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Daewoo Doosan Skid Steer Loader Shop Manual SSL601 – PDF DOWNLOAD
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SSL 601
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Description
Daewoo Doosan Skid Steer Loader Shop Manual SSL601 – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan Skid Steer Loader Shop Manual SSL601 – PDF DOWNLOAD
Shop Manual
SSL 601
Forward :
How to Use This Manual:
- This manual provides information for servicing the DSL 601 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. First locate the major component group, then turn to its Contents page in the manual. (Or, you can continue searching in the main Table of Contents.) Scan down through the group service headings to find the specific procedure.
- Sections are generally organized in the following order of procedures:
- General
- Removal
- Disassembly
- Assembly
- Installation
- Adjustment
- Troubleshooting (Hydraulic, Hydrostatic, and Electrical systems)
The service groups in this manual – their order of presentation and their leading numbering system – match that of the DSL 601 Service Parts Manual. This is done to make it easier for you when ordering parts. The sections include:
- 00 Engine
- 01 Fuel System
- 02 Control System
- 03 Power Train
- 04 Hydraulic System
- 05 Hydrostatic System
- 06 Electrical System
- 07 Frame, Boom, and Bucket
- 08 Paint and Decals
- 09 Factory Options
- 1 O General Information/Miscellaneous Sections 08 and 09 do not apply to service procedures and therefore are not included in this manual. Be certain to observe all Safety information included in these pages .
TABLE OF CONTENTS:
Daewoo Doosan Skid Steer Loader Shop Manual SSL601 – PDF DOWNLOAD
TABLE OF CONTENTS …………………………………………………………………………………………….. i
FORWARD …………………………………………………………………………………………………………….. vii
HOW TO USE THIS MANUAL …………………………………………………………………………. vii
SAFETY. ……………………………………………………………………………………………………… viii
GENERAL PRECAUTIONS FOR DISASSEMBLY. ………………………………………………….. xi
GENERAL PRECAUTIONS FOR ASSEMBLY. ……………………………………………………… xiii
00 ENGINE, 4TN84E ………………………………………………………………………………………………. 1
00.1 GENERAL ……………………………………………………………………………………………… 3
00.1.1 SPECIFICATIONS ………………………………………………………………………….. 5
00.1.2 PERFORMANCE CURVES …………………. .. …………………………………. .. …… 6
FORWARD …………………………………………………………………………………………………………….. vii
HOW TO USE THIS MANUAL …………………………………………………………………………. vii
SAFETY. ……………………………………………………………………………………………………… viii
GENERAL PRECAUTIONS FOR DISASSEMBLY. ………………………………………………….. xi
GENERAL PRECAUTIONS FOR ASSEMBLY. ……………………………………………………… xiii
00 ENGINE, 4TN84E ………………………………………………………………………………………………. 1
00.1 GENERAL ……………………………………………………………………………………………… 3
00.1.1 SPECIFICATIONS ………………………………………………………………………….. 5
00.1.2 PERFORMANCE CURVES …………………. .. …………………………………. .. …… 6
• 00.1.3 MAINTENANCE …………………………………………………………………………….. 7
00.1.4 SERIAL NUMBER LOCATION ………………………………………………………….. 8
00.2 BASIC ENGINE ……………………………………………………………………………………… 9
00.2.1 CYLINDER BLOCK ………………………………………………………………………. 11
