………. 89
CYLINDER BLOCK………………………………………………………… 92
PISTON AND PISTON RINGS………………………………………………… 93
CONNECTING ROD…………………………………………………….. 97
BEARING HOLDER…………………………………………………………101
FRONT CRANKSHAFT BEARING (BUSHING)……………………………………103
CRANKSHAFT…………………………………………………………….105
FLYWHEEL AND RING GEAR………………………………………………….107
CAMSHAFT ASSEMBLY………………………………………………………108
CAMSHAFT GEAR AND BEARING ASSEMBLY……………………………………….108
TIMING GEAR………………………………………………………..109
OIL PUMP………………………………………………………………109
PORT BLOCK…………………………………………………………110
OIL FILTER…………………………………………………………….111
WATER PUMP ASSEMBLY AND THERMOSTAT HOUSING………………………………..112
THERMOSTAT…………………………………………………………….112
GOVERNOR………………………………………………………………113
GOVERNOR OPERATION………………………………………………….114
ENGINE REASSEMBLY SEQUENCE………………………………………………116
CRANKSHAFT AND BEARING HOLDER ASSEMBLY………………………………..117
REAR OIL SEAL………………………………………………………118
BACKPLATE/FLYWHEEL HOUSING…………………………………………..118
FLYWHEEL…………………………………………………………..118
PISTON AND CONNECTING ROD……………………………………………119
OIL INTAKE PIPE AND OIL STRAINER……………………………………..119
OIL SUMP…………………………………………………………..119
DIPSTICK AND TUBE…………………………………………………..119
FRONT PLATE………………………………………………………..120
IDLER GEAR AND OIL PUMP ASSEMBLY……………………………………..120
TIMING GEAR CASE INSTALLATION………………………………………..121
CRANKSHAFT PULLEY…………………………………………………..122
INJECTION PUMP INSTALLATION………………………………………….122
SPILL TIMING PROCEDURE………………………………………………123
REINSTALLATION OF ENGINE INTO SKID STEER FRAME…………………………….132
HOW TO OPERATE THE ENGINE AFTER OVERHAUL………………………………134
COOLING SYSTEM……………………………………………………..135
OPERATION………………………………………………………….135
WATER PUMP ASSEMBLY AND THERMOSTAT HOUSING…………………………….136
RADIATOR…………………………………………………………..138
FUEL SYSTEM………………………………………………………..139
FUEL SPECIFICATIONS…………………………………………………139
DIESEL FUEL………………………………………………………..139
DIESEL FUEL STORAGE…………………………………………………139
FUEL SYSTEM COMPONENTS………………………………………………140
FUEL GAUGE…………………………………………………………141
COLD START AID……………………………………………………..142
FUEL FILTER SYSTEM………………………………………………….142
PRIMING THE FUEL SYSTEM……………………………………………..143
FUEL SYSTEM TESTING…………………………………………………144
FUEL SYSTEM COMPONENTS………………………………………………147
FUEL INJECTION TIMING…………………………………………………..155
MISCELLANEOUS ENGINE ELECTRICAL………………………………………158
SPECIAL TOOLS………………………………………………………160
SECTION 29 – HYDROSTATIC TRANSMISSION…………………………………………… 7
SECTION 29 – HYDROSTATIC TRANSMISSION………………………………………..162
GENERAL INFORMATION…………………………………………………….164
OPERATION………………………………………………………….164
SPECIFICATIONS……………………………………………………..166
TROUBLESHOOTING………………………………………………………..167
HYDROSTATIC DRIVE SYSTEM TESTING……………………………………..169
HYDROSTATIC SYSTEM OIL FLOW………………………………………….172
HYDROSTATIC CHARGE SYSTEM PRESSURE TEST……………………………….175
HYDROSTATIC PUMP CASE DRAIN TEST……………………………………..177
HYDROSTATIC PUMP HIGH-PRESSURE TEST…………………………………..180
HYDROSTATIC PUMP EFFICIENCY TEST……………………………………..182
HYDROSTATIC MOTOR CASE DRAIN TEST…………………………………….184
HYDROSTATIC MOTOR EFFICIENCY TEST…………………………………….185
HYDRAULIC, HYDROSTATIC SYSTEM AIR INGRESS TEST…………………………187
HYDROSTATIC PUMPS…………………………………………………..188
REMOVAL……………………………………………………………….188
DISASSEMBLY……………………………………………………………192
PARTS INSPECTION……………………………………………………198
REASSEMBLY…………………………………………………………201
