A Kobelco TLK series loader backhoe can be stripped to the axles and rebuilt using the 620 pages in factory publication 3517-457-M1-00 NA, which covers four models. The electrical system takes up a large share of this Kobelco TLK 750, 860, 865, 965 service manual PDF, with wiring diagrams that trace your battery, charging and starting circuits. Hydraulic schematics show oil routing through the main control valve, Dukes valve and auxiliary valve. The transmission chapter, one of the longest in the book, works through the powershuttle, 4WD pod, 4 wheel steer pod and 5th speed clutch. Set fan belt deflection to 13 to 19 mm midway between the fan and crankshaft pulleys, and torque the starter solenoid end-cover screws to 2 Nm (1.5 lb ft). A made-up torque on those screws strips the threads. The text is searchable and bookmarked, and the pages print clean, so you can take the brake chapter to the bench and let it soak up oil.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| General Information | 6-15 | Safety Precautions, Using the Service Manual |
| Specifications | 16-37 | General Dimensions, Machine Specifications |
| Electrical System | 38-115 | Battery, Charging System, Starting System |
| Electro-Hydraulic System | 116-197 | Hydraulic System Mechanical Valves |
| Hydraulic Valves | 198-249 | Main Control Valve, Dukes Valve, Auxiliary Valve |
| Hydraulic Pumps | 250-265 | Hydraulic Pumps Service |
| Hydraulic Cylinders | 266-291 | Hydraulic Cylinders Service, Extending Dipperstick Cylinder |
| Power Steering | 292-321 | Power Steering System, Power Steering Cylinders |
| Brake System | 322-343 | Brake Control - 750/860/865, Brake Control - 965 |
| Major Assemblies | 344-367 | Major Assemblies Remove and Refit, Rear Axle Remove and Refit |
| Engine | 368-389 | Engine Service |
| Transmission | 390-465 | Powershuttle Transmission, 4WD Pod, 4WS Pod, 5th Speed Clutch |
| Rigid Drive Axle | 466-499 | Rigid Drive Axle Service |
| Steering Drive Axles | 500-561 | Drive-Steer Axle, 4 Wheel Steer Axles |
| Loader Structure | 562-571 | Loader Structure Service |
| Backhoe Structure | 572-587 | Backhoe Structure Service |
| Cab / ROPS / Chassis | 588-597 | Cab / ROPS Service |
| Attachments | 598-607 | Extending Dipperstick |
| Wheels and Tyres | 608-620 | Wheels and Tyres Service |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| Fan belt tension | 13-19 mm | p. 22 |
| Hydraulic system filter rating | 13 micron absolute | p. 24 |
| Engine valve clearance (Exhaust) | 0.45 mm (0.018 in), hot or cold | p. 22 |
| Solenoid main 'BAT' terminal torque | 6 Nm (4.5 lb ft) | p. 102 |
| M8 Stud torque | 6 Nm (4.5 lb ft) | p. 102 |
| Hydraulic pump flow rate | 49 litres/min. at 225 bar | p. 123 |
| Fuel tank capacity | 98.0 L | p. 31 |
| Engine sump including filter capacity | 10.7 L | p. 21 |
| Hydraulic reservoir capacity | 45.0 L | p. 21 |
| Wheel nut tightness (Rear wheels) | 300 Nm | p. 26 |
| Wheel nut tightness (Front wheels) | 300 Nm | p. 26 |
| Engine valve clearance (Inlet) | 0.2 mm | p. 22 |