00.2.2 CYLINDER HEAD ………………………………………………………………………… 16
00.2.3 PISTON AND PISTON PINS …………………………………………………………. 23
00.2.4 CONNECTING ROD ……………………………………………………………………. 27
00.2.5 CRANKSHAFT AND MAIN BEARING ……………………………………………. 30
00.2.6 CAMSHAFT AND TAPPETS …………………………………………………………. 33
00.2.7 TIMING GEAR ………………………………………………………………………….. … 36
00.2.8 FLYWHEEL …………………………………………………………………………………. 38
00.2.9 SERVICE DATA …….. ……………………………………………………………………. 40
00.2.10 OVER-SIZE AND UNDER-SIZE PARTS ………………………………………….. 44
00.3 FUEL INJECTION EQUIPMENT …………………………………………………………….. 45
00.3.1 FUEL SUPPLY SYSTEM ……………………………………………………………… .47
00.3.2 DISASSEMBLY, REASSEMBLY AND INSPECTION
OF GOVERNOR …………………………………………………………………………. 59
00.3.3 DISASSEMBLY, REASSEMBLY AND INSPECTION OF FUEL
INJECTION PUMP ……….. …………………………………………………………….. 68
00.3.4 ADJUSTMENT OF FUEL INJECTION PUMP AND GOVERNOR. …… … 78
DSL 601
00 Engine, 4TNB4E Table Of Contents
00.3.5 FUEL FEED PUMP ……………………………………………………………………… 84
00.3.6 FUEL INJECTION NOZZLE .. ………………………………………………………… 86
00.1.4 SERIAL NUMBER LOCATION ………………………………………………………….. 8
00.2 BASIC ENGINE ……………………………………………………………………………………… 9
00.2.1 CYLINDER BLOCK ………………………………………………………………………. 11
00.2.2 CYLINDER HEAD ………………………………………………………………………… 16
00.2.3 PISTON AND PISTON PINS …………………………………………………………. 23
00.2.4 CONNECTING ROD ……………………………………………………………………. 27
00.2.5 CRANKSHAFT AND MAIN BEARING ……………………………………………. 30
00.2.6 CAMSHAFT AND TAPPETS …………………………………………………………. 33
00.2.7 TIMING GEAR ………………………………………………………………………….. … 36
00.2.8 FLYWHEEL …………………………………………………………………………………. 38
00.2.9 SERVICE DATA …….. ……………………………………………………………………. 40
00.2.10 OVER-SIZE AND UNDER-SIZE PARTS ………………………………………….. 44
00.3 FUEL INJECTION EQUIPMENT …………………………………………………………….. 45
00.3.1 FUEL SUPPLY SYSTEM ……………………………………………………………… .47
00.3.2 DISASSEMBLY, REASSEMBLY AND INSPECTION
OF GOVERNOR …………………………………………………………………………. 59
00.3.3 DISASSEMBLY, REASSEMBLY AND INSPECTION OF FUEL
INJECTION PUMP ……….. …………………………………………………………….. 68
00.3.4 ADJUSTMENT OF FUEL INJECTION PUMP AND GOVERNOR. …… … 78
DSL 601
00 Engine, 4TNB4E Table Of Contents
00.3.5 FUEL FEED PUMP ……………………………………………………………………… 84
00.3.6 FUEL INJECTION NOZZLE .. ………………………………………………………… 86
• 00.3.7 TROUBLESHOOTING …………………………………………………………………. 92
00.3.8 FUEL FILTER ………………………………………………………………………………. 94
00.3.9 AIR VENTING SYSTEM …… ………… …….. .. ……………………….. ……………. .. 95
00.3.10 SERVICE DATA ……………………………………………… ………………………… … 96
00.4 LUBRICATING SYSTEM ……………………………………………………………………….. 97
00.4.1 LUBRICATION SYSTEM ……………………………………………………………….. 98
00.4.2 LUBE OIL PUMP ……. ……. …………… .. …………………….. .. …………………… 100
00.4.3 LUBE OIL FILTER & OIL PRESSURE CONTROL VALVE. ….. …………. . 103
00.4.4 SERVICE DATA ………………………………………………….. ……………………. 105
00.5 CCCLI NG SYSTEM ……………………………………………………………………………. 107
00.5.1 COOLING SYSTEM ……………………………………………… .. …………………. 108
00.5.2 RADIATOR …………………….. ……. ………………………………………………….. 109
00.5.3 RADIATOR FAN BELT …….. …………………………. .. ………………. .. …….. … . 110
00.5.4 THERMOSTAT ………………………………………………… ……………………….. 111
