KOBELCO COMPACT LOADER WITH ACCESSORIES SL45B – SL55BH HYDRAULIC EXCAVATOR WORKSHOP MANUAL – PDF DOWNLOAD

Description

KOBELCO COMPACT LOADER WITH ACCESSORIES SL45B – SL55BH HYDRAULIC EXCAVATOR WORKSHOP MANUAL – PDF DOWNLOAD

DESCRIPTION:

KOBELCO COMPACT LOADER WITH ACCESSORIES SL45B – SL55BH HYDRAULIC EXCAVATOR WORKSHOP 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 SL45B – SL55BH HYDRAULIC EXCAVATOR WORKSHOP MANUAL – PDF DOWNLOAD

COMPACT LOADER WITH ACCESSORIES SL45B – SL55BH……………………………………………….. 1
WORKSHOP MANUAL…………………………………………………………………………… 1
INDEX……………………………………………………………………………………. 5
SECTION 00 – GENERAL INFORMATION……………………………………………………………. 23
INTRODUCTION………………………………………………………………………….. 24
ABOUT IMPROVEMENTS…………………………………………………………………….. 24
COMPANY POLICY………………………………………………………………………… 25
PARTS AND ACCESSORIES………………………………………………………………….. 25
MODEL CODES…………………………………………………………………………… 25
PRECAUTIONARY STATEMENTS……………………………………………………………….. 26
SAFETY PRECAUTIONS…………………………………………………………………….. 27
GENERAL SAFETY INFORMATION……………………………………………………………… 29
MACHINE MODEL AND SERIAL NUMBER LOCATION…………………………………………………. 31
ENGINE MODEL AND SERIAL NUMBER LOCATION………………………………………………….. 31
MINIMUM HARDWARE TIGHTENING TORQUES……………………………………………………… 32
INSTALLATION OF ADJUSTABLE FITTINGS IN STRAIGHT THREAD O RING BOSSES………………………… 34
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS……………………………………… 34
PIPE THREAD FITTING TORQUE……………………………………………………………… 35
LUBRICANTS AND COOLANTS………………………………………………………………… 35
SEALANTS……………………………………………………………………………… 35
PROPERLY SUPPORT A RAISED MACHINE……………………………………………………….. 36
PROPERLY SUPPORT BOOM ON BOOM LOCK PINS………………………………………………….. 36
RAISING BOOM WITHOUT HYDRAULIC OIL FLOW………………………………………………….. 36
RAISING BOOM WITHOUT BATTERY VOLTAGE (12 VOLTS)…………………………………………… 38
REATTACHING CYLINDERS AFTER REPAIR WITH BOOM RESTING ON BOOM LOCK PINS………………………. 39
MAJOR UNIT OVERHAUL……………………………………………………………………. 40
CAB AND BOOM TILT PROCEDURE…………………………………………………………….. 41
CRANING THE SKID STEER…………………………………………………………………. 47
SPECIAL TOOLS…………………………………………………………………………. 50
SPECIFICATIONS MODEL…………………………………………………………………… 51
DIMENSIONS……………………………………………………………………………. 57
SECTION 10 – ENGINE……………………………………………………………………….. 59
Chapter 1 – SL45B – N844, SL55BH – N844T…………………………………………………. 59
GENERAL ENGINE INFORMATION………………………………………………………….. 61
GENERAL DESCRIPTION………………………………………………………………… 61
ENGINE COMPONENT DESCRIPTIONS……………………………………………………….. 61
ENGINE MODEL AND SERIAL NUMBER LOCATION………………………………………………. 63
TURBOCHARGER LUBRICATION……………………………………………………………. 63
SAFETY PRECAUTIONS…………………………………………………………………. 64
GENERAL ENGINE SPECIFICATIONS ………………………………………………………. 65
TROUBLESHOOTING……………………………………………………………………. 69
SL55BH – EXCESSIVE OIL CONSUMPTION…………………………………………………… 73
SPECIFICATIONS…………………………………………………………………….. 75
SERVICE STANDARDS………………………………………………………………….. 75
TORQUE SPECIFICATIONS………………………………………………………………. 79
ENGINE COMPONENTS ELECTRICAL DIAGRAM…………………………………………………. 80
ENGINE REMOVAL…………………………………………………………………….. 81
ENGINE DISASSEMBLY SEQUENCE…………………………………………………………. 86
ENGINE COMPONENT MAINTENANCE………………………………………………………… 94
VALVE SEAT………………………………………………………………………… 97
CYLINDER BLOCK…………………………………………………………………….. 99
PISTON AND PISTON RINGS……………………………………………………………..100
