DSL602

Shop Manual
SKIDSTEER LOADER
DSL 602
Table Of Contents
Table Of Contents
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
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DSL 601
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 COOLING 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 ................................................................123
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
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DSL 601
Table Of Contents
01 FUEL SYSTEM .................................................................................................................189
01.1 GENERAL.........................................................................................................190
01.2 FUEL LINES .....................................................................................................191
02 CONTROL SYSTEM........................................................................................................1 9 3
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 . ..........................................205
02.2.10 PARKING BRAKE SYSTEM INSTALLATION AND
ADJUSTMENT ...................................................................................206
02.2.11 PEDAL LOCK SYSTEM REMOVAL, INSTALLATION AND
ADJUSTMENT ...................................................................................208
03 POWER TRAIN.................................................................................................................211
03.1 GENERAL.........................................................................................................212
03.2 POWER TRAIN DISASSEMBLY AND ASSEMBLY ........................................213
03.2.1 POWER TRAIN DISASSEMBLY ........................................................213
03.2.2 POWER TRAIN INSTALLATION ........................................................215
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DSL 601
Table Of Contents
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
05.3.1 TEST EQUIPMENT............................................................................248
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DSL 601
Table Of Contents
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
06.3.1 TEST EQUIPMENT ...........................................................................267
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
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DSL 601
Table Of Contents
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
10.4.6 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
vi
DSL 601
Forward How To Use This Manual
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 gen-
erally 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 presenta-

tion and their leading numbering system - match that of the
1340XL/DSL602 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
10 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.
vii
DSL 601
Forward Safety
Safety
All persons repairing or maintaining DAEWOO Skid Steer
Loaders should read and understand all Safety Information
contained in Operation and Maintenance Manual.
It is a requirement that only trained and knowledgeable

mechanics perform required maintenance and repairs on
DAEWOO Skid Steer Loaders. Always refer to the Vehicle
Service Manual and subsequent Technical Bulletins. If a
serviceman or mechanic is unfamiliar with a system on this
machine he must proceed with caution when performing
service work. A knowledge of the system and/or compo-
nents is important before the removal or disassembly of any
component.
All Maintenance and Repairs must be performed to factory

specifications. Should any procedure be in question or not
understood, contact your DAEWOO dealer or DAEWOO
factory rep.
SAFETY INFORMATION
This is the safety-alert symbol.

When you see this symbol on your machine
or in this manual, be alert to the
potential for personal injury.
Follow recommended precautions and
safe operating practices.
SIGNAL WORDS
A signal word - DANGER, WARNING, OR CAUTION - is
used with the safety-alert symbol.
DANGER: Indicates an imminently hazardous situation

which, if not avoided, will result in DEATH or SERIOUS
INJURY. DANGER
WARNING: Indicates a potentially hazardous situation
which, if not avoided, COULD result in DEATH or SERI-
OUS INJURY. WARNING
CAUTION: Indicates a potentially hazardous situation
which, if not avoided, MAY result in INJURY.
CAUTION
ATTENTION: Indicates potential machine damage if a
certain procedure is not followed.
IMPORTANT: Indicates information an operator should

know to prevent minor machine damage if a certain pro-
cedure is not followed.
viii
DSL 601
Forward Safety
WARNING SAFETY INSTRUCTIONS
Carefully read all safety messages in this manual and all safety labels
on your machine. Keep safety labels in good condition. Replace missing or
damaged safety labels. Be sure new equipment components and
repair parts include the current safety labels. Learn how to operate the
machine and how to use controls properly. Do not let anyone operate
the machine without instruction. Keep your machine in proper working
condition. Unauthorized modifications to the machine may impair operator
safety and well being and/or machine life and function.
DANGER SAFETY RULES
• ONLY trained and authorized personnel should operate and maintain the machine.
• Use common sense and follow all safety rules, precautions and instructions when operating or performing
maintenance on the machine.
• When working with another person, be sure all hand signals to be used are understood.
• Certain operating conditions may require reference to applicable ANSI, ISO, EEC or other local and national
regulations. Consult your supervisor or safety coordinator to be sure all applicable standards are being fol-
lowed, and for special operating conditions.
• Never operate equipment under the influence of drugs or alcohol. Certain prescription and over-the-counter
medications can affect alertness and coordination. Follow instructions on labels and/or consult your physi-
cian. Notify your supervisor or consult your physician for clarification.
jacks or hoist. Always use jack stands to support the

WARNING machine before performing any disassembly. Never
The proper maintenance procedures for this machine, use concrete blocks.
recommended by DAEWOO, are outlined in the OPERA-
TION & MAINTENANCE MANUAL for this machine. 4. Lower the bucket or other implements to the ground
before performing any work on the machine. If this can-
Improper performance of service, lubrication or mainte- not be done, make sure the bucket or other implements
nance procedures is dangerous and could result in are blocked correctly to prevent them from dropping
injury or death. Read and understand the OPERATION & unexpectedly.
MAINTENANCE MANUAL before performing any ser-
vice, lubrication or maintenance.
Because of the size of some of the machine components,

the serviceman or mechanic should check the weights
WARNING
noted in this Manual. Use proper lifting procedures when Do not operate this machine unless you have read and
removing any components. understand the instructions in the OPERATION & MAIN-
TENANCE MANUAL. Improper machine operation is
Following is a list of basic precautions that should always be dangerous and could result in injury or death.
observed.
5. Use steps and grab handles (if applicable) when
1. Read and understand all Warning plates and decals mounting or dismounting a machine. Clean any mud or
on the machine before operating, lubricating or repair- debris from steps before using. Always face machine
ing it. when using steps.
2. Always wear protective glasses and protective shoes 6. To avoid back injury, use a hoist when lifting com-
when working around machines. Do not wear loose-fit- ponents which weigh 23 kg (50 lb.) or more. Make sure
ting or torn clothing. Remove all jewelry when working all chains, hooks, slings, etc., are in good condition and
on machinery. are of the correct capacity before a lifting operation.
3. Do not work on any machine that is supported only by
ix
DSL 601
Forward Safety
WARNING
7. To avoid burns, be alert for hot parts on machines 17. Tighten connections to the correct torque. Make
that have just been stopped and for hot fluids in lines, sure that all heat shields, clamps and guards are
tubes and compartments. installed correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
8. Be careful when removing cover plates. Gradually Shields that protect against oil spray coming into
back off the last two bolts or nuts located at opposite contact with hot exhaust components in event of a
ends of the cover or device and pry cover loose to line, tube or seal failure must be installed correctly.
relieve any spring or other pressure, before removing
the last two bolts or nuts completely. 18. Relieve all pressure in air, oil or water systems
before any lines, fittings or related items are discon-
9. Be careful when removing filler caps, breathers and nected or removed. Always make sure all raised
plugs on the machine. Hold a rag over the cap or plug components are blocked correctly and be alert for
to prevent being sprayed or splashed by liquids under possible pressure when disconnecting any device
pressure. The danger is even greater if the machine from a system that utilizes pressure.
has just been stopped because fluids can be hot.
19. Do not operate a machine if any rotating part is
10. Always use tools that are in good condition and be
damaged or contacts any other part during opera-
sure you understand how to use them before perform-
tion. Any high speed rotating component that has
ing any service work.
been damaged or altered should be checked for bal-
11. Reinstall all fasteners with same part number. Do not ance before reusing.
use a lesser quality fastener if replacements are nec-
essary. Do not mix metric fasteners with standard nuts 20. Disconnect the battery when making repairs to
and bolts. prevent unintentional contact with an active
electrical circuit.
12. If possible, make all repairs with the machine parked
on a level, hard surface. Block machine so it does not
roll while working on or under machine.
13. Repairs which require welding should be performed

only with the benefit of the appropriate reference infor-
mation and by personnel certified in welding proce-
dures. Use welder’s gloves, hood/goggles, apron and
other protective clothing appropriate to the welding job
being performed. Determine type of metal being weld-
ed and select correct welding procedure and elec-
trodes, rods or wire to provide a weld metal strength
equivalent at least to that of parent metal.
14. Do not damage wiring during removal operations. Rei-

stall the wiring so it is not damaged nor will be dam-
aged in operation by contacting sharp corners or by
rubbing against some object or hot surface. Do not con-
nect wiring to a line containing fluid. Apply dielectric
grease to contacts.
15. Be sure all protective devices, including guards and

shields, are properly installed and functioning correctly
before starting a repair. If a guard or shield must be
removed to perform the repair work, use extra caution.
16. Loose or damaged fuel, lubricant and hydraulic lines,

tubes and hoses can cause fires. Do not bend or strike
high pressure lines or install ones which have been
bent or damaged. Inspect lines, tubes and hoses care-
fully. Do not check for leaks with your hands.
x
DSL 601
Forward General Precautions For Disassembly
General Precautions For Disassembly Precautions For Disassembly
Preparations before disassembly 1) Removal of parts
1) Wash the machine before moving it to into the repair • Proceed with the disassembly by confirming the
shop. fitting conditions of the relative parts, their posi-
tions fore-and-aft, left-and-right, upper-and-lower,
Prior to moving the machine into the repair shop remove and the sequence of their removal.
dust and dirt thoroughly by washing the machine. Dirt • Confirm match marks for mating joints before
brought into the shop will degrade the cleanliness of the separating parts and where necessary, punch
parts handled in the shop, will produce scratches, and match marks to clearly identify their relative position
can contaminate the inside of reassembled units. to prevent confusion during reassembly.
• For disassembly of certain designated parts, use
2) Checking and inspection before disassembly. specified special tools.
• When a part, after removal of fastening nuts and
Before attempting to disassemble, check thoroughly to bolts, is still found to be unremovable, never
determine the cause of the problem, and record it. This force the part. Carefully check for the cause of the
will not only prevent needless disasssembly and losses tightness and remove the cause.
from neeedless replacement parts and manhour costs, • Keep the disassembled parts in an orderly condi-
but will also prevent repetition of the same problem. tion. Take special care to identify similar parts by
attaching tags or markings.
It is important to keep records of problems and replace- • See that standard parts such as bolts and nuts
ments in order to advise serviceman how to prevent trou- are stored in good order with reference to quantity
ble. Items to be checked and recorded are as follows: and where they are to be used.
• Model, machine serial number and service meter 2) Checking and inspecting during disassembly.
readings.
• Reason for disassembly. • The cause of the actual trouble is often discovered
• Components replaced. in the course of disassembly. Thus careful check-
ing of sliding surfaces for any signs of seizing or
Check for symptom, location and cause of problem. If neces- interference, and their mating conditions, is
sary, try repeating the same problem. important.
• Measure and record during disassembly the var-
• Amount of dirt in air cleaner elements and air ious end clearances, backlashes and protrusions
leakage. that are necessary to determine the trouble.
• Oil levels in the engine oil pan and status of oil (vis-
cosity, color and mixed impurities). 3) Maintaining clearance adjustmnets
• Water mixed in the oil and oil leakage.
• Clogging of the oil filter element. Keep each set of shims or washers stored in an orderly
• Deviations from designated adjusting points. manner so that its original arrangement with the same
• Damaged parts and loosening of tightening fit- clearances can be obtained at reassembly.
tings.
• Maintenance conditions of the machine in service, 4) Maintaining linkage adjustments
if possible.
Be careful to maintain the original adjustment of the rods
3) Preparation for disassembly unless some readjustment is necessary. When it is nec-
essary to remove the rod end for disassembly, measure
To save unnecessary work, reserve the necessary facili- and record the length of the rod before disassembly.
ties, tools, and parts racks as well as adequate floor
space considering the extent of disassembly. Keep the 5) Disassembly of taper-fitted or force-fitted parts
area and facilities clean.
• Remove any scars or dents, clean well and
reassemble.
• When looseness of fit exists in taper-fitted or force-
fitted parts, carefully check for the cause of the
faulty fit, remove the cause and reassemble.
xi
DSL 601
Forward General Precautions For Disassembly
6) Disassemby of bearings up to 10 minutes. Then, rinse it thoroughly with