REINSTALLATION……………………………………………………..207
HYDROSTATIC MOTOR…………………………………………………..209
REMOVAL……………………………………………………………….209
DISASSEMBLY……………………………………………………………213
PARTS INSPECTION……………………………………………………216
REASSEMBLY…………………………………………………………220
REINSTALLATION……………………………………………………..224
HYDRAULIC SYSTEM CLEANING PROCEDURE…………………………………..227
START-UP PROCEDURE AFTER REBUILD (AFTER PUMP OR MOTOR REPLACEMENT)……….230
CHARGE CHECK VALVE………………………………………………….232
REMOVAL AND REPLACEMENT…………………………………………………232
STEERING SYSTEM………………………………………………………..234
HYDROSTATIC SYSTEM CONTROLS………………………………………….234
NEUTRALIZER ASSEMBLY………………………………………………..236
LEFT CONTROL HANDLE WITH NO BOOM CONTROL………………………………242
REMOVAL……………………………………………………………….242
DISASSEMBLY………………………………………………………..242
INSPECTION…………………………………………………………243
REASSEMBLY…………………………………………………………243
REINSTALLATION……………………………………………………..243
LEFT CONTROL HANDLE WITH BOOM CONTROL…………………………………….245
REMOVAL……………………………………………………………245
DISASSEMBLY………………………………………………………..246
INSPECTION…………………………………………………………247
REASSEMBLY…………………………………………………………248
REINSTALLATION……………………………………………………..249
RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL…………………..251
REMOVAL……………………………………………………………….251
DISASSEMBLY………………………………………………………..252
INSPECTION…………………………………………………………254
REASSEMBLY…………………………………………………………255
REINSTALLATION……………………………………………………..258
DRIVE CONTROL ADJUSTMENT PROCEDURE……………………………………….260
NEUTRAL ADJUSTMENT……………………………………………………..261
SECTION 33 – BRAKES AND CONTROLS……………………………………………….. 8
SECTION 33 – BRAKES AND CONTROLS…………………………………………….264
GENERAL INFORMATION…………………………………………………….265
SPECIFICATIONS……………………………………………………..267
TROUBLESHOOTING…………………………………………………….268
TESTING……………………………………………………………270
PARKING BRAKE………………………………………………………….271
REMOVAL AND INSPECTION………………………………………………272
SECTION 35 – HYDRAULIC SYSTEM………………………………………………….. 9
SECTION 35 – HYDRAULIC SYSTEM……………………………………………….284
GENERAL INFORMATION…………………………………………………….286
HYDRAULIC SYSTEM COMPATIBILITY……………………………………….287
BOOM CYLINDER PIVOT PINS…………………………………………….289
BOOM AND CYLINDER PIVOT PIN LOCATION AND MACHINE USAGE………………….289
CONTROL VALVE POWER BEYOND…………………………………………..290
SPECIFICATIONS……………………………………………………..291
TROUBLESHOOTING…………………………………………………….293
AUXILIARY BOOM HYDRAULICS TROUBLESHOOTING……………………………..297
HYDRAULIC SYSTEM TESTING…………………………………………….299
HYDRAULIC SYSTEM OIL FLOW……………………………………………305
CONTROL VALVE – BUCKET SPOOL SHIFTED………………………………….306
CONTROL VALVE – BOOM SPOOL SHIFTED……………………………………307
CONTROL VALVE – AUXILIARY SPOOL SHIFTED……………………………….308
MAIN SYSTEM PRESSURE TESTS………………………………………………309
CHECKING MAIN SYSTEM PRESSURE AT BOOM CYLINDERS………………………..312
CHECKING MAIN SYSTEM PRESSURE AT BUCKET CYLINDERS………………………313
CHECKING MAIN SYSTEM PRESSURE AT AUXILIARY BOOM HYDRAULIC QUICK COUPLERS….314
BOOM CIRCUIT RELIEF VALVE TEST……………………………………….315
GEAR PUMP FLOW EFFICIENCY TEST……………………………………….317
BOOM AND BUCKET SPOOL LOCK SOLENOID TEST………………………………321
HYDRAULIC, HYDROSTATIC SYSTEM AIR INGRESS TEST…………………………323
CONTROL VALVE………………………………………………………324
CONTROL VALVE………………………………………………………….325
DISASSEMBLY AND INSPECTION………………………………………………327
PARTS INSPECTION……………………………………………………331
REASSEMBLY…………………………………………………………332