00.5.5 COOLING WATER PUMP …………………. ……………………………………….. 112
00.5.6 SERVICE DATA ………………. .. …….. .. ………………………………………………. 114
00.6 AIR INDUCTION SYSTEM ………………………………………………………………….. 115
00.6.1 AIR CLEANER …………………………………………………………….. …………… 116
00.7 ELECTRICAL SYSTEM ………………………………………………………………………. 119
00.7.1 ELECTRICAL SCHEMATIC … .. ……………………………………. …………. …… 121
00.7.2 STARTER MOTOR ………………………………………….. ………………………… 125
00.3.8 FUEL FILTER ………………………………………………………………………………. 94
00.3.9 AIR VENTING SYSTEM …… ………… …….. .. ……………………….. ……………. .. 95
00.3.10 SERVICE DATA ……………………………………………… ………………………… … 96
00.4 LUBRICATING SYSTEM ……………………………………………………………………….. 97
00.4.1 LUBRICATION SYSTEM ……………………………………………………………….. 98
00.4.2 LUBE OIL PUMP ……. ……. …………… .. …………………….. .. …………………… 100
00.4.3 LUBE OIL FILTER & OIL PRESSURE CONTROL VALVE. ….. …………. . 103
00.4.4 SERVICE DATA ………………………………………………….. ……………………. 105
00.5 CCCLI NG SYSTEM ……………………………………………………………………………. 107
00.5.1 COOLING SYSTEM ……………………………………………… .. …………………. 108
00.5.2 RADIATOR …………………….. ……. ………………………………………………….. 109
00.5.3 RADIATOR FAN BELT …….. …………………………. .. ………………. .. …….. … . 110
00.5.4 THERMOSTAT ………………………………………………… ……………………….. 111
00.5.5 COOLING WATER PUMP …………………. ……………………………………….. 112
00.5.6 SERVICE DATA ………………. .. …….. .. ………………………………………………. 114
00.6 AIR INDUCTION SYSTEM ………………………………………………………………….. 115
00.6.1 AIR CLEANER …………………………………………………………….. …………… 116
00.7 ELECTRICAL SYSTEM ………………………………………………………………………. 119
00.7.1 ELECTRICAL SCHEMATIC … .. ……………………………………. …………. …… 121
00.7.2 STARTER MOTOR ………………………………………….. ………………………… 125
• 00.7.3 CHARGING EQUIPMENT. ………. .. ……………………………………………….. 139
00.7.4 STARTING AIDS ………… ……………………….. ………………………………… .. . 150
00.7.5 BATTERY ……………………………………………………………….. .. ……………… 151
00.7.6 SERVICE DATA …………………………………………………………………………. 154
00.8 DISASSEMBLY AND REASSEMBLY …………………………………………………….. 155
00.8.1 DISASSEMBLY AND REASSEMBLY PRECAUTIONS …………………….. 156
00.8.2 DISASSEMBLY AND REASSEMBLY ……………………………………………. 157
00.8.3 BOLT/NUT TIGHTENING TORQUE …………………………………………….. 170
00.8.4 TROUBLESHOOTING …………. ……………………………………. ………………. 171
00.8.5 IDENTIFICATION OF PARTS FOR EACH APPLICATION ……….. ……… 177
00.8.6 CONVERSION TABLES ……………………………………………………………… 178
00.9 ENGINE REMOVAL AND INSTALLATION PROCEDURES ………………………. 181
00.9.1 ENGINE/HYDROSTATIC PUMP REMOVAL ………………………………….. 182
00.9.2 ENGINE/HYDROSTATIC PUMP INSTALLATION …………………………… 186
00 Engine, 4TN84E Table Of Contents
• 01 FUEL SYSTEM …………………………………………………………………………………………………. 189
01.1 GENERAL ………………………………………………………………………………………….. 190
01.2 FUEL LINES ………………………………………………………………………………………. 191
02 CONTROL SYSTEM ………………………………………………………………………………………… 1 93
02.1 GENERAL ………………………………………………………………………………………….. 195
02.2 CONTROL SYSTEM REMOVAL AND INSTALLATION
PROCEDURES ………………………………………………………………………………….. 196
02.2.1 SEAT BAR SYSTEM REMOVAL. ……… ………………………….. …….. …… …. 196
02.2.2 SEAT BAR SYSTEM INSTALLATION AND ADJUSTMENT. .. ……. ….. …. 197
02.2.3 DRIVE CONTROL SYSTEM REMOVAL. .. .. ………………………. …………… 198