water.
• Do not attempt to remove a bearing by force, but • If harmful chemical agents are used as the
remove it with a suitable puller such as shown detergent, take care to protect the skin and
in the figure below. eyes. Do not attempt to drain waste fluid into
the sewage system.
2) Dust-proofing
• Cover washed parts in storage to keep them

free from dust and dirt. Cap all pipes.
• Apply suitable rust-preventive treatment to
the parts if they are to be kept an extended period
of time in storage before reassembly.
F-1
7) Safety
• Keep the area where the machine is to be dis-

assembled clean and orderly.
• When loosening a bolt or nut, use a correct
size wrench and always pull the wrench
toward you. Use of a mis-matched wrench
because of confusion between the inch and
metric system, or pushing the wrench away
from your body may cause accidents through
slipping of the wrench or the hand.
• For jobs involving two or more persons, keep
close contact by mutual checking and exch-
ange of necessary signals.
Procesures after disassembly
1) Cleaning
• Wash disassembled parts clean, neatly arrange

the parts according to each assembly, and keep in
storage, free from dust and dirt.
Special care should be taken to remove sludge
and dust thorougly from oil holes in the parts and
from the interior of the tubes.
• More effective cleaning can be achieved by use of
two vessels filled with detergent, one for washing
dirty parts and the other for rinsing.
When washing special parts, increase the number
of vessels and keep the dirty detergent away from
these parts.
• Kerosene or neutral-anhydride light oil is a suit-
able detergent for cleaning viscous bearing oils.
• When washing a large casting, immerse it in a
vessel filled with detergent (alkalinity pH10 to
12, temperature 50 to 70 oC) (122 o to 158 oF) for
xii
DSL 601
Forward General Precautions For Assembly
General Precautions for Assembly from the outside or are used for important parts
that require locking.
• Remove remnants of loctite or any thread bonding
Precautions before assembly
agent from the removed bolts with appropriate solvent.
Apply 2 or 3 drops of fresh loctite before retighten-
(1) Installation of parts
ing bolts.
• Thoroughly clean all parts before assembly. Check (3) Check in the course of assembly
for scratches and nicks on the surfaces of the
parts, and repair if necessary. During assembly, check and record end clearances,
Special care should be paid to the sliding surfaces end plays, protrusions, steps and backlashes at each
of parts which, if left soiled, will cause reduced stage of assembly.
machine life.
• Use detergent to remove any rust preventive (4) Reinsertion of shims
before assembly. • Insert stored sets of shims or washers in their posi-
• Make sure to align match marks of those parts that tions in the same order as disassembly.
are marked before attempting to assemble. • After inserting, check for correct values of clear-
• Use the correct or a press-fitting tool or driver ances.
when assembling bearings, bushings and oil seals.
Also, use the prescribed “special tool” for assem- (5) Assembly of control linkage
bly of certain designated parts.
• Coat the surface parts to be press-fitted with Assemble each control link to the same length as dis-
molybdenum disulfide grease. assembly, unless adjustments are necessary.
Reassemble and properly adjust.
(2) Tightening bolts and nuts
(6) Assembly of taper-fitted or force-fitted parts
• Tighten the bolts and nuts fastening parts together • Repair scratches and nicks, and thoroughly clean
by alternately (left-and-right and upper-and-lower) the parts before fitting.
turning symmetrically opposite nuts and bolts, to • If proper fit cannot be obtained between the taper-
apply even tightening force. fitted parts, carefully check for the cause.
• Check and see that there is no dust, rust or
scratches found on the surface of the shaft on
which an oil seal is to be fitted and coat the shaft
with grease or lubricating oil so that the oil seal can
be installed smoothly.
• When installing an oil seal, use a suitable guide
and jig as shown in the figure below to prevent oil
seal damages.
F-2
• When tightening bolts on certain designated

parts, tighten them in the prescribed sequence as
shown in the figure, in order to exert even torque
on every bolt. In this method called the “template
methods”, the bolts are tightened stepwise and
sometimes loosened, so that the bolts and nuts are
well seated or the bearing comes into close and
even contact.
F-3
• Apply engine oil to the screw threads of certain
designated bolts so that smooth and even tighten-
ing of the bolts may be obtained.
• With wires, cotter pins or lock washers, securely
lock those bolts and nuts which cannot be checked
xiii
DSL 601
• After press-fitting an oil seal, check for alignment. c. When installing a non-split type bear-
Allowable limit of misalignment: ing with necesary interferences of the inner
0.2 mm per 100 mm dia. (1/64” per 3 15/16” dia.). and outer races, use a suitable jig as shown
• When applying bonding agent on the circumference in the figure below to apply the necessary
of an oil seal, avoid contact of the lip surface with pressure to both the inner and outer races.
the bonding agent.
Remove excess bonding agent on the guide and jig
before using them to install another oil seal.
(7) Handling of bearings
Pay special attention to the following instructions

so as not to damage bearing assemblies:
a. Leave the bearings in their original package
until just before installation.
Keep bearings free from dust and dirt. Dust
affects bearing life significantly.
b. Avoid impact loads and do not apply shocks to
the bearings. Absolutely avoid such unreason- F-5
able handling like rotating a bearing excessive-
ly by blowing compressed air to remove deter-
gent from the bearing. (8) Handling of snap rings
Observe the following precautions when installing • When removing or installing snap rings, use a
the bearings: suitable ring plier, taking care not to over
a. Do not attempt to hammer the bearing assem- expand the snap ring.
bly or damage may occur. • Make sure the snap ring is properly seated in
b. When installing a bearing assembly, use a its groove.
suitable jig as shown in the figure below to
apply pressure to the inner race. (9) Assembly of keys and keyways
Apply the shrink fit method to the bearings
requiring large interference. Do not heat any Check for looseness of the key in its keyway and for
bearings requiring large interference. Do not the contact of the keyhead.
heat any bearing assemblies to over 120oC If the keyhead contacts with keyway, remove the
(248oF). excess keyhead.
Excessively high temperature will deteorate the
hardness of the heat treated bearing surface. (10) Safety
• Keep the working area, tools, worker’s hands,

etc. clean and orderly during assembly work.
• Use the correct size wrench when tightening a
bolt or nut to reduce the risk of injury and equip-
ment damage.
• For jobs involving two or more persons, keep
close contact by mutual checking and the
exchange of necessary signs.
Handling of Common Parts
(1) Handling of packings and O-rings

F-4
• Replace all packings, gaskets, O-rings, and copper
packings.
• Coat certain gaskets designated in this
manual with recommended sealant.
xiv
DSL 601
(2) Handling of O-rings
• Use only the O-rings prescribed in the Service Parts

Manual. Special care should be paid to the O-rings
subjected to engine lubricating oil, since they are
made of thermal resistant, aging-free special
materials such as silicon rubber and cannot be
replaced by any other ordinary O-rings.
• Coat the O-rings with oil to protect them from
scratching during installation. Be careful not to
expand the silicon rubber O-rings excessively, or
they will be easily cracked.
(3) Handling of oil seals
• Be careful to see that the oil seal lips face the

proper directions.
F-6
• Keep the oil seals free from dust, and see that
there is no rust or scratches on their surfaces
(especially on the lips).
• Before installation, coat the oil seal with grease
as outlined below, to prevent dry friction which may
occur during the break-in operation of the
machine.
a. In case of a single-lip type oil seal :
Uniformly and lightly coat grease around the lip
on the opposite side of the sealing surface of
the lip.
b. In case of a double-lip type oil seal :
Uniformly coat grease over the surface
between the two lips so that about half of the
space of the hollow found between the lips is
filled with grease.
xv
DSL 601
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xvi
DSL 601
00 Engine, 4TNE84 Contents
00 Engine, 4TNE84
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

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
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
1
DSL 601
00 Engine, 4TNE84 Contents
00.4.3 LUBE OIL FILTER & OIL PRESSURE CONTROL VALVE.................103

00.4.4 SERVICE DATA ..................................................................................105
00.5 COOLING 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

00.8.2 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
2
DSL 601
00 Engine, 4TNE84 00.1 General
00.1 GENERAL
00.1.1 SPECIFICATIONS ...........................................................................5
00.1.2 PERFORMANCE CURVES .............................................................6
00.1.3 MAINTENANCE ...........................................................................7
00.1.4 SERIAL NUMBER LOCATION .........................................................8
3
DSL 601
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
4
DSL 601
00.1.1 Specifications
Model 4TNE84
Application 1340XL/DSL602 SKID STEER LOADER
Type 4 stroke cycle water-cooled diesel engine
Combustion system Direct injection
Aspiration Natural aspiration
No. of cylinders 4
mm 84x86
Bore x Stroke (in) (3.31 x 3.39)
liter
Displacement (cu. in)
1,995 (121.74)
Continu-
Output
HP/rpm -
ous rating
JIS B8002
BS 5514 1 hr-
rating
HP/rpm 41.1/2800
Compression ratio 18.5

Firing order 1-3-4-2
Fuel injection degree
(b TDC)
16°+1°
timing (FID)
Fuel injection kg/cm2

200 (2844)
pressure (PSI)
Direction of rotation Counterclockwise (viewed from flywheel)

Power take off Flywheel
Cooling system Liquid cooling/Radiator
liter
Cooling Engine 2.7 (2.853)
(US qt)
water
liter
capacity Radiator 3.5 (3.7)
(US qt)
No. of
Cooling
Pusher blade- 6-370
fan mm dia
Lubricating system Forced lubrication with trochoid pump
Lubri- liter
Effect (US qt)
2.3 (2.43)
cating
oil cap- liter
acity Max (US qt)
5.8 (6.13)
Recommended oil API CC or CD SAE 10W 30, 30 or 40

Recommended fuel Diesel fuel BS2869 A1, ASTM D975 No.2-D (Cetane No. >45)
Air cleaner Dry paper element
Governor Mechanical centrifugal governor
Starter motor KW/V 2.5/12
Alternator A/V 35/12
kg 194
Weight (dry) (lbs) (428)
mm 649
L (in) (25.6)
*
Dimen- mm 499
W (in)
sions (19.6)
mm 618
H (in) (24.3)
Note: * shows the dimensions of Basic engine from the fan to the flywheel.
5
DSL 601
00.1.2 Performance Curves