CONNECTING ROD……………………………………………………………………..103
BEARING HOLDER……………………………………………………………………..105
CRANKSHAFT BEARING (BUSHING)…………………………………………………………106
CRANKSHAFT…………………………………………………………………………108
FLYWHEEL AND RING GEAR………………………………………………………………110
CAMSHAFT ASSEMBLY…………………………………………………………………..110
CAMSHAFT GEAR AND BEARING ASSEMBLY……………………………………………………111
TIMING GEAR………………………………………………………………………..111
OIL PUMP…………………………………………………………………………..112
OIL FILTER…………………………………………………………………………113
WATER PUMP ASSEMBLY AND THERMOSTAT HOUSING…………………………………………….113
THERMOSTAT REMOVAL………………………………………………………………….113
GOVERNOR…………………………………………………………………………..115
GOVERNOR OPERATION………………………………………………………………….117
ENGINE REASSEMBLY SEQUENCE…………………………………………………………..119
CRANKSHAFT AND BEARING HOLDER ASSEMBLY………………………………………………..120
REAR OIL SEAL………………………………………………………………………120
BACK PLATE/FLYWHEEL HOUSING………………………………………………………….121
FLYWHEEL…………………………………………………………………………..121
PISTON AND CONNECTING ROD……………………………………………………………121
OIl intake and oil strainer………………………………………………………….122
OIL Sump…………………………………………………………………………..122
Dipstick and Tube…………………………………………………………………..122
Front Plate………………………………………………………………………..122
Idler Gear and Oil Pump Assembly (See Section IV Oil Pump)………………………………122
TIMING GEAR CASE……………………………………………………………………124
CRANKSHAFT PULLEY…………………………………………………………………..124
INJECTION PUMP INSTALLATION………………………………………………………….124
ADJUSTING THE FUEL INJECTION TIMING ………………………………………………….125
SPILL-TIMING PROCEDURE………………………………………………………………126
REINSTALLATION OF ENGINE INTO SKID STEER FRAME…………………………………………133
HOW TO OPERATE THE ENGINE AFTER OVERHAUL………………………………………………135
COOLING SYSTEM……………………………………………………………………..136
OPERATION………………………………………………………………………….136
WATER PUMP ASSEMBLY AND THERMOSTAT HOUSING…………………………………………….137
RADIATOR…………………………………………………………………………..138
FUEL SYSTEM………………………………………………………………………..140
FUEL SPECIFICATIONS…………………………………………………………………140
DIESEL FUEL………………………………………………………………………..140
DIESEL FUEL STORAGE…………………………………………………………………140
FUEL SYSTEM COMPONENTS………………………………………………………………141
FUEL GAUGE…………………………………………………………………………142
COLD START AID……………………………………………………………………..143
FUEL FILTER SYSTEM………………………………………………………………….143
PRIMING THE FUEL SYSTEM……………………………………………………………..144
FUEL SYSTEM TESTING…………………………………………………………………145
FUEL SYSTEM COMPONENTS………………………………………………………………148
FUEL INJECTION TIMING……………………………………………………………….154
TURBOCHARGER – SL55BH N844T ENGINE……………………………………………………159
TURBOCHARGER REMOVAL………………………………………………………………..161
MISCELLANEOUS ENGINE ELECTRICAL………………………………………………………174
FUEL SHUT-OFF SLOENOID………………………………………………………………175
SPECIAL TOOLS………………………………………………………………………177
SECTION 27 – REAR DRIVE AXLE (GEARBOXES)……………………………………………………..179
Chapter 1 – Gearboxes…………………………………………………………………..179
GENERAL INFORMATION…………………………………………………………………180
SPECIFICATIONS……………………………………………………………………..182
TROUBLESHOOTING…………………………………………………………………….183
TESTING……………………………………………………………………………185
GEARBOXES………………………………………………………………………….186
REMOVAL AND INSPECTION………………………………………………………………186
DISASSEMBLY………………………………………………………………………..190
PARTS INSPECTION……………………………………………………………………191
REASSEMBLY…………………………………………………………………………192
REINSTALLATION……………………………………………………………………..194