02.2.4 DRIVE CONTROL SYSTEM INSTALLATION AND ADJUSTMENT. …….. 200
02.2.5 HYDRAULIC CONTROL SYSTEM REMOVAL …. …………. .. ……………….. 202
02.2.6 HYDRAULIC CONTROL SYSTEM REASSEMBLY AND
INSTALLATION …. ……………………………………………. ….. … .. ……………….. 203
02.2.7 THROTTLE CONTROL SYSTEM REMOVAL …….. .. …………. .. …………… 204
02.2.8 THROTTLE CONTROL SYSTEM INSTALLATION AND
00.7.4 STARTING AIDS ………… ……………………….. ………………………………… .. . 150
00.7.5 BATTERY ……………………………………………………………….. .. ……………… 151
00.7.6 SERVICE DATA …………………………………………………………………………. 154
00.8 DISASSEMBLY AND REASSEMBLY …………………………………………………….. 155
00.8.1 DISASSEMBLY AND REASSEMBLY PRECAUTIONS …………………….. 156
00.8.2 DISASSEMBLY AND REASSEMBLY ……………………………………………. 157
00.8.3 BOLT/NUT TIGHTENING TORQUE …………………………………………….. 170
00.8.4 TROUBLESHOOTING …………. ……………………………………. ………………. 171
00.8.5 IDENTIFICATION OF PARTS FOR EACH APPLICATION ……….. ……… 177
00.8.6 CONVERSION TABLES ……………………………………………………………… 178
00.9 ENGINE REMOVAL AND INSTALLATION PROCEDURES ………………………. 181
00.9.1 ENGINE/HYDROSTATIC PUMP REMOVAL ………………………………….. 182
00.9.2 ENGINE/HYDROSTATIC PUMP INSTALLATION …………………………… 186
00 Engine, 4TN84E Table Of Contents
• 01 FUEL SYSTEM …………………………………………………………………………………………………. 189
01.1 GENERAL ………………………………………………………………………………………….. 190
01.2 FUEL LINES ………………………………………………………………………………………. 191
02 CONTROL SYSTEM ………………………………………………………………………………………… 1 93
02.1 GENERAL ………………………………………………………………………………………….. 195
02.2 CONTROL SYSTEM REMOVAL AND INSTALLATION
PROCEDURES ………………………………………………………………………………….. 196
02.2.1 SEAT BAR SYSTEM REMOVAL. ……… ………………………….. …….. …… …. 196
02.2.2 SEAT BAR SYSTEM INSTALLATION AND ADJUSTMENT. .. ……. ….. …. 197
02.2.3 DRIVE CONTROL SYSTEM REMOVAL. .. .. ………………………. …………… 198
02.2.4 DRIVE CONTROL SYSTEM INSTALLATION AND ADJUSTMENT. …….. 200
02.2.5 HYDRAULIC CONTROL SYSTEM REMOVAL …. …………. .. ……………….. 202
02.2.6 HYDRAULIC CONTROL SYSTEM REASSEMBLY AND
INSTALLATION …. ……………………………………………. ….. … .. ……………….. 203
02.2.7 THROTTLE CONTROL SYSTEM REMOVAL …….. .. …………. .. …………… 204
02.2.8 THROTTLE CONTROL SYSTEM INSTALLATION AND
• ADJUSTMENT ……………… …………………………………………………… … … … 205
02.2.9 PARKING BRAKE SYSTEM REMOVAL- EARLIER MODELS ………… .. .. 207
02.2.10 PARKING BRAKE SYSTEM INSTALLATION AND
ADJUSTMENT – EARLIER MODELS ……….. ……………………………… …… 209
02.2.11 PARKING BRAKE SYSTEM REMOVAL – LATER MODELS ………………. 211
02.2.12 PARKING BRAKE SYSTEM INSTALLATION AND
ADJUSTMENT – LATER MODELS …………………………. …. .. … ……………. 212
02.2.13 PEDAL LOCK SYSTEM REMOVAL, INSTALLATION AND
ADJUSTMENT – LATER MODELS ……………………………………….. .. …. … 214
03 POWER TRAIN ………………………………………………………………………………………………… 217
03.1 GENERAL ………………………………………………………………………………………….. 218
03.2 POWER TRAIN DISASSEMBLY AND ASSEMBLY. ………………………………….. 219
03.2.1 POWER TRAIN DISASSEMBLY. ……………………………….. .. ……………….. 219
03.2.2 POWER TRAIN INSTALLATION …………………………………………………… 221
00 Engine, 4TN84E Table Of Contents
04 HYDRAULIC SYSTEM ………………………………………………………………………………………. 223 •
HYDRAULIC SCHEMATIC ……………………………………………………………………………. 224
04.1 GENERAL ………………………………………………………………………………………….. 227
