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Daewoo Doosan 450 Plus 460 Plus Skid Steer Loader Shop Manual – PDF DOWNLOAD
Original price was: $65.95.$31.95Current price is: $31.95.
Daewoo Doosan 450 Plus 460 Plus Skid Steer Loader Shop Manual – PDF DOWNLOAD
450 Plus, 460 Plus
Shop Manual
K1040003E
Serial Number 5001 and Up
K1040003E
Serial Number 5001 and Up
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Description
Daewoo Doosan 450 Plus 460 Plus Skid Steer Loader Shop Manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan 450 Plus 460 Plus Skid Steer Loader Shop Manual – PDF DOWNLOAD
450 Plus, 460 Plus
Shop Manual
K1040003E
Serial Number 5001 and Up
K1040003E
Serial Number 5001 and Up
IMPORTANT SAFETY INFORMATION:
- Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
- A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Read and understand all safety precautions and warnings before operating or performing lubrication, maintenance and repair on this product.
- Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety precautions are listed in the “Safety” section of the owner/operation/ maintenance publication.
- Specific safety warnings for all these publications are provided in the description of operations where hazards exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
- If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are identified by the following symbol
FOREWORD :
How to Use This Manual :
- This manual provides information for servicing the skid steer loader.
- All service procedures are broken down into detailed steps, listed in their recommended sequence. The manual uses both photographs and drawings to help locate and itemize components.
- The table of Contents on the preceding pages is your best tool for finding the service procedure you need. Be certain to observe all Safety information included in these pages.
TABLE OF CONTENTS:
Daewoo Doosan 450 Plus 460 Plus Skid Steer Loader Shop Manual – PDF DOWNLOAD
Table of Contents..................................................................... 3 Safety................................................................................ 5 Safety & Foreword................................................................. 7 Important Safety Information.................................................. 11 Safety........................................................................ 13 Foreword...................................................................... 16 How to Use This Manual.................................................... 16 General Precautions for Disassembly....................................... 16 Preparations Before Disassembly....................................... 16 Precautions for Disassembly........................................... 17 Procedures After Disassembly.......................................... 18 General Precautions for Assembly.......................................... 19 Preparations Before Disassembly....................................... 19 Handling of Common Parts.............................................. 22 Engine................................................................................ 23 Engine............................................................................ 25 Safety........................................................................ 31 Safety Precautions........................................................ 31 General Service Information................................................... 54 Component Identification.................................................. 54 Location of Labels........................................................ 55 Function of Major Engine Components....................................... 56 Main Electronic Control Components and Features........................... 57 Function of Cooling System Components..................................... 59 Diesel Fuel............................................................... 60 Diesel Fuel Specifications............................................ 60 Filling The Fuel Tank................................................. 62 Priming the Fuel System............................................... 63 Engine Oil................................................................ 64 Engine Oil Specifications............................................. 64 Engine Oil Viscosity.................................................. 65 Checking Engine Oil................................................... 65 Adding Engine Oil..................................................... 65 Engine Coolant............................................................ 66 Engine Coolant Specifications......................................... 67 Filling Radiator with Engine Coolant.................................. 68 Principal Engine Specifications........................................... 69 4TNV98-Z.............................................................. 69 Engine Service Standards.................................................. 70 Tightening Torques for Standard Bolts and Nuts............................ 71 Periodic Maintenance.......................................................... 73 Before You Begin Servicing................................................ 73 Introduction.............................................................. 87 The Importance of Periodic Maintenance................................ 87 Performing Periodic Maintenance....................................... 87 DOOSAN Replacement Parts.............................................. 87 Required EPA / ARB Maintenance - USA Only............................. 87 EPA / ARB Installation Requirements -USA Only......................... 88 Periodic Maintenance Schedule............................................. 88 Periodic Maintenance Procedures........................................... 90 After Initial 50 Hours of Operation................................... 90 Every 50 Hours of Operation........................................... 96 Every 250 Hours of Operation..........................................101 Every 500 Hours of Operation..........................................105 Every 1000 Hours of Operation.........................................109 Every 1500 Hours of Operation.........................................110 Every 2000 Hours of operation.........................................112 Engine........................................................................115 Before You Begin Servicing................................................115 Introduction..............................................................118 Cylinder Head Specifications..............................................118 Adjustment Specifications.............................................118 Cylinder Head.........................................................118 Intake / Exhaust Valve and Guide......................................118 Push Rod..............................................................119 Valve Spring..........................................................119 Rocker Arm and Shaft..................................................119 Camshaft and Timing Gear Train Specifications.............................120 Camshaft..............................................................120 Idler Gear Shaft and Bushing..........................................120 