SECTION 29 – HYDROSTATIC TRANSMISSION………………………………………………………..197
Chapter 1 – Neutralizer, Pumps, Motors……………………………………………………197
GENERAL INFORMATION…………………………………………………………………199
OPERATION………………………………………………………………………….199
SPECIFICATIONS……………………………………………………………………..201
TROUBLESHOOTING…………………………………………………………………….202
HYDROSTATIC DRIVE SYSTEM TESTING……………………………………………………..204
HYDROSTATIC SYSTEM OIL FLOW………………………………………………………….207
HYDROSTATIC CHARGE SYSTEM PRESSURE TEST……………………………………………….210
HYDROSTATIC PUMP CASE DRAIN TEST……………………………………………………..211
HYDROSTATIC PUMP HIGH-PRESSURE TEST…………………………………………………..214
HYDROSTATIC PUMP EFFICIENCY TEST……………………………………………………..216
HYDROSTATIC MOTOR CASE DRAIN TEST…………………………………………………….218
HYDROSTATIC MOTOR EFFICIENCY TEST…………………………………………………….219
HYDRAULIC, HYDROSTATIC SYSTEM AIR INGRESS TEST…………………………………………221
HYDROSTATIC PUMPS…………………………………………………………………..223
REMOVAL……………………………………………………………………………223
DISASSEMBLY………………………………………………………………………..227
PARTS INSPECTION……………………………………………………………………232
REASSEMBLY…………………………………………………………………………237
HYDRAULIC SYSTEM PUMP INSTALLATION (WITHOUT HIGH FLOW)………………………………….243
HYDRAULIC SYSTEM PUMP / HIGH FLOW PUMP INSTALLATION ……………………………………245
REINSTALLATION……………………………………………………………………..250
HYDROSTATIC MOTOR…………………………………………………………………..254
REMOVAL……………………………………………………………………………254
DISASSEMBLY………………………………………………………………………..258
PARTS INSPECTION……………………………………………………………………263
REASSEMBLY…………………………………………………………………………266
RENSTALLATION………………………………………………………………………275
HYDRAULIC SYSTEM CLEANING PROCEDURE…………………………………………………..281
START-UP PROCEDURE AFTER REBUILD (AFTER PUMP OR MOTOR REPLACEMENT)……………………….284
CHARGE CHECK VALVE………………………………………………………………….286
REMOVAL AND REPLACEMENT……………………………………………………………..286
STEERING SYSTEM…………………………………………………………………….287
HYDROSTATIC SYSTEM CONTROLS………………………………………………………….287
NEUTRALIZER ASSEMBLY………………………………………………………………..289
LEFT CONTROL HANDLE WITH NO BOOM HAND CONTROL………………………………………….293
REMOVAL……………………………………………………………………………293
DISASSEMBLY………………………………………………………………………..293
INSPECTION…………………………………………………………………………294
REASSEMBLY…………………………………………………………………………294
REINSTALLATION……………………………………………………………………..294
LEFT CONTROL HANDLE WITH BOOM HAND CONTROL…………………………………………….296
REMOVAL……………………………………………………………………………296
DISASSEMBLY………………………………………………………………………..297
INSPECTION…………………………………………………………………………298
REASSEMBLY…………………………………………………………………………299
REINSTALLATION……………………………………………………………………..300
RIGHT CONTROL HANDLE WITH AUXILIARY OR BUCKET CONTROL…………………………………..302
REMOVAL……………………………………………………………………………302
DISASSEMBLY………………………………………………………………………..303
INSPECTION…………………………………………………………………………305
REASSEMBLY…………………………………………………………………………306
REINSTALLATION……………………………………………………………………..309
DRIVE CONTROL ADJUSTMENT PROCEDURE……………………………………………………311
NEUTRAL ADJUSTMENT …………………………………………………………………312
SECTION 33 – BRAKES AND CONTROLS…………………………………………………………….315
Chapter 1 – Parking Brake……………………………………………………………….315
GENERAL INFORMATION…………………………………………………………………316
SPECIFICATIONS……………………………………………………………………..318
TROUBLESHOOTING…………………………………………………………………….319
TESTING……………………………………………………………………………321
PARKING BRAKE………………………………………………………………………322
REMOVAL AND INSPECTION………………………………………………………………323
SECTION 35 – HYDRAULIC SYSTEM……………………………………………………………….337