04.1.1 HYDRAULIC SYSTEM …. …………………………. …………………………………. 227
04.1.2 HYDROSTATIC (HST) SYSTEM …………………………………………………… 227
04.2 REMOVAL AND INSTALLATION PROCEDURES ……………………………………. 228
04.2.1 HYDRAULIC CHARGE PUMP. ……………………………………………………… 228
04.2.2 HYDRAULIC CONTROL VALVE …………………………………………………… 229
04.2.3 BOOM AND BUCKET CYLINDERS ……………………………………………… 232
04.2.4 HYDRAULIC LINES ……………………………………………………………………. 234
04.2.5 BOOM AND BUCKET CYLINDER LINES ……………………………………… 235
04.2.6 ATTACHMENT LINES ………………………………………………………………… 236
04.3 TROUBLESHOOTING …………………………………………………………………………. 237
04.3.1 TEST EQUIPMENT. ……………………………………………………………………. 237
04.3.2 TROUBLESHOOTING GUIDE …………………………………………………….. 238
05 HYDROSTATIC SYSTEM …………………………………………………………………………………… 239
05.1 GENERAL ………………………………………………………………………………………….. 240
02.2.9 PARKING BRAKE SYSTEM REMOVAL- EARLIER MODELS ………… .. .. 207
02.2.10 PARKING BRAKE SYSTEM INSTALLATION AND
ADJUSTMENT – EARLIER MODELS ……….. ……………………………… …… 209
02.2.11 PARKING BRAKE SYSTEM REMOVAL – LATER MODELS ………………. 211
02.2.12 PARKING BRAKE SYSTEM INSTALLATION AND
ADJUSTMENT – LATER MODELS …………………………. …. .. … ……………. 212
02.2.13 PEDAL LOCK SYSTEM REMOVAL, INSTALLATION AND
ADJUSTMENT – LATER MODELS ……………………………………….. .. …. … 214
03 POWER TRAIN ………………………………………………………………………………………………… 217
03.1 GENERAL ………………………………………………………………………………………….. 218
03.2 POWER TRAIN DISASSEMBLY AND ASSEMBLY. ………………………………….. 219
03.2.1 POWER TRAIN DISASSEMBLY. ……………………………….. .. ……………….. 219
03.2.2 POWER TRAIN INSTALLATION …………………………………………………… 221
00 Engine, 4TN84E Table Of Contents
04 HYDRAULIC SYSTEM ………………………………………………………………………………………. 223 •
HYDRAULIC SCHEMATIC ……………………………………………………………………………. 224
04.1 GENERAL ………………………………………………………………………………………….. 227
04.1.1 HYDRAULIC SYSTEM …. …………………………. …………………………………. 227
04.1.2 HYDROSTATIC (HST) SYSTEM …………………………………………………… 227
04.2 REMOVAL AND INSTALLATION PROCEDURES ……………………………………. 228
04.2.1 HYDRAULIC CHARGE PUMP. ……………………………………………………… 228
04.2.2 HYDRAULIC CONTROL VALVE …………………………………………………… 229
04.2.3 BOOM AND BUCKET CYLINDERS ……………………………………………… 232
04.2.4 HYDRAULIC LINES ……………………………………………………………………. 234
04.2.5 BOOM AND BUCKET CYLINDER LINES ……………………………………… 235
04.2.6 ATTACHMENT LINES ………………………………………………………………… 236
04.3 TROUBLESHOOTING …………………………………………………………………………. 237
04.3.1 TEST EQUIPMENT. ……………………………………………………………………. 237
04.3.2 TROUBLESHOOTING GUIDE …………………………………………………….. 238
05 HYDROSTATIC SYSTEM …………………………………………………………………………………… 239
05.1 GENERAL ………………………………………………………………………………………….. 240
• 05.1.1 HYDROSTATIC (HST) SYSTEM COMPONENTS …………………………… 240
05.1 .2 OVERVIEW OF OPERATION ………………………………………………………. 240
05.1.3 HST PUMP. ……………………………………………………………………………….. 240
05.1.4 BASIC CLOSED CIRCUIT. …………………………………………………………… 240
05.1.5 CHECK/HIGH PRESSURE RELIEF VALVES ……………….. .. ……………… 240
05.1.6 PUMP CHARGE RELIEF VALVE ………………………………………………….. 240
05.1.7 BYPASS VALVE …………………………………………………………………………. 241
05.1 .8 REPAIRS …………………………………………………………………………………… 241
05.2 REMOVAL, INSTALLATION AND TEST PROCEDURES …………………………. 242