4TNE84
Conditions for performance curves are in accordance

with JIS B8002, ISO 3046/1, BS5514
Intake air temperature: 27°C
Barometric pressure: 750 mmHg
Relative humidity:60%
The curves show performance after 30 hours run-in.
6
DSL 601
00 Engine, 4TNE84
00.1.3 Maintenance
o Maintenance Schedule
In order to insure maximum, trouble-free engine performance at all times, regular inspection,
adjustment and maintenance are vital.
Inspection Daily Every 50 hours Every 100 hours Every 150 hours Every 300 hours Every 500 hours
Check the oil level; fill O
Fuel System Remove sediment from fuel tank O
Clean and replace the fuel filter element O First time O Clean O Replace
Check the oil level-crankcase; fill O

Lubrication
Change the lubricating oil O First time O
system
Replace the lubricating oil filter element O First time O
Fill with cooling water, and check for leakage O
Clean the water jacket line O Clean inside

Cooling Water
Clean the radiator fins O
Adjust V-belt tension O First time O
Electrical Check the battery fluid level; fill O

7
System Check the warning lamps O
O Clean O Replace
Air Cleaner Clean and replace the element (every 50 hrs. in (every 250 hrs.
dusty areas) in dusty areas)
O First time
Cylinder Retighten all nuts and bolts
(Retighten every 2 years)
Heads, etc.
Adjust intake/exhaust valve clearances O
Check for any abnormal fuel injection sound O

Fuel Injection
Check the injection nozzles O
System
Check fuel injection timing O
O First time
Retighten all major nuts and bolts
(Retighten every 2 years)
00.1 General
DSL 601
00.1.4 Serial Number Location

The serial number is stamped on a plate mounted on the
engine valve cover. Always specify this number when
inquiring about ordering parts in order to get correct parts
for the engine being serviced.
8
DSL 601
00 Engine, 4TNE84 00.2 Basic Engine
00.2 BASIC ENGINE

00.2.1 CYLINDER BLOCK ........................................................................................11
00.2.1.1 INSPECTION OF PARTS ..................................................11
00.2.1.2 CLEANING OF OIL HOLES...............................................11
00.2.1.3 COLOR CHECK PROCEDURE..........................................11
00.2.1.4 CYLINDER BORE MEASUREMENT ..................................1 2
00.2.1.5 SLEEVELESS CYLINDER ................................................1 3
00.2.1.5.1 Features of sleeveless construction......................1 3
00.2.1.5.2 Durability of the sleeveless engine .......................1 3
00.2.1.5.3 Overhaul procedure .............................................13
00.2.1.5.4 Handling of FLEX-HONE..............................................15
00.2.1.5.5 Calculation diagram for obtaining crosshatch
angle...................................................................15
00.2.2 CYLINDER HEAD ..........................................................................................16

00.2.2.1 INSPECTING THE CYLINDER HEAD ......................................17
00.2.2.1.1 Distortion of the combustion surface.....................17
00.2.2.1.2 Checking for cracks in the combustion surface .....17
00.2.2.1.3 Checking the intake and exhaust valve seats ........17
00.2.2.2 VALVE SEAT CORRECTION PROCEDURE .......................18
00.2.2.3 INTAKE/EXHAUST VALVES, VALVE GUIDES ....................18
00.2.2.3.1 Wearing and corrosion of valve stem ....................18
00.2.2.3.2 Inspection of valve seat wear and contact
surface ................................................................19
00.2.2.3.3 Valve sinking .......................................................19
00.2.2.3.4 Valve guide .........................................................19
00.2.2.4 VALVE SPRINGS .............................................................20
00.2.2.4.1 Checking valve springs ........................................20
00.2.2.5 ASSEMBLING THE CYLINDER HEAD ...............................21
00.2.2.6 MEASURING THE TOP CLEARANCE......................................21
00.2.2.7 INTAKE AND EXHAUST VALVE ARMS ....................................21
00.2.2.8 ADJUSTMENT OF VALVE HEAD CLEARANCE .....................22
00.2.3 PISTON AND PISTON PIN ...........................................................23

00.2.3.1 PISTON ...........................................................................23
00.2.3.1.1 Piston head and combustion surface ....................23
00.2.3.1.2 Measurement of piston outside
diameter/inspection ..............................................23
00.2.3.1.3 Replacing the piston .....................................................24
00.2.3.2 PISTON PIN ....................................................................24
9
DSL 601
00.2.3.3 PISTON RINGS ...............................................................24

00.2.3.3.1 Measuring the rings .............................................24
00.2.3.3.2 Measuring piston ring gap ....................................25
00.2.3.3.3 Replacing the piston rings ....................................25
00.2.4 CONNECTING ROD.......................................................................................27

00.2.4.1 INSPECTING THE CONNECTING ROD ............................27
00.2.4.1.1 Twist and parallelism of the large and
small ends...........................................................27
00.2.4.1.2 Checking thrust clearance ....................................27
00.2.4.2 CRANK PIN BUSHING .....................................................28
00.2.4.2.1 Checking crank pin bushing .................................28
00.2.4.2.2 Measuring crank pin oil clearance ........................28
00.2.4.2.3 Precautions on replacement of crank
pin bushing .........................................................28
00.2.4.3 PISTON PIN BUSHING .................................................... 28
00.2.4.4 ASSEMBLING PISTON AND CONNECTING ROD .................29
00.2.5 CRANKSHAFT AND MAIN BEARING ..........................................................30

00.2.5.1 CRANKSHAFT .................................................................30
00.2.5.2 MAIN BEARING ...............................................................32
00.2.6 CAMSHAFT AND TAPPETS..........................................................................33

00.2.6.1 CAMSHAFT .....................................................................33
00.2.6.2 TAPPETS ........................................................................34
00.2.7 TIMING GEAR................................................................................................36

00.2.7.1 INSPECTING THE GEARS ...............................................36
00.2.7.2 GEAR TIMING MARKS .....................................................37
00.2.8 FLYWHEEL.....................................................................................................38
00.2.8.1 POSITION OF TOP DEAD CENTER AND FUEL INJECTION
TIMING ...........................................................................38
00.2.9 SERVICE DATA .............................................................................................40
00.2.10 OVER-SIZE AND UNDER-SIZE PARTS........................................................44
10
DSL 601
00.2.1 Cylinder Block

The cylinder block is thin-skinned, (low-weight), short
skirt type with rationally placed ribs. The side walls are
wave shaped to maximize ridigity for strength and low
noise.
1-1 Inspection of parts 1-3 Color check procedure
Make a visual inspection to check for cracks on engines (1) Clean the area to be inspected.
that have frozen up, overturned or otherwise been sub- (2) Color check kit
jected to undue stress. Perform a color check on any por- The color check test kit consists of an aerosol cleaner,
tions that appear to be cracked, and replace the cylinder penetrant and developer.
block if the crack is not repairable. (3) Clean the area to be inspected with the cleaner.
Either spray the cleaner on directly and wipe, or wipe
1-2 Cleaning of oil holes the area with a cloth moistened with cleaner.
(4) Spray on red penetrant
Clean all oil holes, making sure that none are clogged up After cleaning, spray on the red penetrant and allow
and the blind plugs do not come off. 5 ~ 10 minutes for penetration. Spray on more red
penetrant if it dries before it has been able to pene-
Quantity
Color check kit trate.
Part code No. 97550-004560 Penetrant 1 (5) Spray on developer
Developer 2 Remove any residual penetrant on the surface after the
Cleaner 3 penetrant has penetrated, and spray on the developer.
If there are any cracks in the surface, red dots or a red
line will appear several minutes after the developer dries.
Hold the developer 300 ~ 400mm (11.8110 ~ 15.7480in.)
away from the area being inspected when spraying,
making sure to coat the surface uniformly.
(6) Clean the surface with the cleaner.
Note..Be sure to read the instruction for the color kit

before use.
11
DSL 601
1-4 Cylinder bore measurement
Measure the bore diameter with a cylinder gauge at the

positions shown in the figure.
Replace the cylinder bore when the measured value
exceeds the wear limit. Measurement must be done at
least at 3 positions as shown in the figure, namely, top,
middle and bottom positions in both directions along the
crankshaft rotation and crankshaft center lines.
mm (in.)
Standard Wear limit
Cylinder bore dia

See separate service data
(page2-30,31)
Cylinder roundness
12
DSL 601
1-5 Sleeveless cylinder 1-5.2 Durability of the sleeveless engine
1-5.1 Features of sleeveless construction The conventional models of engine (T and TH Series) are
equipped with wet liners or sleeves to the standard speci-
(1) Improved reliability for tightness of combustion gas, fication. Tests in Yanmar Laboratory have proven that the
cooling water, and lubricating oil. sleeveless engine is improved in wear resistance by about
The sleeveless design permits tightening a cylinder 20% as compared with the conventional T and TH Series
head gasket evenly between the flat surface of the engine, which have long and widely been used and
cylinder block and of the cylinder head, thereby marked fair durability in the market.
improving tightness. A decision should be made as to whether the sleeveless
(2) The sleeveless design has eliminated increase in lubri- engine requires overhauling by checking increase in lubri-
cating oil consumption and blow-by caused by cating oil consumption or blow-by indicates rapid change.
deformed or defective sleeves, thus assuring stabilized
engine performance. 1-5.3 Overhaul procedure
(3) “Sleeveless” cooling improves the cooling efficiency
of the piston and ring, with enhanced engine durability. Following figure shows the time of the first to third over-
hauling and, the service life of the sleeveless cylinder
together with necessary honing or boring.
(1) How to re-hone the sleeveless cylinder

Prepare a motor-driven drill, “Flex-Hone”, and
honing fluid.
13
DSL 601
Rehorning FLEX-HONE Applicable

tool Size Grain
Granular grindstone boring dia.
type size
Model type (mm)
Silicon carbide
4TNE84 GB89 GRIT180 76-89
(for cast iron)
The ÒFlex-HoneÓ is commercially available, and is ready for

shipment from Yanmar on request. (Manufacturer: Brush
Research Mfg. Co., Inc.
Note: Commence honing when 1/3-1/4 of the length of the grinding
wheel protrudes from the top of the cylinder, and continue until
1/3-1/4 protrudes from the bottom.
Finally bore the cylinder and hone to the cylinder inside

diameter, D, in the following table.
Cylinder I.D. Cylinder I.D.(D) Length along

after fine boring after honing cylinder I.D.(L)
(mm) (mm) (mm)
4TNE84 84.22 84.25 + 0.03

0
150.5
Applying the honing fluid to the Flex-Hone. Insert the Flex-

Hone while turning it, and move it up and down for about
30 sec so that a cross hatch angle becomes 30° to 40°.
Extract the Flex-Hone while turning it.
(2) How to re-bore the sleeveless cylinder.