Chapter 1 – Valves, Gear Pump, Cylinders, and Pedal Controls………………………………..337
GENERAL INFORMATION…………………………………………………………………339
HYDRAULIC SYSTEM COMPATIBILITY……………………………………………………….340
BOOM CYLINDER PIVOT PINS…………………………………………………………….342
BOOM AND CYLINDER PIVOT PIN LOCATION AND MACHINE USAGE………………………………….342
CONTROL VALVE POWER BEYOND…………………………………………………………..343
SPECIFICATIONS……………………………………………………………………..344
TROUBLESHOOTING…………………………………………………………………….348
AUXILIARY BOOM HYDRAULICS TROUBLESHOOTING……………………………………………..352
HYDRAULIC SYSTEM TESTING…………………………………………………………….354
HYDRAULIC SYSTEM OIL FLOW……………………………………………………………360
CONTROL VALVE – BUCKET SPOOL SHIFTED………………………………………………….361
CONTROL VALVE – BOOM SPOOL SHIFTED……………………………………………………362
CONTROL VALVE – AUXILIARY SPOOL SHIFTED……………………………………………….363
MAIN SYSTEM PRESSURE TESTS…………………………………………………………..364
CHECKING MAIN SYSTEM PRESSURE AT BOOM CYLINDERS………………………………………..366
CHECKING MAIN SYSTEM PRESSURE AT BUCKET CYLINDERS, 1……………………………………367
CHECKING MAIN SYSTEM PRESSURE AT AUXILIARY BOOM HYDRAULIC QUICK COUPLERS, 1……………….368
BOOM CIRCUIT RELIEF VALVE TEST……………………………………………………….369
GEAR PUMP FLOW EFFICIENCY TEST……………………………………………………….371
BOOM AND BUCKET SPOOL LOCK SOLENOID TEST………………………………………………375
HYDRAULIC, HYDROSTATIC SYSTEM AIR INGRESS TEST…………………………………………377
CONTROL VALVE………………………………………………………………………379
CONTROL VALVE………………………………………………………………………380
REMOVAL……………………………………………………………………………380
DISASSEMBLY AND INSPECTION…………………………………………………………..381
PARTS INSPECTION……………………………………………………………………385
REASSEMBLY…………………………………………………………………………386
REINSTALLATION……………………………………………………………………..389
HYDRAULIC PUMP……………………………………………………………………..390
PUMP REMOVAL……………………………………………………………………….391
HYDRAULIC SYSTEM PUMP REMOVAL/ DISASSEMBLY (WITHOUT HIGH FLOW) ………………………….392
HYDRAULIC SYSTEM PUMP AND HIGH FLOW PUMP REMOVAL/DISASSEMBLY…………………………….392
HIGH FLOW PUMP PARTS INSPECTION………………………………………………………394
HYDRAULIC SYSTEM PUMP PARTS INSPECTION………………………………………………..395
HYDRAULIC SYSTEM PUMP REASSEMBLY/ INSTALLATION (WITHOUT HIGH FLOW) ………………………397
HYDRAULIC SYSTEM PUMP AND HIGH FLOW PUMP REASSEMBLY/ INSTALLATION………………………..400
NEW HYDRAULIC SYSTEM PUMP INSTALLATION (WITHOUT HIGH FLOW)………………………………406
NEW HYDRAULIC SYSTEM PUMP / HIGH FLOW PUMP INSTALLATION…………………………………408
GEAR PUMP START-UP PROCEDURE…………………………………………………………414
CYLINDERS, BOOM AND BUCKET…………………………………………………………..415
BOOM CYLINDER………………………………………………………………………417
REMOVAL……………………………………………………………………………417
DISASSEMBLY………………………………………………………………………..419
PARTS INSPECTION……………………………………………………………………420
REASSEMBLY…………………………………………………………………………421
REINSTALLATION……………………………………………………………………..423
BUCKET CYLINDER…………………………………………………………………….423
REINSTALLATION……………………………………………………………………..423
REMOVAL……………………………………………………………………………423
DISASSEMBLY………………………………………………………………………..424
PARTS INSPECTION……………………………………………………………………425
REASSEMBLY…………………………………………………………………………426
REINSTALLATION……………………………………………………………………..428
PEDAL CONTROLS……………………………………………………………………..429
REMOVAL With Boom and Bucket Pedal Controls……………………………………………429
PEDAL INSPECTION With Boom and Bucket Pedal Controls …………………………………..429
PEDAL REINSTALLATION With Boom and Bucket Pedal Controls………………………………..431