Timing Gear Backlash..................................................120 Crankshaft and Piston Specifications......................................121 Crankshaft............................................................121 Thrust Bearing........................................................121 Piston................................................................121 Piston Ring...........................................................122 Connecting Rod........................................................122 Tappet................................................................123 Cylinder Block Specifications.............................................123 Cylinder Block........................................................123 Special Torque Chart......................................................124 Torque for Bolts and Nuts.............................................124 Special Service Tools.....................................................125 Measuring Instruments.....................................................127 4-valve Cylinder Head.....................................................129 4-Valve Cylinder Head Components......................................129 Disassembly of 4-Valve Cylinder Head..................................131 Cleaning of Cylinder Head Components..................................135 Inspection of Cylinder Head Components................................135 Inspection of Push Rods...............................................135 Inspection of Rocker Arm Assembly.....................................136 Inspection of Valve Guides............................................136 Inspection of Cylinder Head...........................................137 Inspection of Intake and Exhaust Valves...............................137 Reassembly of Cylinder Head...........................................140 Measuring and Adjusting Valve Clearance...................................146 4-Valve Cylinder Heads................................................147 Crankshaft and Camshaft Components........................................150 Disassembly of Engine.................................................152 Disassembly of Camshaft and Timing Components.........................153 Disassembly of Crankshaft and Piston Components.......................158 Inspection of Crankshaft and Camshaft Components......................162 Honing and Boring.....................................................168 Reassembly of Crankshaft and Piston Components........................169 Reassembly of Camshaft and Timing Components..........................174 Final Reassembly of Engine............................................179 EGR System................................................................180 EGR System............................................................180 Inspecting/Cleaning EGR Related Components............................183 Fuel System...................................................................187 Before You Begin Servicing................................................187 Introduction..............................................................190 Fuel Injection Pump...................................................190 Stop Solenoid.........................................................191 Cold Start Device.....................................................191 Trochoid Fuel Pump....................................................192 Electronically Controlled Governor....................................192 Fuel System Specifications................................................193 Special Torque Chart..................................................193 Test and Adjustment Specifications....................................193 Special Service Tools.....................................................193 Measuring Instruments.....................................................194 Fuel System Diagram.......................................................195 Fuel System Components....................................................197 4-Valve Cylinder Head.................................................197 Fuel Injection Pump.......................................................199 Removal of Fuel Injection Pump........................................199 Installation of Fuel Injection Pump...................................203 Checking and Adjusting Fuel Injection Timing..............................208 Determining the Fuel Injection Timing Specification...................208 Checking Fuel Injection Timing........................................209 Adjusting Fuel Injection Timing.......................................212 Fuel Injectors............................................................213 Removal of Fuel Injectors.............................................213 Testing of Fuel Injectors.............................................213 Disassembly and Inspection of Fuel Injectors..........................215 Adjusting Fuel Injector Pressure......................................216 Reassembly of Fuel Injectors..........................................217 Installation of the Fuel Injectors....................................217 Cooling System................................................................218 Before You Begin Servicing................................................218 Introduction..............................................................221 Cooling System Diagram....................................................221 Engine Coolant Pump Components............................................222 Engine Coolant System Check...............................................223 Engine Coolant Pump.......................................................223 Disassembly of Engine Coolant Pump....................................225 Cleaning and Inspection...............................................225 Reassembly of Engine Coolant Pump.....................................226 Installation of Engine Coolant Pump...................................226 Lubrication System............................................................228 Before You Begin Servicing................................................228 Introduction..............................................................230 Oil Pump Service Information..............................................230 Lubrication System Diagram................................................231 Checking Engine Oil Pressure..............................................232 Trochoid Oil Pump.........................................................232 4TNV98 Oil Pump Components............................................232 Disassembly of Oil Pump...............................................232 Cleaning and Inspection...............................................233 Reassembly of Oil Pump................................................235 Starter Motor.................................................................236 Before You Begin Servicing................................................236 Introduction..............................................................238 Starter Motor Specifications..............................................238 Starter Motor Troubleshooting.............................................239 Starter Motor Components..................................................240 Starter