Carry out fine boring before honing.
Use a hone consisting of the GC grain (green
carborundum) of grain size of #300, and vitrified
bond (bonding agent). Select the revolutions and
feed rate of honing according to the following table.
Revolutions (rpm) Feed Rate (m/min)
4TNE84 230-260 18-21.5
(The above table provides a cross hatch angle of 35° +5°
14
DSL 601
1-5.4 Handling of FLEX-HONE 1-5.5 Calculation diagram for obtaining crosshatch

angle
• Use the Flex Hone by mounting it on a motor-driven
(stepless variable speed,) drill. Calculation diagram for obtaining crosshatch angle cross-
• Use soluble type grinding fluid for grinding. Do not hatching varies with circumferential speed and axial
employ dry type grinding. Use neither emulsion type speed. The following diagram is a calculation diagram for
grinding fluid nor petroleum-base (wash oil) grinding obtaining a crosshatch angle.
fluid.
• After grinding, be sure to clean the grain ball in warm [EXAMPLE] Where a workpiece is 100 mm in inside
water of about 30° -40°C using a bristled brush or the diameter and is rotated at a head speed of 95 r.p.m., a bro-
like. Do not store the grain ball with chipping powder ken line connecting the two extends to 29.8 m/min on the
or worn grain particles left deposited. circumferential speed axis. Where a stroke is 200 mm in
Otherwise, grinding capacity decreases. length and number of stroke reciprocations is 27.5/min, an
• The Flex Hone is intended only for wet type grinding. axial speed of 11.0 m/min is obtained. When the point
Never use it for the dry type grinding purpose. (29.8 m/min at an axial speed), a crosshatch angle of 40°
is obtained in the center.
Part list for Oversize piston and piston ring

Oversize: 0.25 mm:
Refer to the parts catalogs.
• Never keep the Flex Hone immersed in thinner, gaso-

line, gas oil, etc. Be sure to keep it dry for storage.
Otherwise, the binder of grain particles is inversely
influenced.
15
DSL 601
00.2.2 Cylinder Head

The cylinder head is 3- or 4-cylinder integral construction. IMPORTANT:
The area between the intake port and exhaust port is Cylinder head assembly differs among engine models. If
cooled by a water jet. an incorrect cylinder head is installed, combustion perfor-
mance will drop. Be sure to check the applicable engine
model identification mark (I. D. Mark) on the cylinder head
assembly to insure use of the correct part.
16
DSL 601
2-1 Inspecting the cylinder head
The cylinder head is subjected to severe operating condi-

tions with repeated high pressure, high temperature and
cooling. Thoroughly remove all the carbon and dirt after
disassembly and carefully inspect all parts.
2-1.1 Distortion of the combustion surface

2-1.3 Checking the intake and exhaust valve seats
Carefully check for cylinder head distortion as this leads to
gasket damage and compression leaks. Check the surface and width of the valve seats.
(1) Clean the cylinder head surface. If they are too wide, or if the surfaces are rough, correct to
(2) Place a straight-edge along each of the four sides the following standards:
and each diagonal. Measure the clearance between
the straight-edge and combustion surface with a feeler
gauge.
Measurement procedures
Intake 120°
mm (in.) Seat angle
Exhaust 90°
Standard Wear limit
mm (in.)
Cylinder head distortion
(Page 2-30,31) Seat width Standard Wear limit
Intake See separate service data

Exhaust (Page 2-30,31)
2-1.2 Checking for cracks in the combustion surface
Remove the fuel injection nozzle, intake and exhaust valve

and clean the combustion surface. Check for discoloration
or distortion and conduct a color check test to check for
any cracks.
17
DSL 601
2-2 Valve seat correction procedure NOTE: Clean the valve and cylinder head with light oil
or the equivalent after valve seat finishing is
The most common method for correcting unevenness of completed, and-make sure that there are no
the seat surface with a seat grinder is as follows: grindings remaining.
(1) Use a seat grinder to make the surface even.
First use 70° grinder, then grind the seat to the stan-
dard dimension with a 15° grinder.
NOTE:1. Insert adjusting shims between the valve

spring and cylinder head when seats have been
refinished with a seat grinder.
2. Measure valve distortion after valve seat refinish-
ing has been completed, and replace the
Intake valve 30° valve and valve seat if it exceeds the tolerance.
Seat grinder
Exhaust valve 45°
2-3 Intake/exhaust valves, valve guides
Note: When seat adjustment is necessary, be sure to
check the valve and valve guide. If the clearance 2-3.1 Wearing and corrosion of valve stem
exceeds the tolerance, replace the valve or the
valve guide, and then grind the seat. Replace the valve if the valve stem is excessively worn or
corroded.
(2) Knead valve compound with oil and finish the valve
seat with a lapping tool.
(3) Final finishing should
be done with oil only.
Lapping tool mm (in.)

Use a rubber cap type lapping Valve stem outside dia. Standard Wear limit
tool for cylinders without
Intake
a lapping tool groove slit. See separate service data
18
DSL 601
2-3.2 Inspection of valve seat wear and contact surface (2) Replacing the valve guide
Use the insertion tool and tap in the guide with a
Inspect for valve seat scratches and excessive wear. mallet.
Check to make sure the contact surface is normal. The
seat angle must be checked and adjusted if the valve seat
contact surface is smaller than the width of the valve
seat.
Note: Keep in mind that the intake and exhaust valve

have different diameters.
2-3.3 Valve sinking
Over long periods of use and repeated lappings, combustion

efficiency may drop. Measure the sinking distance and
replace the valve and valve seat if the valve sink exceeds
the tolerance.
The intake valve guide and exhaust valve guide are of dif-
ferent shapes/dimensions. The one with a groove around
it is the exhaust valve guide and the one without is the
intake valve guide.
(3) Valve guide projection

The valve guide should project the following “A” from
the top of the cylinder head.
mm (in.)
Standard Wear limit

Valve sink
(Page 2-30,31)
2-3.4 Valve guide
(1) Measuring inner diameter of valve guide.

Measure the inner diameter of the valve guide and Valve guide See separate service data
replace it if it exceeds the wear limit. mm (in.) projection A (Page 2-30,31)
Standard Wear limit
Intake
Valve guide See separate service data
inside dia.
NOTE: The inner diameter standard dimensions assume a
pressure fit.
19
DSL 601
(4) Valve stem seals (4) Assembling valve springs

The valve stem seals in the intake/exhaust valve The side with the smaller pitch (painted yellow)
guides cannot be re-used once they are removed-be should face down (cylinder head).
sure to replace them.
When assembling the intake/exhaust valves, apply an
adequate amount of engine oil on the valve stem
before inserting them.
NOTE: The pitch of the valve spring is not even. The side
with the smaller pitch (yellow) should face down
(cylinder head) when assembled.
2-4 Valve springs
(5) Spring retainer and spring cotter
2-4.1 Checking valve springs
Inspect the inside face of the spring retainer, the out
side surface of the spring cotter, the contact area of
(1) Check the spring for scratches or corrosion.
the spring cotter inside surface and the notch in the
(2) Measure the free length of the spring.
head of the valve stem. Replace the spring retainer
and spring cotter when the contact area is less than
70%, or when the spring cotter has been recessed
because of wear.
(3) Measure inclination.
20
DSL 601
2-5 Assembling the cylinder head (5) Measure the three positions where each fuse is
broken and calculate the average.
Partially tighten the bolts in the specified order and then (0.71~0.75mm(0.028~0.0295in.) is ideal)
tighten to the specified torque, being carful not to distort
the head.
(1) Clean out the cylinder head bolt holes.
(2) Check for foreign matter on the cylinder head
surface that comes in contact with the block.
(3) Coat the head bolt threads and nut seats with lube
oil.
(4) Use the positioning pins to line up the head gasket
with the cylinder block.
(5) Match up the cylinder head with the head gasket and
mount.
Exhaust manifold side
mm (in.)
Top clearance See separate service data

(Page 2-30,31)
2-7 Intake and exhaust valve arms
Valve arm and valve arm bushing wear may alter open-
ing/closing timing of the valve, and may in turn affect engine
performance according to the extent of the change.
kg-m (ft-lb)
First Final
Tightening torque See separate service data

(Page 2-30,31)
2-6 Measuring top clearance
(1) Place a high quality fuse (Ø1.5mm (0.059in.), 10mm

(0.3937in.) long) in three positions on the flat part of
the piston head.
(2) Assemble the cylinder head gasket and the cylinder
block and tighten the bolts in the specified order to the
specified torque.
(3) Turn the crank, (in the direction of engine revolution),
and press the fuse against the piston until it breaks.
(4) Remove the head and take out the broken fuse.
21
DSL 601
(1) Valve arm shaft and valve arm bushing 2-8 Adjustment of valve head clearance
Measure the outer diameter of the shaft and the inner
diameter of the bearing, and replace if wear exceeds (1) Make adjustments when the engine is cool.
the limit. mm (in.)
Intake and exhaust valve clearance 0.2 (0.0079)
mm (in.)
Standard Wear limit
Intake and exhaust

valve rocker arm
shaft outside dia.
Intake and exhaust See separate service data

valve rocker arm
bushing inside dia. (assembled) (Page 2-30,31)
Valve rocker arm
shaft and bushing clearance (2) Do not fail to adjust the opening and closing angles for both
at assembly intake and exhaust valves when reassembling the timing
gear.
Replace the valve arm shaft bushing if it moves and
replace the entire valve arm if there is no tightening
clearance.
(2) Valve arm spring

Check the valve arm spring and replace it if it is cor-
roded or worn.
(3) Valve arm and valve top retainer wear
Inspect the contact surface of the valve arm and
replace it if there is abnormal wear or flaking.
(4) Inspect the contact surface of the valve clearance
adjustment screw and push rod and replace if there is
abnormal wear or flaking.
Intake valve open b.TDC

Intake valve closed a.BDC See separate service data
Exhaust valve open b.BDC (Page 2-30, 31)
Exhaust valve closed a.TDC
22
DSL 601
00.2.3 Piston and Piston Pin

The piston is made up of an aluminum alloy with less ther- 3-1 Piston
mal expansion.
There is a clearance between the outside diameter of the 3-1.1 Piston head and combustion surface
piston and the inside diameter of the cylinder. The clear- Remove the carbon that has accumulated on the piston
ance is an important factor that has influence on the lubric- head and combustion surface, taking care not to scratch
ity between the piston and cylinder, lubricating oil con- the piston. Check the combustion surface for any damage.
sumption, the noise level of the cylinder.
In Yanmar engines, both piston and cylinder have identifi- 3-1.2 Measurement of piston outside diameter/inspection
cation marks to ensure proper clearance between the pis- (1) Replace the piston if the outside of the piston or ring
ton and cylinder on respective top surfaces. grooves are worn.
In Yanmar factory, the piston is assembled into the cylinder (2) Measure the piston O.D. of location “A” from the
block with the same identification mark. bottom at right angles to the piston pin.
The following shows combinations of identification marks
for the piston and cylinder block.
Identification of pistion
L ML MS S
L O O B B
Cylinder
M B O O B
block
S B B O O
Note 1: O. . . . . Fixed
X. . . . . Do not fix
mm(in.)
Standard Wear limit
See separate service data (page 2-31, 32)
23
DSL 601
3-1.3 Replacing the piston 3-3 Piston rings
A floating type piston pin is used in this engine. The piston There are 2 compression rings and 1oil ring.
pin can be pressed into the piston pin hole at room tem- The absence of an oil ring on the piston skirt prevents oil
perature (coat with oil to make it slide in easily). from being kept on the thrust surface and in turn provides
good lubrication.
3-2 Piston pin
Measure the outer diameter and replace the pin if it is 3-3.1 Measuring the rings
excessively worn.
Measure the thickness and width of the rings, and the ring-
to-groove clearance after installation. Replace if wear
exceeds the limit.
mm (in.)
Standard Wear limit
Piston pin insert
hole dia.
Piston pin
(Page 2-31,32)
outside dia.
Standard clearance
24
DSL 601
mm (in.)
3-3.3 Replacing the piston rings
Standard Wear limit
Groove width
(1) Thoroughly clean the ring grooves when replacing
piston rings.
First
piston Ring width
(2) The side with the manufacturer’s mark (near piston
ring ring gap) should face up.
Groove and
ring clearance
Groove width
Second
piston Ring width
ring (Page 2-31,32)
Groove and
ring clearance
Groove width
Oil ring Ring width