PEDAL REMOVAL With Boom and Bucket Hand Controls……………………………………….434
PEDAL INSPECTION With Boom and Bucket Hand Controls…………………………………….435
PEDAL REINSTALLATION With Boom and Bucket Hand Controls…………………………………436
HYDRAULIC COOLING, FILTER, RESERVOIR SYSTEM……………………………………………439
FILTER SYSTEM………………………………………………………………………440
FILTER REMOVAL……………………………………………………………………..440
BASE REMOVAL……………………………………………………………………….440
REASSEMBLY…………………………………………………………………………441
OIL COOLER…………………………………………………………………………441
OIL COOLER REMOVAL………………………………………………………………….441
REASSEMBLY…………………………………………………………………………442
OIL RESERVOIR………………………………………………………………………442
OIL RESERVOIR REMOVAL……………………………………………………………….443
REINSTALLATION……………………………………………………………………..444
ADAPTING ATTACHMENTS WITH PREVIOUS-STYLE SUPPLIED BALL/PIN COUPLERS TO FLAT-FACED COUPLERS….445
SECTION 37 – TOWING HOOKS AND BALLASTING……………………………………………………..447
Chapter 1 – Rear Counterweights………………………………………………………….447
REAR COUNTERWEIGHTS 3……………………………………………………………….448
REAR COUNTERWEIGHT SUPPORT REMOVAL……………………………………………………448
SECTION 39 – FRAMES………………………………………………………………………..449
Chapter 1 – Lower Main, ROPS…………………………………………………………….449
GENERAL INFORMATION…………………………………………………………………450
ROPS………………………………………………………………………………450
ROPS FRAME…………………………………………………………………………450
REMOVAL……………………………………………………………………………450
REINSTALLATION……………………………………………………………………..456
SECTION 44 – AXLES AND WHEELS Chapter 1 – Axles……………………………………………….459
Chapter 1 – Axles………………………………………………………………………459
GENERAL INFORMATION…………………………………………………………………460
SPECIFICATIONS……………………………………………………………………..462
TROUBLESHOOTING…………………………………………………………………….463
TESTING……………………………………………………………………………465
AXLES……………………………………………………………………………..466
AXLE HOUSING ASSEMBLY REMOVAL………………………………………………………..466
DISASSEMBLY………………………………………………………………………..467
PARTS INSPECTION……………………………………………………………………469
REASSEMBLY…………………………………………………………………………470
REINSTALLATION……………………………………………………………………..472
FINAL DRIVE………………………………………………………………………..473
DRIVE CHAIN AND SPROCKET REMOVAL……………………………………………………..473
PARTS INSPECTION……………………………………………………………………477
REASSEMBLY…………………………………………………………………………478
TYRES/WHEELS……………………………………………………………………….480
TYRE AND TRACK INSTALLATION………………………………………………………….481
SECTION 50 – CAB CLIMATE CONTROL…………………………………………………………….483
Chapter 1 – Heater/Defroster…………………………………………………………….483
HEATER/DEFROSTER (CAB)………………………………………………………………484
SECTION 55 – ELECTRICAL SYSTEM………………………………………………………………491
Chapter 1 – Advanced Warning System, Circuits, Alternator, and Starter……………………….491
GENERAL ELECTRICAL INFORMATION……………………………………………………….496
DEFINITION OF TERMS…………………………………………………………………497
ADAPTING ATTACHMENTS REQUIRING 12V ELECTRICAL POWER…………………………………….499
SPECIFICATIONS……………………………………………………………………..504
ADVANCED WARNING SYSTEM……………………………………………………………..511
ELECTRONIC INSTRUMENT CLUSTER (EIC)…………………………………………………..511
(EIC) ELECTRONIC INSTRUMENT CLUSTER FRONT PANEL ……………………………………….512
EIC FUNCTIONAL GROUPS……………………………………………………………….513
ENGINE PREHEAT……………………………………………………………………..518
AUTOMATIC SHUTDOWN………………………………………………………………….518
OPERATING MODE……………………………………………………………………..519
BROKEN ALTERNATOR/WATER PUMP BELT WARNING, 3…………………………………………..521
FUEL LEVEL…………………………………………………………………………522
EIC INTERLOCKS……………………………………………………………………..522