Motor.............................................................241 Removal of Starter Motor..............................................241 Disassembly of Starter Motor..........................................241 Cleaning and Inspection...............................................244 Reassembly of Starter Motor...........................................249 Check Pinion Projection Length........................................251 No-Load Test..........................................................252 Installation of Starter Motor.........................................252 Alternator....................................................................253 Before You Begin Servicing................................................253 Introduction..............................................................257 Alternator Specifications.................................................257 Dynamo Specifications.....................................................257 Alternator Troubleshooting................................................258 Alternator Components.....................................................260 Alternator Wiring Diagram.................................................262 Alternator Standard Output................................................263 Alternator................................................................264 Removal of Alternator.................................................264 Disassembly of Alternator.............................................265 Reassembly of Alternator..............................................267 Installation of Alternator............................................269 Dynamo Component Location.................................................270 Dynamo Wiring Diagram.....................................................271 Operation of Dynamo.......................................................271 Dynamo Standard Output....................................................272 Testing of Dynamo.........................................................273 Testing Stator Coil Continuity........................................273 Testing Stator Coil Short-to-Ground...................................273 Testing Dynamo Regulated Output.......................................273 Dynamo....................................................................274 Removal of Dynamo.....................................................274 Disassembly of Dynamo.................................................274 Reassembly of Dynamo..................................................275 Installation of Dynamo................................................276 Electric Wiring...............................................................277 Electric Wiring Precautions...............................................277 Electrical Wire Resistance................................................278 Battery Cable Resistance..................................................279 Electrical Wire Sizes - Voltage Drop......................................280 Conversion of Awg to European Standards...................................281 Troubleshooting...............................................................282 Special Service Tools.....................................................282 Troubleshooting by Measuring Compression Pressure.........................283 Compression Pressure Measurement Method...............................283 Standard Compression Pressure (Reference Value).......................284 Engine Speed and Compression Pressure (Use for Reference).............284 Measured Value and Troubleshooting....................................285 Quick Reference Table for Troubleshooting.................................286 Failure Diagnosis Table.......................................................287 Electrical wiring.............................................................292 Vehicle System........................................................................293 Vehicle System....................................................................295 Important Safety Information..................................................299 Specifications................................................................301 Dimensional & Performance Specification...................................301 Dimensional Specifications............................................301 Definitions: (DOOSAN Skid Steer Loader)...............................304 Operational Specification (Per SAE J732 Feb 80).......................306 Service Schedule..........................................................315 Special Torque............................................................317 Mounting gp-Engine & HST Pump.........................................317 Canopy gp.............................................................318 Mount gp-Covers.......................................................318 Chain Drive Group.....................................................319 Disassembly & Assembly........................................................320 Quick-Tach................................................................320 Remove & Install Quick-Tach...........................................320 Disassembly & Assemble Quick-Tach.....................................321 Reassemble and Install the Quick-Tach.................................322 Bucket Cylinder...........................................................322 Remove & Install Bucket Cylinder......................................322 Boom Lock & Boom Cylinder.................................................326 Boom Assembly & Boom Stopper..............................................327 Remove & Install Boom Assembly........................................327 Adjustment of Boom Stopper............................................329 Canopy....................................................................330 Drive Control System......................................................333 Neutral Adjusting of Linkage..........................................333 Hydraulic Control System..................................................334 Adjustment Procedure..................................................334 Parking Brake System......................................................335 Removal...............................................................335 Remove the Cable Assemblies...........................................335 Remove the Parking Brake Assemblies (Each Side).......................336 Installation and Adjustment...........................................337 Chain Drive System........................................................339 Power Train Disassembly...............................................339 Remove the Axle Shaft.................................................341 Hydrostatic Pump..........................................................344 Remove & Install Hydrostatic Pump.....................................344 Control Valve.............................................................345 Remove & Install Hydraulic Control Valve..............................345 Oil Filter................................................................345 Remove & Install Oil Filter...........................................345 Muffler...................................................................345 Remove & Install