(3) After fitting the piston ring, make sure it moves easily
Groove and and smoothly.
ring clearance (4) Stagger the piston rings at 120° intervals, making
3-3.2 Measuring piston ring gap sure none of them line up with the piston.
Press the piston ring onto a cylinder and measure the pis-
ton ring gap with a gauge.
Press on the ring about 30 mm (1.811 in.) from the bottom
of the cylinder.
mm (in.)
Standard Wear limit
First piston ring gap

Second piston ring gap
(Page 2-31,32)
Oil ring gap
25
DSL 601
(5) The oil ring is provided with a coil expander. The coil
expander joint should be opposite (staggered 180°)
the oil ring gap.
26
DSL 601
00.2.4 Connecting Rod

The connecting rod is made of high-strength forger carbon
steel.
The large end with the special aluminum-alloy metal can
be separated into two and the small end has a copper alloy
coil bushing.
mm(in.)
Standard Wear limit
Connecting rod See separate service data
twist and parallelity (Page 2-32,33)
4-1.2 Checking thrust clearance
Fit the respective crank pins to the connecting rod and

check to make sure that the clearance in the crankshaft
direction is correct.
4-1 Inspecting the connecting rod
4-1.1 Twist and parallelism of the large and small ends
Insert the measuring tool into the large and small ends of
the connecting rod. Measure the extent of twist and
parallelism and replace if they exceed the tolerance.
mm(in.)
Standard Wear limit
Connecting rod side See separate service data
clearance (Page 2-31,32)
27
DSL 601
4-2 Crank pin bushing 4-2.3 Precautions on replacement of crank pin bushing
4-2.1 Checking crank pin bushing (1) Wash the crank pin bushing.
(2) Wash the large end cap, mount the crank pin bushing
Check for flaking, melting or seizure on the contact sur- and make sure that it fits tightly on the large end cap.
face. (3) When assembling the connecting rod, match up the
large end and large end cap number. Coat the bolts
4-2.2 Measuring crank pin oil clearance with engine oil and gradually tighten them alternately
to the specified torque.
Use a plastic gauge. If a torque wrench is not available, make match
marks on the the bolt heads and large end cap (to
indicate the proper torque position) and retighten the
bolts to those positions.
Procedure
(1) Use the press gauge (Plastigage) for measuring oil (4) Make sure there is no sand, metal cuttings or other
clearance in the crank pin. foreign matter in the lube oil, and that the crankshaft
(2) Mount the connecting rod on the crank pin (tighten to is not scratched. Take special care in cleaning the oil
specified torque.) holes.
See separate service data 4-3 Piston pin bushing

Connecting rod tightening torque
(Page 2-31,32)
(1) Measuring piston pin clearance
(3) Remove the connecting rod and measure the broken Excessive piston pin bushing wear may result in dam-
plastic gauge with measuring scale. (Plastic gauge) age to the piston pin or the piston itself.
28
DSL 601
4-4 Assembling piston and connecting rod

mm(in.)
Standard Wear limit
The piston and connecting rod should be assembled so
Piston pin bushing
inside dia. See separate service data that the match mark on the connecting rod large end faces
Piston pin and bushing (Page 2-31,32) the fuel injection pump side and the combustion chamber
oil clearance above the piston is close to the fuel injection pump.
(2) Replacing piston pin bushing
1) When the bushing for the connecting rod piston pin is
either worn out or damaged, replace it by using the
“piston pin extracting tool” installed on a press.
NOTE: Force the piston pin bushing into position so that

its oil hole coincides with the hole on the small
end of the connecting rod.
29
DSL 601
00.2.5 Crankshaft and Main Bearing

The crank pin and crank journal have been high-frequency
hardened for superior durability, and the crankshaft is pro-
vided with four balance weights for optimal balance. The
crankshaft main bearing is of the hanger type, with
5-1 Crankshaft
(1) Color check of shaft

Perform a color check after cleaning the crankshaft,
and replace the crank shaft if there is any cracking or
considerable damage.
30
DSL 601
(2) Bending of the crankshaft

Support the crankshaft with V-blocks at both ends
of the journals. Measure the deflection of the center
journal with a dial gauge while rotating the crankshaft
to check the extent of crankshaft bending.
Crankshaft bend Less than 0.02mm(0.0007in)
(3) Measuring the crank pin and journal

Measure the extent of journal wear (roundness, taper).
Regrind it to the proper shape if it is within the outer
diameter limit, and replace if not.
mm(in.)
Standard Wear limit
Outside dia.
Crank pin Bushing inside dia.
Crank pin and bushing oil clearance
Outside dia.
(Page2-31,32,33,34)
Crankjournal Bushing inside dia.
Crank journal and bushing oil clearance
Fillet rounding of crank pin and journal
31
DSL 601
(4) Checking side clearance of the crankshaft

After assembling the crankshaft, tighten the main
bearing cap to the specified torque, and move the
crankshaft to one side, placing a dial gauge on one
end of the shaft to measure thrust clearance.
This measurement can also be effected by inserting
the gauge directly into the clearance between the
thrust bearing and crankshaft thrust surface.
Replace the thrust bearing if it is worn beyond the
limit.
mm(in.)
Standard Wear limit
Crankshaft side gap
(Page 2-32, 33)
5-2 Main bearing
(1) Inspecting the main bearing NOTE: When assembling the bearing cap, keep the fol
Check for flaking, seizure or burning of the contact lowing in mind.
surface and replace if necessary. 1) The lower metal (cap side) has no oil groove.
(2) Measuring the inner diameter of metal 2) The upper metal (cylinder block side) has an
Tighten the cap to the specified torque and measure oil groove.
the inner diameter of the metal. 3) Check the cylinder block alignment No.
Bearing cap bolt tightening torque See separate service data 4) The ÒFWÓ on the cap lies on the flywheel side.
(Page 2-32,33)
32
DSL 601
00.2.6 Camshaft and Tappets

6-1 Camshaft
The camshaft is normalized and the cam and bearing

surfaces are surface hardened and ground. The cams
have a curve that minimizes the repeated shock on the
valve seats and maximizes valve seat life.
(1) Checking the camshaft side gap

The standard bearing near the end of the camshaft
by the cam gear receives the load, resulting in rapid
wear of the end of the bearing and enlargement of
the side gap. Therefore, measure the thrust gap
before disassembly. As the cam gear is shrink-fitted
to the cam, be careful when replacing the thrust bear
ing.
(2) Measure the camshaft height, and replace the cam if

it is worn beyond the limit.
mm (in.)
Camshaft height Standard Wear limit
Intake cam See separate service data
Exhaust cam (page2-32,33)
mm(in.)
Standard Wear limit

Camshaft side gap (Page 2-32,33)
33
DSL 601
(3) Measure the camshaft outer diameter and the

camshaft bearing inner diameter. Replace if they
exceed the wear limit or are damaged.
mm(in.)
Standard
Wear limit
Gear case side Intermediate Flywheel side
Camshaft journal outside dia.
Camshaft journal bushing inside dia. See separate service data

(Page 2-32, 33)
Cylinder block bearing inside dia.
Oil clearance
(4) Bending of the camshaft 6-2 Tappets

Support both ends of the camshaft with V-blocks,
place a dial gauge against the central bearing areas (1) The tappets are offset to rotate during operation and
and measure bending. Replace if excessive. thereby prevent uneven wearing. Check the contact
of each tappet and replace if excessively or unevenly
worn.
NOTE: The reading on the dial gauge is divided by two to

obtain the extent of bending.
mm(in.)
Wear limit
Camshaft deflection
(Page 2-32,33)
NOTE: When removing tappets, be sure to keep them

separate for each cylinder and intake/exhaust
valve.
34
DSL 601
(2) Measure the outer diameter of the tappet, and

replace if worn beyond the limit.
mm (in.)
Standard Wear limit
Tappet stem outside dia.
Tappet guide hole inside See separate service data
dia. (cylinder block)
(Page 2-32, 33)
Tappet stem and guide
hole oil clearance
(3) Measuring push rods.

Measure the length and bending of the push rods.
mm (in.)
Standard Wear limit
Push rod length

Push rod bend
(Page 2-32,33)
Push rod dia.
35
DSL 601
00.2.7 Timing Gear

The timing gear is helical type for minimum noise and spe-
cially treated for high durability.
mm(in.)
No.of Teeth Face Width Helical angle Back lash Back lash
Wear limit
Camshaft gear
Idle gear
Crankshaft gear
Lubricating oil pump gear See separate service data
(Page 2-33)
Idle gear
Fuel injection pump gear
7-1 Inspecting the gears
(1) Inspect the gears and replace if the teeth are damaged (3) Idling gear
or worn. The bushing is pressure fitted into the idling gear.
(2) Measure the backlash of all gears that mesh, and Measure the bushing inner diameter and the outer
replace the meshing gears as a set if wear exceeds the diameter of the shaft, and replace the bushing or
limit. idling gear shaft if the oil clearance exceeds the wear
limit. A, B and C are inscribed on the end of the
NOTE: If backlash is excessive, it will not only result in idling gear. When assembling, these marks should
excessive noise and gear damage, but also lead align with those on the cylinder block.
to bad valve and fuel injection timing and a
decrease in engine performance.
36
DSL 601
mm (in.)
Standard Wear limit
Idle shaft dia.
Idle shaft bushing See separate service data
inside dia.
(Page 2-32)
Idle shaft and bushing
oil clearance
7-2 Gear timing marks
Match up the timing marks on each gear when assembling