REINSTALLATION……………………………………………………..336
HYDRAULIC PUMP……………………………………………………..337
PUMP REMOVAL…………………………………………………………..338
DISASSEMBLY……………………………………………………………340
PARTS INSPECTION……………………………………………………341
REASSEMBLY…………………………………………………………343
INSTALLATION……………………………………………………….346
CYLINDERS, BOOM AND BUCKET…………………………………………..347
REMOVAL……………………………………………………………….348
DISASSEMBLY……………………………………………………………350
PARTS INSPECTION……………………………………………………351
REASSEMBLY…………………………………………………………353
REINSTALLATION……………………………………………………..354
REMOVAL……………………………………………………………….355
DISASSEMBLY……………………………………………………………356
PARTS INSPECTION……………………………………………………357
REASSEMBLY…………………………………………………………357
REINSTALLATION……………………………………………………..358
PEDAL CONTROLS……………………………………………………..359
REMOVAL With Boom and Bucket Pedal Controls……………………………….359
PEDAL INSPECTION With Boom and Bucket Pedal Controls……………………359
PEDAL REINSTALLATION With Boom and Bucket Pedal Controls………………..361
PEDAL REMOVAL With Boom and Bucket Hand Controls…………………………..364
PEDAL INSPECTION With Boom and Bucket Hand Controls…………………….365
PEDAL REINSTALLATION With Boom and Bucket Hand Controls…………………366
HYDRAULIC COOLING, FILTER, RESERVOIR SYSTEM……………………………….369
FILTER SYSTEM………………………………………………………….370
FILTER REMOVAL…………………………………………………………370
BASE REMOVAL…………………………………………………………..370
REASSEMBLY…………………………………………………………371
OIL COOLER…………………………………………………………371
OIL COOLER REMOVAL……………………………………………………..371
REASSEMBLY…………………………………………………………372
OIL RESERVOIR………………………………………………………….373
OIL RESERVOIR REMOVAL…………………………………………………..374
REINSTALLATION……………………………………………………..375
SECTION 37 – TOWING HOOKS AND BALLASTING………………………………………… 11
SECTION 37 – TOWING HOOKS AND BALLASTING……………………………………..376
REAR COUNTERWEIGHTS…………………………………………………….377
REAR COUNTERWEIGHT SUPPORT RE-MOVAL………………………………………377
SECTION 39 – FRAMES…………………………………………………………… 11
SECTION 39 – FRAMES………………………………………………………..378
GENERAL INFORMATION…………………………………………………….379
CAB AND ROPS…………………………………………………………..380
REMOVAL……………………………………………………………….380
REINSTALLATION……………………………………………………..387
SECTION 44 – AXLES AND WHEELS………………………………………………….. 12
SECTION 44 – AXLES AND WHEELS……………………………………………….394
GENERAL INFORMATION…………………………………………………….395
SPECIFICATIONS……………………………………………………..397
TROUBLESHOOTING…………………………………………………….398
TESTING……………………………………………………………400
AXLES…………………………………………………………………401
AXLE HOUSING ASSEMBLY REMOVAL……………………………………………401
DISASSEMBLY……………………………………………………………402
PARTS INSPECTION……………………………………………………404
REASSEMBLY…………………………………………………………405
REINSTALLATION……………………………………………………..407
FINAL DRIVE………………………………………………………..409
REMOVAL……………………………………………………………….409
PARTS INSPECTION……………………………………………………416
REASSEMBLY…………………………………………………………417
TYRES/WHEELS…………………………………………………………..423
TYRE AND TRACK INSTALLATION………………………………………….424
LOADER BOOM STOP ADJUSTMENT………………………………………….425
SECTION 50 – CAB CLIMATE CONTROL……………………………………………….. 12
SECTION 50 – CAB CLIMATE CONTROL…………………………………………….428
HEATER/DEFROSTER (CAB)………………………………………………….429
SECTION 55 – ELECTRICAL SYSTEM…………………………………………………. 13
SECTION 55 – ELECTRICAL SYSTEM………………………………………………436
GENERAL ELECTRICAL INFORMATION…………………………………………..441
DEFINITION OF TERMS…………………………………………………442