EIC LOCK MODE………………………………………………………………………523
EIC ENGINE PREHEAT………………………………………………………………….524
TROUBLESHOOTING…………………………………………………………………….525
ADVANCED WARNING SYSTEM (AWS)………………………………………………………..528
EIC BOARD SELF TEST…………………………………………………………………529
DIAGNOSTIC AND SETUP MODES…………………………………………………………..530
ARROW, OPEN BOOK, AND AUDIBLE ALARM TEST………………………………………………532
DIAGNOSTIC MODE EIC CIRCUIT TESTS…………………………………………………….532
EIC SETUP MODE……………………………………………………………………..536
ELECTRONIC INSTRUMENT CLUSTER (EIC) AND STARTER CIRCUITS:……………………………….544
BLOWN FUSE SYMPTOMS AND TESTING………………………………………………………544
TESTING OTHER EIC FUNCTIONS………………………………………………………….546
EIC BOARD READING ACCURACY…………………………………………………………..549
EIC BOARD CLAIMS WARRANTY……………………………………………………………551
ELECTRICAL CIRCUITS…………………………………………………………………552
SEAT SWITCH CIRCUIT TO EIC BOARD……………………………………………………..553
SEAT BELT SWITCH CIRCUIT TO EIC BOARD ………………………………………………..554
IGNITION SWITCH CIRCUIT TO EIC BOARD………………………………………………….555
CRANKING CIRCUIT (STARTER MOTOR)……………………………………………………..556
“SERVICE/RUN” SWITCH IN THE “RUN” POSITION ……………………………………………557
CRANKING CIRCUIT GROUND……………………………………………………………..558
OPERATING CONDITIONS “SERVICE/RUN” SWITCH IN THE “SERVICE” POSITION………………………558
SERVICE/RUN SWITCH IN THE “SERVICE” POSITION…………………………………………..559
CRANKING CIRCUIT GROUND……………………………………………………………..560
START RELAY OPERATION……………………………………………………………….560
START RELAY CIRCUIT…………………………………………………………………561
START RELAY GROUND CIRCUIT…………………………………………………………..562
START INTERLOCK RELAY OPERATION………………………………………………………562
START INTERLOCK CIRCUIT……………………………………………………………..563
START INTERLOCK GROUND CIRCUIT……………………………………………………….564
START CIRCUIT………………………………………………………………………564
REMOVAL, INSTALLATION AND WIRING OF ELECTRICAL COMPONENTS……………………………….565
BATTERY……………………………………………………………………………566
REMOVAL……………………………………………………………………………566
INSTALLATION……………………………………………………………………….566
EIC (ELECTRONIC INSTRUMENT CLUSTER) BOARD REMOVAL………………………………………567
EIC (Electronic Instrument Cluster) WIRING…………………………………………….568
EIC (Electronic Instrument Cluster) BOARD INSTALLATION………………………………….569
IGNITION (KEY) SWITCH WIRING…………………………………………………………570
REMOVAL……………………………………………………………………………570
INSTALLATION……………………………………………………………………….570
SERVICE/RUN SWITCH WIRING……………………………………………………………573
SERVICE/RUN SWITCH – SERVICE POSITION…………………………………………………573
SERVICE/RUN SWITCH – RUN POSITION…………………………………………………….573
SERVICE/RUN SWITCH………………………………………………………………….574
REMOVAL……………………………………………………………………………574
INSTALLATION……………………………………………………………………….574
SEAT AND SEAT BELT SWITCH WIRING……………………………………………………..575
SEAT SWITCH REMOVAL…………………………………………………………………575
SEAT SWITCH INSTALLATION…………………………………………………………….576
SEAT BELT BUCKLE AND SWITCH ASSEMBLY REMOVAL…………………………………………..576
SEAT BELT BUCKLE INSTALLATION………………………………………………………..576
ROAD LIGHT AND WORK LIGHT SWITCH WIRING……………………………………………….577
ROAD LIGHT AND WORK LIGHT SWITCH……………………………………………………..578
REMOVAL……………………………………………………………………………578
INSTALLATION……………………………………………………………………….578
ENGINE FUSE AND RELAY PANEL………………………………………………………….579
ACCESSORY RELAY WIRING………………………………………………………………580
ACCESSORY RELAY…………………………………………………………………….580
REMOVAL……………………………………………………………………………580
INSTALLATION……………………………………………………………………….580