(A, B and C).
37
DSL 601
00.2.8 Flywheel
The flywheel used in the 4TN series engines employ a bal-
anced flywheel. The timing marks are punched on the cir-
cumference of the flywheel. These marks are used for
checking the fuel injection timing.
8-1 Position of top dead center and fuel injection timing
(1) Marking
38
DSL 601
9. Crankshaft pulley
The crankshaft pulley of the 4TN series engines employ a

balanced pulley.
39
DSL 601
00.2.9 Service Data

Wear
Item Unit Standard
limit
Cylinder block
. mm 84.00-84.03 84.2
•Cylinder bore dia
(in) (3.307-3.308) (3.315)
mm 0-0.01 0.02
•Cylinder roundness
(in) (0-0.0004) (0.0008)
•Top position A mm(in) 20(0.787) -
Cylinder head
mm 0.05 and less 0.15
•Cylinder head distortion
(in) (0.002) (0.006)
•Seat Iintake deg 120 -
angle Exhaust deg 90 -
mm 1.07-1.24 1.74
Intake
•Seat (in) (0.042-0.049) (0.069)
width mm 1.24-1.35 1.94
Exhaust
(in) (0.049-0.053) (0.076)
•Seat grinder Intake deg 30 -
(valve seat angle) Exhaust deg 45 -
mm 7.960-7.975 7.90
•Valve stem Intake (in) (0.313-0.314) (0.311)
outside dia mm 7.955-7.970 7.90
Exhaust
(in) (0.313-0.314) (0.311)
•Position A
mm(in) 30(1.181) -
(valve stem O.D. measuring point)
•Position B
mm(in) 60(2.362) -
(valve stem O.D. measuring point)
mm 0.3-0.5 1.0
Intake
(in) (0.012-0.020) (0.039)
•Valve sink
mm 0.3-0.5 1.0
Exhaust
(in) (0.012-0.020) (0.039)
mm 8.010-8.025 8.10
Intake
•Valve guide (in) (0.3154-0.316) (0.319)
inside dia. mm 8.015-8.030 8.10
Exhaust
(in) (0.3156-0.316) (0.319)
•Valve guide projection A mm(in) 15(0.591) -
mm 40 39.5
Free lenght(A)
•Valve (in) (1.575) (1.55)
spring 1.1
Inclination(B) mm(in) -
(0.044)
•Cylinder head kg-m 3.5-4.3
First -
tightening torque (ft-lb) (25.23-31.10)
(Tighten separately kg-m 7.5-8.5
Final -
with 2-3 times) (ft-lb) (54.23-61.46)
mm 0.64-0.82
•Top clearance -
(in) (0.0252-0.0323)
•Intake & exhaust valve rocker mm 15.966-15.984 15.955
arm shaft outside dia. (in) (0.6286-0.6293) (0.628)
•Intake & exhaust valve rocker mm 16.000-16.020 16.090
arm bushing inside dia. (in) (0.630-0.631) (0.634)
•Valve rocker arm shaft & mm 0.016-0.054 0.135
bushing clearance at assembly (in) (0.0006-0.0021) (0.0053)
•Intake & exhaust valve clearance mm(in) 0.2(0.0079) -
•Intake valve open bTDC deg 10-20 -
•Intake valve closed aBDC deg 40-50 -
•Exhaust valve open bBDC deg 51-61 -
•Exhaust valve closed aTDC deg 13-23 -
40
DSL 601
Wear
Item Unit Standard
limit
Piston & Piston pin
. mm 83.898-83.928 83.8
•Piston outside dia.
(in) (3.303-3.304) (3.299)
•Position A
mm(in) 24(0.945) -
(piston O.D. measuring point)
. mm 26.000-26.009 26.02
•Piston pin hole dia. of piston
(in) (1.0236-1.024) (1.024)
mm 25.987-26.000 25.90
•Piston pin outside dia.
(in) (1.023-1.024) (1.020)
. mm 0-0.022 0.045
•Piston and piston pin clearance
(in) (0-0.0009) (0.0018)
mm 2.065-2.080
Groove width -
(in) (0.081-0.082)
mm 1.970-1.990
•First piston ring Ring width -
(in) (0.0776-0.0783)
mm 0.075-0.110 0.25
Clearance
(in) (0.0030-0.0043)T/C (0.010)
mm 2.035-2.050
Groove width -
(in) (0.080-0.081)
mm 1.970-1.990
•2nd piston ring Ring width -
(in) (0.0776-0.0783)
mm 0.045-0.080 0.25
Clearance
(in) (0.0018-0.0031) (0.0098)
mm 4.015-4.030
Groove width -
(in) (0.158-0.159)
mm 3.970-3.990
•Oil ring Ring width -
(in) (0.156-0.157)
mm 0.025-0.060 0.2
Clearance
(in) (0.0010-0.0024) (0.0079)
. mm 0.20/0.25-0.40/0.45 1.5
•First ring gap
(in) (0.008/0.010-0.016/0.018) (0.059)
. mm 0.20-0.40 1.5
•2nd ring gap
(in) (0.008-0.016) (0.059)
. mm 0.25-0.45 1.5
•Oil ring gap
(in) (0.010-0.018) (0.059)
Connecting rod
mm 0.03/100 and less 0.08
•Connecting rod twist and Parallelity
(in) (0.0012/3.937) (0.003)
mm 0.20-0.40 0.55
•Connecting rod side clearance
(in) (0.0079-0.0157) (0.0217)
kg-m 4.5-5.0
•Connecting rod tightening torque -
(ft-lb) (32.53-36.15)
mm 26.025-26.038 26.1
•Piston pin bushing inside dia.
(in) (0.0246-1.0251) (1.028)
mm 0.025-0.051 0.11
•Piston pin and bushing oil clearance
(in) (0.0010-0.0020) (0.0043)
Crankshaft and main bearing
mm Less than 0.02
•Crankshaft bend -
(in) (0.001)
mm 47.952-47.962 47.91
•Crank pin outside dia.
(in) (1.8879-1.8883) (1.886)
mm 48.000-48.042 48.07
•Crank pin bushing inside dia.
(in) (1.888-1.891) (1.893)
mm 0.038-0.090 0.16
•Crank pin and bushing oil clearance
(in) (0.0015-0.0035) (0.0063)
mm 49.952-49.962 49.90
•Crank journal outside dia.
(in) (1.967-1.967) (1.965)
mm 50.000-50.045 50.10
•Crank journal bushing inside dia.
(in) (1.969-1.970) (1.972)
41
DSL 601
Wear
Item Unit Standard
limit
. mm 0.038-0.093 0.15
•Crank journal and bushing oil clearance
(in) (0.0015-0.0037) (0.0059)
mm 3.500-3.800
•Fillet rounding of crank pin and journal -
(in) (0.138-1.150)
mm 0.090-0.271 0.33
•Crankshaft side gap
(in) (0.004-0.011) (0.013)
kg-m 9.5-10.5
•Main Bearing cap bolt tightening torque -
(ft-lb) (68.69-75.92)
Camshaft and tappets
. mm 0.05-0.20 0.4
•Camshaft side gap
(in) (0.002-0.008) (0.016)
mm 38.635-38.765 38.4
Intake cam
(in) (1.521-1.526) (1.512)
•Camshaft height
mm 38.635-38.765 38.4
Exhaust cam
(in) (1.521-1.526) (1.512)
mm 44.925-44.950 44.8
Gearcase side (in) (1.769-1.770) (1.764)
•Camshaft journal mm 44.910-44.935 44.8
outside dia. Intermediate (in) (1.768-1.769) (1.764)
mm 44.925-44.950 44.8
Flywheel side (in) (1.769-1.770) (1.764)
mm 44.990-45.055
Gearcase side (in) (1.771-1.774) -
•Camshaft journal
mm
camshaft bearing Middle (in) - -
inside dia.
mm
Flywheel side (in) - -
mm
Gearcase side (in) - -
•Cylinder block
mm 45.000-45.025
camshaft bearing Middle (in) (1.772-1.773) -
inside dia.
mm 45.000-45.025
Flywheel side (in) (1.772-1.773) -
mm 0.040-0.130 0.2
Gearcase side (in) (0.0016-0.0051) (0.0079)
•Camshaft bearing mm 0.065-0.115 0.2
oil clearance Middle (in) (0.0026-0.0045) (0.0079)
mm 0.050-0.100 0.2
Flywheel side (in) (0.0020-0.0039) (0.0079)
•Camshaft deflection mm(in) 0.02(0.001) -
mm 11.975-11.990 11.93
•Tappet stem outside dia.
(in) (0.472-0.472) (0.470)
mm 12.000-12.018 12.05
•Tappet guide hole inside dia.
(in) (0.472-0.473) (0.474)
mm 0.010-0.043
•Tappet stem and guide hole oil clearance -
(in) (0.0004-0.0017)
mm 178.25-178.75
•Push rod length -
(in) (7.018-7.037)
mm Less than 0.03
•Push rod bend -
(in) (0.001)
•Push rod dia. mm(in) 8(0.315) -
Timing gear
mm 45.950-45.975 45.93
•Idle shaft dia.
(in) (1.809-1.810) (1.808)
mm 46.000-46.025 46.08
•Idle shaft bushing inside dia.
(in) (1.811-1.812) (1.814)
mm 0.025-0.075 0.15
•Idle shaft and bushing oil clearance
(in) (0.0010-0.0030) (0.0059)
42
DSL 601
Timing gear
Wear
Item Unit Standard
limit
No. of teeth 56
Face width 18
•Camshaft gear Helical angle left
Backlash between 0.04-0.12 0.2

camgear and idle gear (0.0016-0.0047) (0.0079)
No. of teeth 43
Face width 18
•Idle gear Helical angle right
Backlash between idle 0.04-0.12 0.2

gear and crankshaft gear (0.0016-0.0047) (0.0079)
No. of teeth 28
Face width 40
•Camshaft gear Helical angle left
Backlash between crankshaft 0.04-0.12 0.2

gear and oil pump gear (0.0043-0.0075) (0.0079)
•Lubricating No. of teeth 29
oil pump Face width 8
gear Helical angle right
No. of teeth 43
Face width 18
•Idle gear Helical angle right
Backlash between idle 0.04-0.12 0.2
gear and fuel injection (0.0016-0.0047) (0.0079)
pump
•Fuel No. of teeth 56
injection Face width 10
pump gear Helical angle left
43
DSL 601
00.2.10 Over-size and Under-size Parts

Outer diameter(at measuring point) mm(in) 84.150-84.165
Piston (3.3130-3.3136)
Identification OS25
49.75-49.795
Inner diameter mm(in)
Crank-journal metal (1.9587-1.9604)
Identification -
47.75-47.795
Crank-pin metal Inner diameter mm(in)
(1.8799-1.8817)
Identification -
26.024-26.085
Piston pin metal* Inner diameter(after in compressed) mm(in)
(1.0246-1.0270)
Identification w/oil hole
NOTE: 1) Under-sized piston pin should be unprepared.

