Description
Doosan 1340XL (DSL602) Skid Steer Loader Shop Manual
Doosan 1340XL (DSL602) Skid Steer Loader Index:
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, 4TNE84 ………………………………………………………………………………………………….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
04 HYDRAULIC SYSTEM………………………………………………………………………………………..217
HYDRAULIC SCHEMATIC ……………………………………………………………………………..218
04.1 GENERAL……………………………………………………………………………………………219
04.1.1 HYDRAULIC SYSTEM ……………………………………………………………..219
04.1.2 HYDROSTATIC (HST) SYSTEM ………………………………………………..219
04.2 REMOVAL AND INSTALLATION PROCEDURES…………………………………….220
04.2.1 HYDRAULIC CHARGE PUMP …………………………………………………..220
04.2.2 HYDRAULIC CONTROL VALVE…………………………………………………221
04.2.3 BOOM AND BUCKET CYLINDERS ……………………………………………224
04.2.4 HYDRAULIC LINES………………………………………………………………….226
04.2.5 BOOM AND BUCKET CYLINDER LINES ……………………………………227
04.2.6 ATTACHMENT LINES……………………………………………………………….228
04.3 TROUBLESHOOTING…………………………………………………………………………..229
04.3.1 TEST EQUIPMENT…………………………………………………………………..229
04.3.2 TROUBLESHOOTING GUIDE …………………………………………………..230
05 HYDROSTATIC SYSTEM…………………………………………………………………………………….231
05.1 GENERAL……………………………………………………………………………………………232
05.1.1 HYDROSTATIC (HST) SYSTEM COMPONENTS ………………………..232
05.1.2 OVERVIEW OF OPERATION…………………………………………………….232
05.1.3 HST PUMP ……………………………………………………………………………..232
05.1.4 BASIC CLOSED CIRCUIT…………………………………………………………232
05.1.5 CHECK/HIGH PRESSURE RELIEF VALVES ………………………………232
05.1.6 PUMP CHARGE RELIEF VALVE ……………………………………………….232
05.1.7 BYPASS VALVE……………………………………………………………………….233
05.1.8 REPAIRS…………………………………………………………………………………233
05.2 REMOVAL, INSTALLATION AND TEST PROCEDURES………………………….234
05.2.1 HYDROSTATIC (HST) PUMP ASSEMBLY…………………………………..234
05.2.2 HST MOTOR……………………………………………………………………………236
05.2.3 HYDRAULIC FILTER MOUNTING………………………………………………237
05.2.4 DRAIN RELIEF VALVE……………………………………………………………..238
05.2.5 HYDROSTATIC (HST) LINES…………………………………………………….239
05.3 TROUBLESHOOTING…………………………………………………………………………..248
05.3.1 TEST EQUIPMENT………………………………………………………………….248
05.3.2 TROUBLESHOOTING GUIDE …………………………………………………..249
Table Of Contents
DSL 601
v
06 ELECTRICAL SYSTEM ………………………………………………………………………………………253
ELECTRICAL WIRING DIAGRAM…………………………………………………………………..254
06.1 GENERAL……………………………………………………………………………………………255
06.2 COMPONENTS, SYSTEMS AND OPERATION ……………………………………….256
06.2.1 COMPONENT LOCATIONS ………………………………………………………256
06.2.2 STARTING SYSTEM ………………………………………………………………..258
06.2.3 CHARGING SYSTEM……………………………………………………………….259
06.2.4 LIGHTING AND AUXILIARY SYSTEM ………………………………………..260
06.2.5 INSTRUMENT PANEL………………………………………………………………261
06.3 TROUBLESHOOTING…………………………………………………………………………..267
06.3.1 TEST EQUIPMENT …………………………………………………………………267
06.3.2 TROUBLESHOOTING GUIDE …………………………………………………..268