Muffler..............................................345 Radiator & Oil Cooler.....................................................346 Remove And Install Radiator & Oil Cooler..............................346 Flexible Coupling Assembly................................................348 Assembly Procedure....................................................348 Wheel & Tire..............................................................349 Remove And Install Wheel & Tire.......................................349 Hydraulic System......................................................................355 Hydraulic & Hydrostatic Systems...................................................357 Important Safety Information..................................................361 Systems Operation.............................................................363 Hydraulic System..........................................................363 HST System................................................................365 Hydraulic Control Valve...................................................368 Configuration.........................................................368 Schematic.............................................................369 Operations............................................................370 Electrical Connections................................................372 Optional Bucket Self-Leveling System......................................373 Operation.............................................................373 Self-Leveling.........................................................374 Bucket Cylinder Extended..............................................375 Retracting Boom Cylinder..............................................376 Extending Bucket Cylinder.............................................377 Retracting Bucket Cylinder............................................378 HST Pump..................................................................379 HST Motor.................................................................381 Specifications................................................................383 Hydrostatic Systems.......................................................383 Hydrostatic Transmission Pump.........................................383 Hydraulic Systems.........................................................384 Hydraulic Motor.......................................................384 Gear Pump.............................................................384 Control Valve.........................................................384 Pressure and Flow of Standard Skid Steer Loader.......................385 Pressure and Flow of High Flow Skid Steer Loader......................385 Boom Cylinder.........................................................385 Bucket Cylinder.......................................................386 Hydraulic Filter......................................................386 Hydraulic Lines and Fittings..........................................386 Fluid Capacity........................................................387 Oil Type..............................................................387 Testing & Adjusting...........................................................388 Trouble Shooting..........................................................388 Visual Checks.........................................................388 Hydraulic System......................................................389 Boom and Bucket Cylinders.............................................389 Control Valve.........................................................390 Hydrostatic Pump......................................................392 Hydrostatic Motor.....................................................396 Hydraulic System..........................................................397 Hydrostatic System........................................................399 Start-Up Procedure of Hydrostatic System..............................399 Hydrostatic Pump......................................................400 Disassembly & Assembly........................................................402 HST Pump..................................................................402 HST Motor.................................................................407 Hydraulic Control Valve...................................................428 Boom Cylinder.........................................................431 Bucket Cylinder.......................................................432 Hydraulic Schematic...........................................................433 Hydraulic & Hydrostatic Systems - Pilot Control (Optional)........................435 Important Safety Information..................................................439 Systems Operation.............................................................441 Hydraulic System..........................................................441 HST System................................................................443 Hydraulic Control Valve...................................................445 Configuration.........................................................445 Schematic.............................................................446 Electrical Connections................................................447 Self-Leveling.........................................................448 Bucket Cylinder Extended..............................................449 Retracting Boom Cylinder..............................................450 Extending Bucket Cylinder.............................................451 HST Pump..................................................................452 HST Motor.................................................................454 Specifications................................................................455 Hydrostatic Systems.......................................................455 Hydrostatic Transmission Pump.........................................455 Hydraulic Systems.........................................................456 Hydraulic Motor.......................................................456 Gear Pump.............................................................456 Control Valve.........................................................456 Pressure and Flow of Standard Skid Steer Loader.......................457 Pressure and Flow of High Flow Skid Steer Loader......................457 Boom Cylinder.........................................................457 Bucket Cylinder.......................................................458 Hydraulic Filter (Main)...............................................458 HST Joystick Valve....................................................458 Boom Joystick Valve...................................................459 Feeding Unit..........................................................459 Hydraulic Filter (Pilot)..............................................459 Needle Valve..........................................................459 Hydraulic Lines and Fittings..........................................460 Fluid Capacity........................................................460 Oil Type..............................................................460 Testing & Adjusting...........................................................461 Trouble