ADAPTING ATTACHMENTS REQUIRING 12V ELECTRICAL POWER…………………….444
SPECIFICATIONS……………………………………………………..448
ELECTRICAL DIAGRAM………………………………………………….451
ADVANCED WARNING SYSTEM……………………………………………..455
ELECTRONIC INSTRUMENT CLUSTER (EIC)…………………………………..455
EIC (ELECTRONIC INSTRUMENT CLUSTER) FRONT PANEL………………………..456
EIC FUNCTIONAL GROUPS……………………………………………….457
ENGINE PREHEAT……………………………………………………..462
AUTOMATIC SHUTDOWN………………………………………………….462
OPERATING MODE……………………………………………………..463
BROKEN ALTERNATOR/WATER PUMP BELT WARNING, 3…………………………..465
FUEL LEVEL…………………………………………………………466
EIC INTERLOCKS……………………………………………………..466
EIC LOCK MODE………………………………………………………467
EIC ENGINE PREHEAT………………………………………………….468
TROUBLESHOOTING…………………………………………………….469
ADVANCED WARNING SYSTEM (AWS)………………………………………..472
EIC BOARD SELF TEST…………………………………………………473
DIAGNOSTIC AND SETUP MODES…………………………………………..474
ARROW, OPEN BOOK, AND AUDIBLE ALARM TEST………………………………476
DIAGNOSTIC MODE EIC CIRCUIT TESTS…………………………………….476
EIC SETUP MODE……………………………………………………..480
ELECTRONIC INSTRUMENT CLUSTER (EIC) AND STARTER CIRCUITS………………..488
BLOWN FUSE SYMPTOMS AND TESTING………………………………………488
TESTING OTHER EIC FUNCTIONS………………………………………….490
EIC BOARD READING ACCURACY…………………………………………..493
EIC BOARD CLAIMS WARRANTY……………………………………………495
ELECTRICAL CIRCUITS…………………………………………………496
SEAT SWITCH CIRCUIT TO EIC BOARD……………………………………..497
SEAT BELT SWITCH CIRCUIT TO EIC BOARD…………………………………498
IGNITION SWITCH CIRCUIT TO EIC BOARD………………………………….499
CRANKING CIRCUIT (STARTER MOTOR)……………………………………..500
“SERVICE/RUN” SWITCH IN THE “RUN” POSITION…………………………….501
CRANKING CIRCUIT GROUND……………………………………………..502
OPERATING CONDITIONS “SERVICE/RUN” SWITCH, 1, IN THE “SERVICE” POSITION…..502
SERVICE/RUN SWITCH IN THE “SERVICE” POSITION…………………………..503
CRANKING CIRCUIT GROUND……………………………………………..504
START RELAY OPERATION……………………………………………….504
START RELAY CIRCUIT…………………………………………………505
START RELAY GROUND CIRCUIT…………………………………………..506
START INTERLOCK RELAY OPERATION………………………………………506
START INTERLOCK CIRCUIT……………………………………………..507
START INTERLOCK GROUND CIRCUIT……………………………………….508
START CIRCUIT………………………………………………………508
REMOVAL, INSTALLATION AND WIRING OF ELECTRICAL COMPONENTS…………………..509
BATTERY……………………………………………………………510
REMOVAL……………………………………………………………….510
INSTALLATION……………………………………………………….510
EIC (Electronic Instrument Cluster) BOARD REMOVAL………………………….511
EIC (Electronic Instrument Cluster) WIRING…………………………….512
IGNITION (KEY) SWITCH WIRING…………………………………………514
REMOVAL……………………………………………………………….514
INSTALLATION……………………………………………………….514
CAB FUSE PANEL WIRING……………………………………………….515
CAB FUSE BLOCK AND PANEL REMOVAL……………………………………..516
CAB FUSE BLOCK AND PANEL INSTALLATION…………………………………516
SERVICE/RUN SWITCH WIRING……………………………………………517
SERVICE/RUN SWITCH – SERVICE POSITION ………………………………..517
SERVICE/RUN SWITCH – RUN POSITION…………………………………….517
SERVICE/RUN SWITCH REMOVAL………………………………………………518
SERVICE/RUN SWITCH INSTALLATION………………………………………518
SEAT AND SEAT BELT SWITCH WIRING……………………………………..519
SEAT SWITCH REMOVAL…………………………………………………….519
SEAT SWITCH INSTALLATION…………………………………………….520
SEAT BELT BUCKLE AND SWITCH ASSEMBLY REMOVAL…………………………..520
SEAT BELT BUCKLE INSTALLATION………………………………………..520
ROAD LIGHT AND WORK LIGHT SWITCH WIRING……………………………….521