05.2.1 HYDROSTATIC (HST) PUMP ASSEMBLY. …………………………………….. 242
05.2.2 HST MOTOR …………………………………………………………………………….. 244
05.2.3 HYDRAULIC FILTER MOUNTING ………………………………………………… 245
05.2.4 DRAIN RELIEF VALVE ………………………………………………………. ……….. 246
05.2.5 HYDROSTATIC {HST) LINES ………………………………………………………. 247
05.3 TROUBLESHOOTING …………………………………………………………………………. 248
05.3.1 TEST EQUIPMENT ……………………………………………………………………. 248
05.3.2 TROUBLESHOOTING GUIDE. …………………………………………………….. 249
00 Engine, 4TN84E Table Of Contents
• 06 ELECTRICAL SYSTEM ……………………………………………………………………………………… 253
ELECTRICAL WIRING DIAGRAM …………………………………………………………………. 254
06.1 GENERAL ………………………………………………………………………………………….. 257
06.2 COMPONENTS, SYSTEMS AND OPERATION ………………………………………. 258
06.2.1 COMPONENT LOCATIONS ……….. .. …………………………………………….. 258
06.2.2 STARTING SYSTEM ………. ………………………………. …………………………. 260
06.2.3 CHARGING SYSTEM …………………………………………………………………. 261
06.2.4 LIGHTING AND AUXILIARY SYSTEM …………….. ……………………………. 262
06.2.5 INSTRUMENT PANEL. ……………………………………….. ……………………… 263
06.3 TROUBLESHOOTING …………………………………………………………………………. 269
06.3.1 TEST EQUIPMENT. ……………………………………………………………………. 269
06.3.2 TROUBLESHOOTING GUIDE ……………………………………………………… 270
07 FRAME, BOOM, AND BUCKET ………………………………………………………………………….. 273
07 .1 GENERAL ………………………………………………………………………………………….. 275
07.2 ,REMOVAL, INSTALLATION AND ADJUSTMENT PROCEDURES …………….. 276
07.2.1 BUCKET ……………………. …………………………………………………… ………… 276
07.2.2 QUICK-TACH ……………………………………………………………………………… 277
07.2.3 BUCKET CYLINDERS, BOOM CYLINDERS, BOOM LOCK,
AND BOOM ………………………………………………………………………………. 280
07.2.4 SEAT BAR AND SEAT …………………………… .. ………………………………….. 282
07.2.5 CANOPY. ….. … ………………………………………….. .. ……………………………… 283
07.2.6 REAR DOOR AND ENGINE HOOD ………………………………………………. 285
07.2.7 UPPER PLATE AND FLOOR PLATE …………………………….. ………………. 287
07.2.8 BOTTOM PLATE AND ENGINE OIL PAN COVER. …………………………. 288
07.2.9 TANKS ……………………………………………………………………………………… 289
10 GENERAL INFORMATION/MISCELLANEOUS …………………………………………………….. 291
10.1 PERIODIC MAINTENANCE …………………………………………………………………. 293
10.1.1 SAFETY WARNINGS ………………………………………………………………….. 293
10.1.2 ACCESS TO ITEMS REQUIRING SERVICE ………………………………….. 294
10.1.3 BOOM LOCK OPERATION ……. … ……………………………………. …………… 296
10.1.4 DAILY PRE/POST START CHECKS …. ………………………………………….. 297
10.1.5 SERVICE SCHEDULE ………………………………………………………………… 298
00 Engine, 4TN84E Table Of Contents
10.1 .6 LUBRICATION POINTS …………. …………………………………………………… 300
10.1.7 OPERATOR RESTRAINT LUBRICATION AND
05.1 .2 OVERVIEW OF OPERATION ………………………………………………………. 240
05.1.3 HST PUMP. ……………………………………………………………………………….. 240
05.1.4 BASIC CLOSED CIRCUIT. …………………………………………………………… 240
05.1.5 CHECK/HIGH PRESSURE RELIEF VALVES ……………….. .. ……………… 240
05.1.6 PUMP CHARGE RELIEF VALVE ………………………………………………….. 240
05.1.7 BYPASS VALVE …………………………………………………………………………. 241
05.1 .8 REPAIRS …………………………………………………………………………………… 241
05.2 REMOVAL, INSTALLATION AND TEST PROCEDURES …………………………. 242
05.2.1 HYDROSTATIC (HST) PUMP ASSEMBLY. …………………………………….. 242
05.2.2 HST MOTOR …………………………………………………………………………….. 244
05.2.3 HYDRAULIC FILTER MOUNTING ………………………………………………… 245