07 STRUCTURES AND CHASSIS…………………………………………………………………………….271
07.1 GENERAL……………………………………………………………………………………………273
07.2 REMOVAL, INSTALLATION AND ADJUSTMENT PROCEDURES…………….274
07.2.1 BUCKET………………………………………………………………………………….274
07.2.2 QUICK-TACH …………………………………………………………………………..275
07.2.3 BUCKET CYLINDERS, BOOM CYLINDERS, BOOM LOCK,
AND BOOM……………………………………………………………………………..278
07.2.4 SEAT BAR AND SEAT ………………………………………………………………281
07.2.5 CANOPY…………………………………………………………………………………282
07.2.6 REAR DOOR AND ENGINE HOOD ……………………………………………283
07.2.7 UPPER PLATE AND FLOOR PLATE…………………………………………..285
07.2.8 BOTTOM PLATE AND ENGINE OIL PAN COVER………………………..286
07.2.9 TANKS ……………………………………………………………………………………287
10 GENERAL INFORMATION/MISCELLANEOUS ……………………………………………………..289
10.1 PERIODIC MAINTENANCE …………………………………………………………………..291
10.1.1 SAFETY WARNINGS ……………………………………………………………….291
10.1.2 ACCESS TO ITEMS REQUIRING SERVICE ……………………………….292
10.1.3 BOOM LOCK OPERATION………………………………………………………..294
10.1.4 DAILY PRE/POST START CHECKS …………………………………………..295
10.1.5 SERVICE SCHEDULE………………………………………………………………296
10.1.6 LUBRICATION POINTS…………………………………………………………….298
10.1.7 OPERATOR RESTRAINT LUBRICATION AND
MAINTENANCE ……………………………………………………………………….300
10.1.8 ENGINE LUBRICATION…………………………………………………………….301
10.1.9 ENGINE COOLING SYSTEM …………………………………………………….302
10.1.10 FAN BELT ……………………………………………………………………………….303
10.1.11 TWO STAGE AIR FILTER………………………………………………………….304
10.1.12 SPARK ARRESTOR………………………………………………………………….305
10.1.13 BATTERY ………………………………………………………………………………..306
10.1.14 FUEL SYSTEM/FILTERS …………………………………………………………..306
10.1.15 INJECTION PUMP PRIMING …………………………………………………….307
10.1.16 HYDRAULIC SYSTEM MAINTENANCE ……………………………………..307
10.1.17 CHAIN CASE DRAIN AND REFILL …………………………………………….308
10.1.18 PARKING BRAKE ADJUSTMENT………………………………………………308
10.1.19 PEDAL LOCK ADJUSTMENT…………………………………………………….309
10.1.20 TIRE MAINTENANCE ……………………………………………………………….311
10.2 TOWING PROCEDURES………………………………………………………………………312
10.3 DIMENSIONS……………………………………………………………………………………….313
10.4 OPERATIONAL SPECIFICATIONS…………………………………………………………316
10.4.1 PERFORMANCE ……………………………………………………………………..316
10.4.2 POWER UNIT ………………………………………………………………………….317
10.4.3 FINAL DRIVE COMPONENTS…………………………………………………..318
10.4.4 HYDROSTATIC TRANSMISSION PUMP…………………………………….319
10.4.5 HYDRAULIC SYSTEM ……………………………………………………………..320
10.4.6 ELECTRICAL COMPONENTS …………………………………………………..324
10.4.7 INSTRUMENTS ……………………………………………………………………….325
10.4.8 SEAT………………………………………………………………………………………326
10.5 FLUID SPECIFICATION AND REFILL CAPACITIES ………………………………..327
10.6 TIGHTENING SPECIFICATIONS AND PROCEDURES…………………………….328
10.6.1 TORQUES FOR MAJOR COMPONENTS …………………………………..328
10.6.2 STANDARD TORQUES FOR METRIC FASTENERS……………………329
10.6.3 LINES, HOSES, FITTINGS, AND SEALS ……………………………………330