Shooting..........................................................461 Visual Checks.........................................................461 Hydraulic System......................................................462 Hydrostatic System........................................................464 Start-up Procedure of Hydrostatic System..............................464 Preparations..........................................................466 Filling of the Axial Piston Unit......................................466 Testing the direction of rotation of the engine.......................468 Testing hydraulic fluid supply........................................468 Performing Functional Test............................................469 Performing Flushing cycle.............................................469 Hydraulic System......................................................470 Boom and Bucket Cylinders.............................................470 Control Valve.........................................................471 HST Pump..............................................................472 Disassembly & Assembly........................................................476 HST Pump..................................................................476 Danger Labels and Pictograms..........................................476 Safety................................................................477 Basic Safety Information..............................................477 Requirements on the Personnel.........................................480 Description...........................................................481 Description...........................................................482 Sectional View........................................................483 Adjustment Instructions - Low Pressure Valve (Boost Pressure).........484 Adjustment Instructions - Mechanical "Zero Position"..................485 HP- Valves (High Pressure)............................................486 HP- Valves (High Pressure)............................................487 Adjustment Instructions - DA Control..................................488 General Repair Instructions...........................................489 Seal Kits and Sub-Assemblies..........................................490 Seal Kits and Sub-Assemblies..........................................491 Sealing of the Drive Shaft............................................493 Sealing of the Inner Gear Pump........................................494 Sealing of the Inner Gear Pump........................................495 Sealing of the Inner Gear Pump........................................497 Sealing of the Control Piston Cover...................................498 Sealing of the Valves.................................................499 Sealing of the Valves.................................................501 Pump Disassembly......................................................502 Pump Disassembly......................................................504 Pump Disassembly......................................................505 Pump Disassembly......................................................506 Pump Disassembly......................................................507 Pump Disassembly......................................................508 Pump Disassembly......................................................509 Disassembly of the Positioning Piston - Case with Turcon-Glyd-Ring....510 Inspection Notes......................................................511 Inspection Notes......................................................511 Inspection Notes......................................................513 Assembly Case - Turcon-Glyd-Ring......................................514 Assembly of the Pump..................................................515 Assembly of the Pump..................................................516 Assembly of the Pump..................................................517 Assembly of the Pump..................................................518 Assembly of the Pump..................................................519 Assembly of the Pump..................................................520 Assembly of the Pump..................................................521 Assembly of the Pump..................................................522 Assembly of the Pump..................................................523 Assembly of the Pump..................................................524 Assembly Guidelines for Tightening Torques............................525 Assembly Guidelines fot Tightening Torques............................526 Tightening Torques....................................................527 Devices...............................................................528 Hydraulic Control Valve...................................................530 Hydraulic Schematic...........................................................533 Electrical System.....................................................................535 Electrical System.................................................................537 Important Safety Information..................................................541 Introduction..............................................................543 Electrlacl Wire Color.................................................543 Electrical Supply System..................................................544 Engine Starting Circuit...................................................545 Start Operation.......................................................545 Operation After Start Process.........................................547 Engine Preheating System..................................................548 Engine Stop System........................................................550 Charging System...........................................................551 Instrument System.........................................................552 Instrument Panel......................................................552 Operation.............................................................553 Instrument System Schematic...............................................556 Control Unit Operation....................................................557 Engine Control............................................................558 Engine Control Dial.......................................................559 Engine Control Schematic..................................................560 Engine Overheat Prevention System.........................................561 Engine Control Unit.......................................................562 Contorl Failure Detection.................................................563 Diagnostic list.......................................................563 Flashing patterns of engine check lamp....................................566 Fuel Injection Pump...........................................................567 Egr Valve.....................................................................568 Electrical Schematic (450Plus/460Plus)............................................569 450Plus/460Plus...............................................................573
DAEWOO DOOSAN 450 PLUS 460 PLUS SKID STEER LOADER SHOP MANUAL – PDF DOWNLOAD:
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