05.2.4 DRAIN RELIEF VALVE ………………………………………………………. ……….. 246
05.2.5 HYDROSTATIC {HST) LINES ………………………………………………………. 247
05.3 TROUBLESHOOTING …………………………………………………………………………. 248
05.3.1 TEST EQUIPMENT ……………………………………………………………………. 248
05.3.2 TROUBLESHOOTING GUIDE. …………………………………………………….. 249
00 Engine, 4TN84E Table Of Contents
• 06 ELECTRICAL SYSTEM ……………………………………………………………………………………… 253
ELECTRICAL WIRING DIAGRAM …………………………………………………………………. 254
06.1 GENERAL ………………………………………………………………………………………….. 257
06.2 COMPONENTS, SYSTEMS AND OPERATION ………………………………………. 258
06.2.1 COMPONENT LOCATIONS ……….. .. …………………………………………….. 258
06.2.2 STARTING SYSTEM ………. ………………………………. …………………………. 260
06.2.3 CHARGING SYSTEM …………………………………………………………………. 261
06.2.4 LIGHTING AND AUXILIARY SYSTEM …………….. ……………………………. 262
06.2.5 INSTRUMENT PANEL. ……………………………………….. ……………………… 263
06.3 TROUBLESHOOTING …………………………………………………………………………. 269
06.3.1 TEST EQUIPMENT. ……………………………………………………………………. 269
06.3.2 TROUBLESHOOTING GUIDE ……………………………………………………… 270
07 FRAME, BOOM, AND BUCKET ………………………………………………………………………….. 273
07 .1 GENERAL ………………………………………………………………………………………….. 275
07.2 ,REMOVAL, INSTALLATION AND ADJUSTMENT PROCEDURES …………….. 276
07.2.1 BUCKET ……………………. …………………………………………………… ………… 276
07.2.2 QUICK-TACH ……………………………………………………………………………… 277
07.2.3 BUCKET CYLINDERS, BOOM CYLINDERS, BOOM LOCK,
AND BOOM ………………………………………………………………………………. 280
07.2.4 SEAT BAR AND SEAT …………………………… .. ………………………………….. 282
07.2.5 CANOPY. ….. … ………………………………………….. .. ……………………………… 283
07.2.6 REAR DOOR AND ENGINE HOOD ………………………………………………. 285
07.2.7 UPPER PLATE AND FLOOR PLATE …………………………….. ………………. 287
07.2.8 BOTTOM PLATE AND ENGINE OIL PAN COVER. …………………………. 288
07.2.9 TANKS ……………………………………………………………………………………… 289
10 GENERAL INFORMATION/MISCELLANEOUS …………………………………………………….. 291
10.1 PERIODIC MAINTENANCE …………………………………………………………………. 293
10.1.1 SAFETY WARNINGS ………………………………………………………………….. 293
10.1.2 ACCESS TO ITEMS REQUIRING SERVICE ………………………………….. 294
10.1.3 BOOM LOCK OPERATION ……. … ……………………………………. …………… 296
10.1.4 DAILY PRE/POST START CHECKS …. ………………………………………….. 297
10.1.5 SERVICE SCHEDULE ………………………………………………………………… 298
00 Engine, 4TN84E Table Of Contents
10.1 .6 LUBRICATION POINTS …………. …………………………………………………… 300
10.1.7 OPERATOR RESTRAINT LUBRICATION AND
• MAINTENANCE ………… ….. … ……………………………………. … ………………. 302
10.1.8 ENGINE LUBRICATION …………………………………… ………… ………………. 303
10.1.9 ENGINE COOLING SYSTEM …………. .. .. ………………………………………… 304
10.1.10 FAN BELT. …………………………………………………………… ………………… .. .. 305
10.1.11 TWO STAGE AIR FILTER ……………. ………. …………………………………. …. 306
10.1 .12 SPARK ARRESTOR ……………………………………………………………………. 307
10.1 .13 BATTERY. …………………………….. ………………………………………… … .. ……. 308
10.1.14 FUEL SYSTEM/FILTERS ……… …………………… …… ………………. …. ………. 308
10.1.15 INJECTION PUMP PRIMING ……………. .. ….. …………. …………………… ….. 309
10.1.16 HYDRAULIC SYSTEM MAINTENANCE …. .. ………….. ………………………. 309
10.1 .17 CHAIN CASE DRAIN AND REFILL ……… ….. ………………….. ………………. 310
10.1 .18 PARKING BRAKE ADJUSTMENT – EARLIER MODELS …………………… 311