Use a standard parts in case of up to service limit.
2) Marked* Piston pin metal are finishing of the inside-
diameter unnecessary, and it is pressed-in to the connecting
rod only.
3) Refer to the parts catalogs concerning the parts code
numbers.
44
DSL 601
00 Engine, 4TNE84 00.3 Fuel Injection Equipment
00.3 FUEL INJECTION

EQUIPMENT
00.3.1 FUEL SUPPLY SYSTEM................................................................47
00.3.1.1 FUEL SUPPLY SYSTEM ...................................................47
00.3.1.1.1 Fuel injection pump construction ..........................48
00.3.1.2 FUEL INJECTION PUMP SPECIFICATIONS ......................49
00.3.1.3 FUNCTIONING OF FUEL INJECTION PUMP.....................49
00.3.1.4 INJECTION VOLUME CONTROL ......................................49
00.3.1.5 GOVERNOR CONSTRUCTION .........................................51
00.3.1.6 FUNCTION OF GOVERNOR .............................................55

OF GOVERNOR ............................................................................59
00.3.2.1 GOVERNOR DISASSEMBLY ............................................60
00.3.2.2 INSPECTION OF GOVERNOR .........................................64
00.3.2.3 ASSEMBLING THE GOVERNOR.......................................64

OF FUEL INJECTION PUMP ........................................................68
00.3.3.1 DISASSEMBLY OF FUEL INJECTION PUMP.....................69
00.3.3.2 INSPECTION OF FUEL INJECTION PUMP .......................73
00.3.3.3 REASSEMBLY OF FUEL INJECTION PUMP......................74
00.3.4 ADJUSTMENT OF FUEL INJECTION PUMP

AND GOVERNOR ........................................................................78
00.3.4.1 PREPARATIONS (YPES TYPE) ........................................78
00.3.4.2 ADJUSTMENT OF TOP CLEARANCE ...............................79
00.3.4.3 ADJUSTING OF INJECTION TIMING ................................80
00.3.4.4 PLUNGER PRESSURE TEST ....................................................81
00.3.4.5 DELIVERY VALVE PRESSURE TEST................................81
00.3.4.6 ADJUSTING INJECTION VOLUME
(UNIFORMITY OF EACH CYLINDER) ...............................81
00.3.4.6.1 Measuring injection volume ..................................81
00.3.4.6.2 Adjustment of injection volume .............................81
00.3.4.7 ADJUSTMENT OF GOVERNOR ........................................82
00.3.4.7.1 Adjusting the fuel limit bolt ...................................82
00.3.4.7.2 Adjusting RPM limit bolt .......................................82
00.3.4.7.3 Adjusting idling ....................................................82
45
DSL 601
00.3.4.7.4 Check the injection volume when starting .............83

00.3.4.8 ADJUSTMENT OF TORQUE RISE ....................................83
00.3.4.8.1 Models with angleich spring .................................83
00.3.4.8.2 Models with torque spring ....................................83
00.3.5 FUEL FEED PUMP .....................................................................................84

00.3.5.1 CONSTRUCTION OF FUEL FEED PUMP ..........................84
00.3.5.2 FUEL FEED PUMP SPECIFICATIONS ..............................85
00.3.5.3 DISASSEMBLY AND REASSEMBLY OF
FUEL FEED PUMP ...........................................................85
00.3.5.3.1 Disassembly ........................................................85
00.3.5.3.2 Reassembly .........................................................85
00.3.5.4 FUEL FEED PUMP INSPECTION ......................................85
00.3.6 FUEL INJECTION NOZZLE ...........................................................86

00.3.6.1 FUNCTIONING OF FUEL INJECTION NOZZLE .................86
00.3.6.2 TYPE/CONSTRUCTION OF FUEL INJECTION NOZZLE ....86
00.3.6.3 FUEL INJECTION NOZZLE DISASSEMBLY.......................88
00.3.6.4 FUEL INJECTION NOZZLE INSPECTION .........................89
00.3.6.4.1 Washing ..............................................................89
00.3.6.4.2 Nozzle inspection ................................................89
00.3.6.5 FUEL INJECTION NOZZLE REASSEMBLY........................90
00.3.6.6 ADJUSTING FUEL INJECTION NOZZLE ...........................90
00.3.6.6.1 Adjusting opening pressure ..................................90
00.3.6.6.2 Injection test........................................................91
00.3.7 TROUBLESHOOTING ..................................................................92

00.3.7.1 TROUBLESHOOTING OF FUEL INJECTION PUMP ...........92
00.3.7.2 MAJOR FAULTS AND TROUBLESHOOTING .....................92
00.3.8 FUEL FILTER ...............................................................................................94
00.3.9 AIR VENTING SYSTEM ..............................................................................95
00.3.10 SERVICE DATA ...........................................................................................96
46
DSL 601
00.3.1 Fuel Supply System

1. Fuel Supply System
The 4TNE84 Engine uses a Model YPES Bosch in-line

type with the camshaft driven by engine gears via the
timing gears. The feed pump is driven by the camshaft of
the fuel injection pump. The filtered fuel is fed to the
reservoir in the pump housing. The plunger increases the
pressure, and the fuel passes through the injection pipe to
be injected into each cylinder by the fuel injection nozzle.
47
DSL 601
1-1 Fuel Injection Pump Construction
48
DSL 601
Bosch type fuel injection pump is an in-line type pump The fuel injection pump supplies pressurized fuel to the
with a governor incorporated. injection nozzles through the action of the plunger. The
A camshaft is built into the fuel injection pump, which has plunger reciprocates in the plunger barrel through a fixed
a drive cam for the fuel feed pump and tappet-drive cams stroke and is lapped for a precise fit. A lead groove is heli-
for the plunger. cally cut in the plunger, and this leads to a connecting
A timing gear and drive gear are mounted on the drive side groove which goes to the top of the plunger.
of the camshaft, and a governor weight on the opposite There is a port into the plunger barrel which serves as both
side. an intake and discharge port. The fuel comes through this
As the plunger rises, the fuel oil opens the delivery valve port into the plunger chamber, is pressurized by the
and goes through the high pressure pipe to the fuel injec- plunger, opens the delivery valve, flows to the fuel injection
tion nozzles. nozzle through the fuel injection pipe and is injected into
When the control rack connected to the governor lever the combustion chamber. Fuel injection terminates after
moves, the pinion turns the plunger. This changes the fuel the pressurized fuel has been discharged. This happens
discharge and intake positions and in turn controls the when the lead groove lines up with the discharge groove
amount of fuel injected. as the plunger rises and the pressure in the fuel injection
pipe drops.
1-2 Fuel injection pump specifications The control sleeve groove is fitted to the plunger flange.
The control sleeve is secured to the control pinion and the
Type YPES-CL pinion teeth and rack gear teeth are engaged.
The plunger is controlled by the rack, enabling continuous
Specifications See separate service data changing of the volume of fuel injected from zero to maxi-
(Page 3-51)
mum. A fuel leak return hole is provided in the plunger bar-
rel. This returns fuel leaking from the gap between the
plunger and the barrel to the fuel lines. This prevents dilu-
tion of the lubricant in the cam chamber.
1-3 Functioning of fuel injection pump
1-4 Injection volume control
(1) Full injection volume position

When the rack is set at the maximum setting, fuel
injection starts earlier. It occurs when the widest part
of the lead groove on the upper part of plunger lines
up with the intake port in the barrel. At this time, the
1. Plunger 6. Control sleeve
2. Plunger barrel 7. Control pinion
3. Load groove 8. Control rack
4. Intake port 9. Fuel leak return groove
5. Delivery valve 10. Protector
49
DSL 601
narrowest part of the lower lead groove lines up with plunger and sucks up fuel from the nozzle valve to prevent
the discharge port, prolonging the length of injection after drip.
and increasing the volume of fuel injected. When the plunger lead lines up with the discharge port of
This setting is normally used for starting and max. the plunger barrel, the injection pressure drops, and the
output operation. delivery valve is brought down by the delivery valve spring.
(2) Half injection volume position
When the rack is returned towards zero from the
maximum setting, discharge starts later and ends earl-
ier, decreasing the volume of fuel injected.
(3) No fuel injection

When the rack is set near zero, the intake/discharge
port in the barrel is always open, so no fuel is pres-
surized (even though the plunger continues to recipro-
cate).
At this time, the suck-back collar (1) blocks off the fuel
injection pipe and the delivery chamber, and the valve con-
tinues to descend until the seat (2) comes in contact with
the barrel. The fuel oil pressure in the fuel injection pipe
decreases proportionately with the lowering of the valve
(due to increased volume).
This accelerates closing of the nozzle valve, and sucks up
fuel from the nozzle to prevent it from dripping.
This increases nozzle life and improves combustion effi-
The delivery valve at the top of the plunger prevents ciency.
fuel in the fuel injection pipe from flowing back to the
50
DSL 601
1-5 Governor construction
Usage conditions of diesel engines are extremely varied, Injection pump is equipped with the all speed governor.
with a wide range of loads and rpms. The governor plays The construction will be explained accordingly to the cut-
an important role in the operation of the engine by quickly way views.
adjusting the position of the control rack to control the
amount of fuel injected according to changes in rpm.
It also automatically controls the engine to prevent engine
rpm from exceeding the maximum, and keeps the engine
from stopping.
51
DSL 601
The governor weight mounted on the end of the fuel injec- The governor lever rotates smoothly on the same governor
tion pump cam shaft rotates around the governor support shaft. The bottom part of this lever is in contact with the
pin, driven by the cam shaft, and is force outwards by the sleeve through the shifter, which is in contact with the bot-
centrifugal force acting on the weight. tom of the tension lever through the excess fuel spring. It
The thrust force acting on the cam shaft due to this cen- therefore moves with the tension lever according to
trifical force acts on the lower part of the tension lever increases/decreases in engine speed.
through the sleeve. A starting excess fuel spring is mount-
ed on the bottom of the tension lever. The top of the governor lever is connected to the fuel
One end of the governor spring is hooked to the right upper pump control rack through the governor link. The move-
end of the tension lever, and the other end to the spring ment of the lever controls the volume of fuel injected by the
lever of the control lever shaft. pump. When speed increases the lever rotates clockwise
As the spring lever and control lever are mounted on the to cause the control rack to reduce fuel, and when speed
same shaft, when the control lever is turned towards full, decreases the lever rotates counterclockwise to cause the
the governor spring is pulled and the load gradually control rack to increase fuel, thus engine speed is con-
increases. trolled.
Since the tension lever can move freely around the gover-
nor shaft on the player bearing, as speed increases and The top of the tension lever comes in contact with the stop-
the shifter is pushed to the left, the tension lever rotates per built into the top of the governor case to limit the max-
clockwise, and when speed decreases, the tension lever imum fuel injection volume.
rotates counterclockwise.
Types of governors according to their different structures
Governors that are equipped with a YPES-CL series fuel

injection pump come in a number of variations. The gov-
ernor is designed in accordance with individual engine
structures and parts
(1) Shape of control and stop levers

The control and stop levers that operate the governor
have different shapes depending on engine design and
method of attachment, as seen in the pictures below.
The motion of the control lever is regulated by the max-
imum speed adjustment bolt and the idling adjustment
bolt. This maintains the necessary engine speed.
52
DSL 601
(2) Engine stop device

The stop lever can be operated by a push-pull cable,
magnetic solenoid or a stop motor. The governor is
equipped in one of three designs depending on the
intended purpose.
The engine can be stopped by pulling the stop

lever in direction A either manually or electrically
with a:
A
(1) Push-pull cable.
(2) Stop motor.
(3) Magnetic solenoid.
This method always requires an electromagnetic

solenoid. The engine is started by pulling in direction
toward A, which is opposite that in method A above.
B When the engine current ceases, the engine is
stopped automatically by the solenoid return spring.
This is one lever control method has no stop lever.