ROAD LIGHT AND WORK LIGHT SWITCH REMOVAL………………………………….522
ROAD LIGHT AND WORK LIGHT SWITCH INSTALLATION………………………….522
ENGINE FUSE AND RELAY PANEL………………………………………….523
ACCESSORY RELAY WIRING………………………………………………524
ACCESSORY RELAY REMOVAL……………………………………………..524
ACCESSORY RELAY INSTALLATION…………………………………………524
PREHEAT CIRCUIT BREAKER WIRING……………………………………….525
PREHEAT CIRCUIT BREAKER REMOVAL………………………………………….525
PREHEAT CIRCUIT BREAKER INSTALLATION………………………………….525
START INTERLOCK RELAY WIRING…………………………………………526
START INTERLOCK RELAY REMOVAL……………………………………………527
START INTERLOCK RELAY INSTALLATION……………………………………527
ENGINE FUSE PANEL WIRING…………………………………………….528
ENGINE FUSE BLOCK REMOVAL……………………………………………529
ENGINE FUSE BLOCK INSTALLATION……………………………………….529
ALTERNATOR EXCITE RESISTOR WIRING…………………………………….530
ALTERNATOR EXCITE RESISTOR REMOVAL……………………………………….530
ALTERNATOR EXCITE RESISTOR INSTALLATION……………………………….530
START RELAY WIRING………………………………………………….531
START RELAY REMOVAL…………………………………………………….531
START RELAY INSTALLATION…………………………………………….531
PREHEAT RELAY WIRING………………………………………………..532
PREHEAT RELAY REMOVAL…………………………………………………..533
PREHEAT RELAY INSTALLATION…………………………………………..533
PREHEAT GLOW PLUG REMOVAL……………………………………………534
PREHEAT GLOW PLUG INSTALLATION……………………………………….534
FUEL SYSTEM COMPONENTS………………………………………………535
ELECTRIC FUEL PUMP………………………………………………….537
ELECTRIC FUEL PUMP REMOVAL………………………………………………538
FUEL SHUTOFF SOLENOID…………………………………………………..538
FUEL SHUTOFF SOLENOID TESTING………………………………………..538
REPLACEMENT OF FUEL SHUTOFF SOLENOID……………………………………..539
AIR FILTER RESTRICTION INDICATOR SWITCH…………………………………..540
REMOVAL……………………………………………………………540
INSTALLATION……………………………………………………….540
ENGINE COOLANT TEMPERATURE SENDER………………………………………..540
REMOVAL……………………………………………………………540
INSTALLATION……………………………………………………….540
ENGINE OIL PRESSURE SWITCH………………………………………………541
REMOVAL……………………………………………………………541
INSTALLATION……………………………………………………….541
HYDROSTATIC CHARGE PRESSURE SWITCH……………………………………….541
REMOVAL……………………………………………………………541
INSTALLATION……………………………………………………….541
HYDRAULIC OIL FILTER RESTRICTION SWITCH…………………………………..542
REMOVAL……………………………………………………………542
INSTALLATION……………………………………………………….542
HYDRAULIC OIL TEMPERATURE SENDER…………………………………………542
REMOVAL……………………………………………………………542
INSTALLATION……………………………………………………….543
BOOM/BUCKET CONTROL VALVE SPOOL LOCK SOLENOIDS…………………………….544
REMOVAL……………………………………………………………544
INSTALLATION……………………………………………………….544
WIRE HARNESS……………………………………………………….545
MAIN WIRE HARNESS REMOVAL……………………………………………….545
MAIN WIRE HARNESS INSTALLATION……………………………………….550
ROAD/WORK LIGHTS……………………………………………………….554
ALTERNATOR (40 AMP VERSION)……………………………………………..558
CHARGING CIRCUIT……………………………………………………558
ALTERNATOR SERVICE SPECIFICATIONS…………………………………….560
ALTERNATOR – SYSTEM TESTING AND TROUBLESHOOTING………………………..561
SERVICE PRECAUTIONS…………………………………………………564
INITIAL TESTS………………………………………………………564
ALTERNATOR…………………………………………………………….569
DISASSEMBLY……………………………………………………………570
ALTERNATOR REINSTALLATION……………………………………………576
STARTER……………………………………………………………….577
STARTER MOTOR TROUBLESHOOTING………………………………………..577
STARTER MOTOR………………………………………………………….579
REMOVAL……………………………………………………………579