PREHEAT CIRCUIT BREAKER WIRING……………………………………………………….581
PREHEAT CIRCUIT BREAKER……………………………………………………………..581
REMOVAL……………………………………………………………………………581
INSTALLATION……………………………………………………………………….581
START INTERLOCK RELAY WIRING…………………………………………………………582
START INTERLOCK RELAY REMOVAL………………………………………………………..583
START INTERLOCK RELAY INSTALLATION……………………………………………………583
PREHEAT RELAY WIRING………………………………………………………………..588
PREHEAT RELAY REMOVAL……………………………………………………………….589
PREHEAT RELAY INSTALLATION…………………………………………………………..589
PREHEAT GLOW PLUG REMOVAL……………………………………………………………590
PREHEAT GLOW PLUG INSTALLATION……………………………………………………….590
FUEL SYSTEM COMPONENTS………………………………………………………………591
ELECTRIC FUEL PUMP………………………………………………………………….593
ELECTRIC FUEL PUMP REMOVAL…………………………………………………………..594
FUEL SHUTOFF SOLENOID……………………………………………………………….594
FUEL SHUTOFF SOLENOID TESTING………………………………………………………..594
REPLACEMENT OF FUEL SHUTOFF SOLENOID………………………………………………….595
AIR FILTER RESTRICTION INDICATOR SWITCH……………………………………………….596
REMOVAL……………………………………………………………………………596
INSTALLATION……………………………………………………………………….596
ENGINE COOLANT TEMPERATURE SENDER…………………………………………………….596
REMOVAL……………………………………………………………………………596
INSTALLATION……………………………………………………………………….596
ENGINE OIL PRESSURE SWITCH…………………………………………………………..597
REMOVAL……………………………………………………………………………597
INSTALLATION……………………………………………………………………….597
HYDROSTATIC CHARGE PRESSURE SWITCH……………………………………………………597
REMOVAL……………………………………………………………………………597
INSTALLATION……………………………………………………………………….597
HYDRAULIC OIL FILTER RESTRICTION SWITCH……………………………………………….598
REMOVAL……………………………………………………………………………598
INSTALLATION……………………………………………………………………….598
HYDRAULIC OIL TEMPERATURE SENDER……………………………………………………..598
REMOVAL……………………………………………………………………………598
INSTALLATION……………………………………………………………………….599
BOOM/BUCKET CONTROL VALVE SPOOL LOCK SOLENOIDS…………………………………………600
REMOVAL……………………………………………………………………………600
INSTALLATION……………………………………………………………………….601
WIRE HARNESS……………………………………………………………………….602
MAIN WIRE HARNESS REMOVAL……………………………………………………………602
MAIN WIRE HARNESS INSTALLATION……………………………………………………….607
ROAD/WORK LIGHTS……………………………………………………………………611
ALTERNATOR (40 AMP VERSION)………………………………………………………….615
CHARGING CIRCUIT……………………………………………………………………615
ALTERNATOR SERVICE SPECIFICATIONS…………………………………………………….617
ALTERNATOR – SYSTEM TESTING AND TROUBLESHOOTING NO CHARGING……………………………..618
ALTERNATOR…………………………………………………………………………622
ALTERNATOR REMOVAL………………………………………………………………….622
DISASSEMBLY………………………………………………………………………..623
ALTERNATOR REINSTALLATION……………………………………………………………630
STARTER……………………………………………………………………………631
STARTER MOTOR TROUBLESHOOTING………………………………………………………..631
STARTER MOTOR………………………………………………………………………633
REMOVAL……………………………………………………………………………633
STARTER DISASSEMBLY…………………………………………………………………638
INSPECTION AND REPAIR……………………………………………………………….642
REASSEMBLY…………………………………………………………………………647
STARTER REINSTALLATION………………………………………………………………651
SECTION 82 – FRONT LOADER (BOOM AND MOUNTING PLATE)……………………………………………653
Chapter 1 – Buckets…………………………………………………………………….653
GENERAL INFORMATION…………………………………………………………………654
BUCKETS……………………………………………………………………………654
BOOM LOCK PINS AND LINKAGE…………………………………………………………..655
BOOM………………………………………………………………………………655