10.1.19 PARKING BRAKE ADJUSTMENT – LATER MODELS ….. …. .. .. .. ………… 312
10.1 .20 PEDAL LOCK ADJUSTMENT – LATER MODELS ……. …………………….. 313
10.1.21 TIRE MAINTENANCE ……………… … ……. .. ………….. ………………………. …. 315
10.2 TOWING PROCEDURES …………………………………………………………………….. 316
10.3 DIMENSIONS …………………………………………………………………………………….. 317
10.4 OPERATIONAL SPECIFICATIONS ……………………………………………………….. 320
10.4.1 PERFORMANCE ……………………………………………………………………….. 321
10.4.2 POWER UNIT. ……………………………………. …………………………………….. 321
10.4.3 FINAL DRIVE COMPONENTS ……………………………………………………… 322
10.1.8 ENGINE LUBRICATION …………………………………… ………… ………………. 303
10.1.9 ENGINE COOLING SYSTEM …………. .. .. ………………………………………… 304
10.1.10 FAN BELT. …………………………………………………………… ………………… .. .. 305
10.1.11 TWO STAGE AIR FILTER ……………. ………. …………………………………. …. 306
10.1 .12 SPARK ARRESTOR ……………………………………………………………………. 307
10.1 .13 BATTERY. …………………………….. ………………………………………… … .. ……. 308
10.1.14 FUEL SYSTEM/FILTERS ……… …………………… …… ………………. …. ………. 308
10.1.15 INJECTION PUMP PRIMING ……………. .. ….. …………. …………………… ….. 309
10.1.16 HYDRAULIC SYSTEM MAINTENANCE …. .. ………….. ………………………. 309
10.1 .17 CHAIN CASE DRAIN AND REFILL ……… ….. ………………….. ………………. 310
10.1 .18 PARKING BRAKE ADJUSTMENT – EARLIER MODELS …………………… 311
10.1.19 PARKING BRAKE ADJUSTMENT – LATER MODELS ….. …. .. .. .. ………… 312
10.1 .20 PEDAL LOCK ADJUSTMENT – LATER MODELS ……. …………………….. 313
10.1.21 TIRE MAINTENANCE ……………… … ……. .. ………….. ………………………. …. 315
10.2 TOWING PROCEDURES …………………………………………………………………….. 316
10.3 DIMENSIONS …………………………………………………………………………………….. 317
10.4 OPERATIONAL SPECIFICATIONS ……………………………………………………….. 320
10.4.1 PERFORMANCE ……………………………………………………………………….. 321
10.4.2 POWER UNIT. ……………………………………. …………………………………….. 321
10.4.3 FINAL DRIVE COMPONENTS ……………………………………………………… 322
• 10.4.4 HYDROSTATIC TRANSMISSION PUMP ………………………………………. 323
10.4.5 HYDRAULIC SYSTEM ……………….. ……………… ……. …. ……. ……….. .. …… 324
10.4.6 ELECTRICAL COMPONENTS ………………….. ………………………………… 328
10.4. 7 INSTRUMENTS …………………………………………. ……………………………… 329
10.4.8 SEAT. …………. ……………………………………….. …. ………………………………. 330
10.5 FLUID SPECIFICATION AND REFILL CAPACITIES ……………………………….. 331
10.6 TIGHTENING SPECIFICATIONS AND PROCEDURES ……………………………. 332
10.6.1 TORQUES FOR MAJOR COMPONENTS ……………………………………… 332
10.6.2 STANDARD TORQUES FOR METRIC FASTENERS .. ……………. ……….. 333
10.6.3 LINES, HOSES, FITTINGS, AND SEALS ……………………………………….. 334
10.4.5 HYDRAULIC SYSTEM ……………….. ……………… ……. …. ……. ……….. .. …… 324
10.4.6 ELECTRICAL COMPONENTS ………………….. ………………………………… 328
10.4. 7 INSTRUMENTS …………………………………………. ……………………………… 329
10.4.8 SEAT. …………. ……………………………………….. …. ………………………………. 330
10.5 FLUID SPECIFICATION AND REFILL CAPACITIES ……………………………….. 331
10.6 TIGHTENING SPECIFICATIONS AND PROCEDURES ……………………………. 332
10.6.1 TORQUES FOR MAJOR COMPONENTS ……………………………………… 332
10.6.2 STANDARD TORQUES FOR METRIC FASTENERS .. ……………. ……….. 333
10.6.3 LINES, HOSES, FITTINGS, AND SEALS ……………………………………….. 334
DAEWOO DOOSAN SKID STEER LOADER SHOP MANUAL SSL601 – PDF DOWNLOAD:
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R.D