STARTER DISASSEMBLY…………………………………………………584
INSPECTION AND REPAIR……………………………………………….588
REASSEMBLY…………………………………………………………594
STARTER REINSTALLATION………………………………………………597
MISCELLANEOUS ENGINE COMPONENTS………………………………………598
GLOW PLUG………………………………………………………….598
GLOW PLUG TROUBLESHOOTING……………………………………………598
OIL PRESSURE SWITCH…………………………………………………599
FUEL SHUT-OFF SOLENOID………………………………………………599
SECTION 82 – FRONT LOADER (Boom And Mounting Plate)………………………………. 17
SECTION 82 – FRONT LOADER (Boom And Mounting Plate)……………………………600
GENERAL INFORMATION…………………………………………………….601
BUCKETS……………………………………………………………601
BOOM LOCK PINS AND LINKAGE………………………………………………602
BOOM………………………………………………………………602
ATTACHMENT MOUNTING PLATE……………………………………………….603
BOOM AND CYLINDER PIVOT PINS…………………………………………604
BOOM AND CYLINDER PIVOT PIN LOCATION AND MACHINE USAGE………………….604
BOOM/CYLINDER PIVOT PINS SIZE………………………………………..605
PALLET FORK……………………………………………………………606
UTILITY FORK…………………………………………………………..607
BUCKETS……………………………………………………………….608
BUCKET LATCH PLATE INSTALLATION PROCEDURE…………………………………609
DIRT TOOTH KIT INSTALLATION……………………………………………..612
BUCKET TOOTH SPACING………………………………………………..613
BOOM LOCK PIN/LINKAGE……………………………………………….615
REMOVAL……………………………………………………………615
REINSTALLATION……………………………………………………..616
BOOM, UPPER AND LOWER LINK…………………………………………..618
FRONT BOOM MOUNTING PLATE PIVOT HUB REPLACEMENT……………………………624
BOOM, UPPER AND LOWER LINK REINSTALLATION……………………………..626
ATTACHMENT MOUNTING PLATE……………………………………………631
REPAIR/REBUILD MOUNTING PLATE………………………………………..631
LATCH LEVER AND PIN REMOVAL/REPAIR……………………………………….631
PARTS INSPECTION……………………………………………………633
CHECKING PROCEDURE FOR BUCKETS AND ATTACHMENTS…………………………637
CHECKING PROCEDURE………………………………………………….639
CHECKING THE LOADER FACEPLATE………………………………………..640
SECTION 88 – ACCESSORIES………………………………………………………. 18
SECTION 88 – ACCESSORIES……………………………………………………642
GENERAL INFORMATION…………………………………………………….643
ADAPTING ATTACHMENTS REQUIRING 12V ELECTRICAL POWER…………………….643
HYDRAULIC SYSTEM COMPATIBILITY……………………………………….647
ARM PADS FOR CAB SIDE PANELS…………………………………………….649
ARMRESTS FOR DELUXE SEAT………………………………………………..650
FOREARM RESTS………………………………………………………….651
BACK-UP ALARM………………………………………………………….652
BLOCK HEATER (ENGINE)…………………………………………………..653
ELECTRIC POWER SUPPLY (12 VOLT, 15 AMP)…………………………………..654
EXHAUST (ENGINE)……………………………………………………….655
ASPIRATOR PRECLEANER MUFFLER…………………………………………….655
HORN………………………………………………………………….657
SHOULDER BELT (SEAT)……………………………………………………658
SLOW-MOVING VEHICLE (SMV) SIGN KIT……………………………………….659
WARNING LIGHT (ROTARY BEACON)……………………………………………660
WARNING LIGHTS (FOUR-WAY FLASHERS/TURN SIGNAL/HORN)………………………..663
SECTION 90 – PLATFORMS, CAB, BODYWORK, AND DECALS………………………………… 19
SECTION 90 – PLATFORMS, CAB, BODYWORK, AND DECALS……………………………..668
GENERAL INFORMATION…………………………………………………….669
SEAT AND SEAT PAN SUPPORT……………………………………………….669
SEAT REMOVAL…………………………………………………………..671
SEAT PAN SUPPORT REMOVAL………………………………………………..671
SEAT, SWITCH AND PAN REINSTALLATION…………………………………..673
SAFETY DECALS………………………………………………………….675

KOBELCO COMPACT LOADER WITH ACCESSORIES SL35B – SL40B HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:

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