ATTACHMENT MOUNTING PLATE……………………………………………………………656
BOOM AND CYLINDER PIVOT PINS…………………………………………………………656
BOOM AND CYLINDER PIVOT PIN LOCATION AND MACHINE USAGE …………………………………656
BOOM/CYLINDER PIVOT PINS SIZE………………………………………………………..657
PALLET FORK ……………………………………………………………………….658
UTILITY FORK……………………………………………………………………….659
BUCKETS……………………………………………………………………………660
CUTTING EDGE (REPLACEMENT)…………………………………………………………..660
BUCKET LATCH PLATE INSTALLATION PROCEDURE……………………………………………..661
DIRT TOOTH KIT INSTALLATION………………………………………………………….663
BUCKET TOOTH SPACING………………………………………………………………..665
BOOM LOCK PIN LINKAGE……………………………………………………………….667
REMOVAL……………………………………………………………………………667
REINSTALLATION……………………………………………………………………..668
BOOM, UPPER AND LOWER LINK…………………………………………………………..670
REMOVAL……………………………………………………………………………670
FRONT BOOM MOUNTING PLATE PIVOT HUB REPLACEMENT………………………………………..676
BOOM, UPPER AND LOWER LINK REINSTALLATION……………………………………………..677
ATTACHMENT MOUNTING PLATE……………………………………………………………681
REMOVAL……………………………………………………………………………681
REPAIR/REBUILD MOUNTING PLATE………………………………………………………..682
LATCH LEVER AND PIN REMOVAL/REPAIR……………………………………………………682
PARTS INSPECTION……………………………………………………………………684
CHECKING PROCEDURE FOR BUCKETS AND ATTACHMENTS…………………………………………688
CHECKING PROCEDURE………………………………………………………………….690
CHECKING THE LOADER FACEPLATE………………………………………………………..691
SECTION 88 – ACCESSORIES……………………………………………………………………693
Chapter 1 – Dealer Installed Options……………………………………………………..693
GENERAL INFORMATION…………………………………………………………………694
ADAPTING ATTACHMENTS REQUIRING 12V ELECTRICAL POWER…………………………………….694
HYDRAULIC SYSTEM COMPATIBILITY……………………………………………………….699
ARM PADS FOR CAB SIDE PANELS…………………………………………………………701
ARMRESTS FOR DELUXE SEAT…………………………………………………………….701
FOREARM RESTS………………………………………………………………………702
BACK-UP ALARM………………………………………………………………………703
BLOCK HEATER (ENGINE)……………………………………………………………….704
ELECTRIC POWER SUPPLY (12 VOLT, 15 AMP)……………………………………………….705
EXHAUST (ENGINE) CATALYTIC MUFFLER……………………………………………………706
ASPIRATOR PRECLEANER MUFFLER…………………………………………………………706
HIGH FLOW HYDRAULICS………………………………………………………………..708
HIGH FLOW HYDRAULICS TROUBLESHOOTING………………………………………………….710
HIGH FLOW HYDRAULICS COMPONENT REPLACEMENT…………………………………………….712
HORN………………………………………………………………………………719
SHOULDER BELT (SEAT)………………………………………………………………..720
SLOW-MOVING VEHICLE (SMV) SIGN KIT……………………………………………………721
WARNING LIGHT (ROTARY BEACON)………………………………………………………..722
WARNING LIGHTS (FOUR-WAY FLASHERS/TURN SIGNAL/HORN)…………………………………….725
SECTION 90 – PLATFORM, CAB, BODYWORK, AND DECALS………………………………………………729
Chapter 1 – Cab and Seat………………………………………………………………..729
GENERAL INFORMATION…………………………………………………………………730
SEAT AND SEAT PAN SUPPORT……………………………………………………………730
CAB INNER SHELL…………………………………………………………………….731
SEAT REMOVAL……………………………………………………………………….731
SEAT PAN SUPPORT REMOVAL…………………………………………………………….731
SEAT, SWITCH AND PAN REINSTALLATION…………………………………………………..733
CAB INNER SHELL…………………………………………………………………….735
REMOVAL……………………………………………………………………………735
REINSTALLATION……………………………………………………………………..742
SAFETY DECALS………………………………………………………………………750

KOBELCO COMPACT LOADER WITH ACCESSORIES SL45B – SL55BH HYDRAULIC EXCAVATOR WORKSHOP MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

S.M