The engine is stopped only by returning the control
C itself from the idle position.
(The idling adjustment mechanism must be
installed outside of the governor.)
53
DSL 601
(3) Torque rise equipment

As mentioned before, this governor has a structure that torque spring as torque rise equipment. In this way the
allows you to equip it with an angleich spring and/or requirements for different engines can be fulfilled.
With angleich spring With torque spring

Structure
Function
Optimum partial return percentage assured. Smooth torque rise characteristics obtained.
(4) Tension lever shape

The governor has a design which allows you to adjust tension lever of the governor spring. This is a very
the speed compensation rate for partial loads. This valuable feature for engines in which performance
can be done by changing the governor spring hook depends on low speed torque. It also promotes
position of the tension lever and with the adaptable better use of generator engines using 50 Hz/60 Hz.
Type A Type B
Structure
54
DSL 601
1-6 Function of Governor (2) Starting control

Moving the control lever to the max. speed position
(1) Function of governor pulls the governor spring, and moves the tension lever
Following is a representation of the movement until it comes in contact with the control stopper.
characteristics of the control rack at respective speeds, When this is done, the excess fuel spring located in
with the speed rising from 0, with the governor control between the tension lever and governor lever holds the
lever at the maximum speed position. control rack at the max. starting injection volume
position R
A-B.
After the engine is started, the excess fuel spring is

compressed when the centrifugal force of the governor
weight overcomes the set load of the excess fuel
spring as speed exceeds N , speed goes from B to
b
C’(on models with angleich spring) or B to C (on

models without angleich spring). The rack reaches the
position of R where the governor lever and tension
C
lever are interlocked.
A-B: Fuel volume condition during starting. Volume is

controlled by excess fuel spring.
B-C: The rack moves towards decrease after engine starts
and speed increase as the load of the excess fuel
spring is overcome by the centrifugal force of the
governor weight.
C-D: High torque at low speed is developed by increasing
fuel injection volume equivalent to the angleich
stroke.
D-E: Condition when the thrust force exceeds that of the
angleich spring force on the bottom of the tension
lever and it gradually pushes the rack to decrease
fuel when engine speed increases.
E-F: Condition when both right and left ends of the shifter
come in contact with the sleeve and the bottom of the
tension lever, and the control rack is kept at the nor-
mal position by the stopper. (max. injection volume
position on models not equipped with an angleich
spring)
F: Point when governor spring starts to take effect.
This is the rated output of the engine.
F’: Point when governor starts to take effect on models
with torque spring.
G: Continuous rating point (usually 85-90% injection
volume of F point).
H: No load max. speed
L: Low-idle position
55
DSL 601
(3) Idling (5) Necessity and function of angleich

Idling is controlled by the governor spring and excess Engine air intake efficiency decreases as speed
fuel spring as this governor is not equipped with an increases, while the pump injection characteristics
idling spring. When the control lever is returned to the tend to increase as speed rises, at the same rack posi-
idling position after the engine is started, the governor tion. Accordingly, the governor must satisfy the
spring tension decreases and the tension lever required injection curves represented in the diagram
descends clockwise, and the governor weight load below in order to obtain sufficient output at low speed,
keeps the governor spring and the excess fuel spring and not emit black smoke at high speed. The angleich
load in equilibrium to maintain idling speed at (R ).
L spring was devised to provide for maximum torque at
low speed by setting injection volume at point A, and
shifting injection volume to point B’ at high engine
speed.
The angleich spring is mounted to the lower part of the

tension lever (however some engines are not equipped
with an angleich spring depending on usage and speed
NOTE: Depending on specifications, the governor can be range utilized).
provided with an idling spring. When engine speed is low, the governor weight cannot
compress the angleich spring as the angleich spring
(4) Maximum speed load is larger than the governor weight thrust load, and
The angle of the control lever is set at determined the control rack is held at a position (Rc) to increase
engine speed. The governor keeps engine speed con- injection volume.
stant by adjusting speed when load changes. Furthermore, as engine speed rises, the angleich spring
For example, if the operator moves the control lever is gradually compressed as governor weight thrust load
with the link from the idling position to max. output, increases and exceeds angleich load, before high speed
governor spring tension increases, the tension lever is control is effected. When the governor lever and the bot-
pulled until it comes in contact with the full load stop- tom of the tension lever come into contact (end of angle-
per, the movement of the governor lever is transmitted ich stroke), injection volume is reduced by that amount,
to the control rack via the link, maintaining the full load and the rack reaches the rated position (R ).
E
rack position, and engine speed increases until the

governor weight thrust load and governor spring ten-
sion come into equilibrium at full load max.speed.
56
DSL 601
(6) Necessity of torque spring and function

Engines used in construction machinery are subjected
to sudden loads which cause a decrease in speed and
sometimes results in stopping of the engine. A torque
spring is provided to move the control rack towards
injection volume increase when engine speed
decreases, to increase torque to withstand overloads,
and in turn prevent the engine from stopping. The
governor control lever is fixed at point G in the diagram
at right, the continuous rated output position. At this
time, when engine is loaded, the tension lever encom-
passes the torque spring, the control rack comes away
from full load stopper, and fluctuates between G and H
according to engine load.
When the load on the engine exceeds the continuous
rated output, speed decreases, governor spring ten-
sion exceeds the governor weight thrust load and over
comes the torque spring set load. The tension lever
then gradually causes the control rack to move
towards injection volume increase via the governor
lever and link, and the torque rise stroke ends when
the control rack reaches F’.
57
DSL 601
The torque spring thus provides for increasing injection (8) Stopping engine
volume when speed decreases to increase engine The engine stops when you turn the governor control
torque and in turn prevent engine stopping due to sud- lever all the way towards stop.
den increases in load, which also provides for strong On engines equipped with a stop device, the engine
engine output characteristics. can be stopped by moving the control rack to the stop
position, regardless of the control lever position.
(7) No-load maximum speed
When the load decreases from full load max. speed
and engine speed increases, the increased thrust load
of the governor weight acting on the governor spring
through the tension lever exceeds the set load of the
spring, the tension lever and governor lever descend
clockwise; the control rack is pushed to the no-load
injection volume position (RH) and the engine is oper-
ated at no-load max. speed.
When the engine is being used at a partial load, the
governor spring functions in the same way at a lower
speed (i, i”-j) as for full load max. speed, as the gover-
nor spring set load is smaller.
58
DSL 601
00.3.2 Disassembly, Reassembly and Inspection

of Governor
1 Governor case 12 Washer 23 Adjusting spring assembly

2 Governor case cover 13 Governor link 24 Governor weight assembly
3 Control lever 14 Governor shaft 25 Governor weight
4 Governor lever assembly 15 Control lever shaft 26 Pin
5 Governor lever 16 Governor spring 27 Governor weight support
6 Tension lever 17 Stop lever 28 Governor weight nut
7 Bushing 18 Stop lever return spring 29 Governor sleeve
8 Spring pin 19 Stop lever stop pin 30 Control rack
9 Shim 20 Torque spring assembly 31 Fuel pump cam shaft
10 Throttle spring 21 Angleich spring assembly
11 Shifter 22 Fuel stopper (limit bolt) assembly
59
DSL 601
2-1 Governor disassembly (3) Remove the governor case bolt. Remove the governor
case (parallel pin) from the fuel pump unit while lightly
Type YPES Governor tapping the governor case with a wood hammer. Create
a gap between the governor case and fuel pump by
(1) Remove the governor case cover. moving only the moving parts of the governor lever.
(4) Pull out the governor link snap pin by inserting needle
nosed pliers between the fuel pump and governor case.
NOTE: Loosen the hex bolt on models with an angleich

spring.
(2) Remove the control lever hex nut, and pull out the
control lever from the control lever shaft.
(5) The governor and fuel pump come apart by sliding the
governor case and fuel pump apart and pulling out the
link pin of the fuel control rack.
60
DSL 601
(8) Remove the snap-rings on both ends of the governor

lever shaft.
(6) Remove the stop lever return spring from the governor (9) Put a rod 8mm (0.3150in.) in dia. or less in one end of
lever shaft. the governor lever shaft, and tap the governor shaft
until the O-ring comes out the other side of the
governor case.
(7) Use needle nosed pliers to unhook the governor (10) After you remove the O-ring, lightly tap the end of the
spring from the tension lever and control lever shaft. shaft that you removed the O-ring from, and remove
the governor lever shaft. Then remove the governor
shaft assembly and washer.
61
DSL 601
NOTE: The governor assembly consists of the governor

lever, tension bar, bushing, throttle spring and
shifter, and is normally not disassembled.
The spring pin is removed when you replace the
shifter or throttle spring.
(12) When you need to pull out the stop lever, remove the
stop lever shaft stop pin, and lightly tap the inside of
the governor case.
(11) Remove the governor link from the governor lever. (13) When you need to pull out the control lever shaft, tap
the end of the shaft with a wood hammer.
NOTE: 1. Do not remove the fuel limit nut from the

governor case unless necessary.
62
DSL 601
2. On models with torque springs, first remove the (16) Remove the governor weight assembly from the fuel
box nut and stop nut, and then the torque spring pump cam using the governor weight pulling tools.
assembly.
(14) Pull out the governor sleeve on the end of the fuel
camshaft by hand.
(15) Turn the governor weight with a box spanner two or

three times to loosen it, stopping it with the hole in the
fuel coupling ring or holding the coupling with a vise.
NOTE: The governor weight assembly is made up of

the governor weight, support and pin. Do not
NOTE: When the taper fit comes apart after you have disassemble.
removed the nut, the governor weight may fly out
--Be Careful.
63
DSL 601
2-2 Inspection of governor 2) Measure the free length of the governor spring, and
replace if it exceeds the limit.
Inspection of governor weight assembly See service data sheet for free length of governor
(1) Replace the governor weight if it does not open and spring.
close smoothly.
(6) Inspection of angleich spring

assembly
(2) Replace the governor weight if the contact surface with 1) Inspect the sliding surface
governor sleeve is extremely worn. of piston and the contact
(3) Replace if there is governor weight support/pin wear or surface with shifter, and
caulking is loose. replace if necessary.
(4) Replace if the governor weight support stopper is 2) Replace the angleich spring
excessively worn. assembly if it is broken.
Inspection of governor sleeve
Sectional view of angleich

spring.
(7) Inspection of torque spring assembly
1) Inspect the tip of the piston and contact surface for
wear and replace if necessary.
2) Replace the assembly if the torque spring is broken.
(1) Replace the governor sleeve if the contact surface with

governor weight is worn or there is pitching.
(2) Replace the governor sleeve if the contact surface with
shifter is considerably worn or there is pitching.
(3) If the governor sleeve does not move smoothly above
the cam shaft due to governor sleeve inner dia. wear
or other reasons, replace.
2-3 Assembling governor
Inspection of governor lever assembly
(1) Measure the clearance between the governor shaft Inspect all parts after disassembly and replace any parts
and bushing, and replace if it exceeds the limit. as necessary. Before starting reassembly, clean new parts
mm(in.) and parts to be reused, and put them in order.
Standard Standard Make sure to readjust the unit after reassembly to obtain
Limit
Dimensions Clearance the specified performance.
Governor shaft 7.986~7.995
outer dia. (0.3144~0.3147) 0.065~0.124 0.5
8.060~8.110 (0.0025~0.0048) (0.0196)
(1) Insert the governor weight assembly in the taper por-
Bushing inner dia.
(0.3173~0.3192) tion at the end of the fuel pump camshaft, stopping it
(2) Inspect the shifter contact surface, and replace the with the hole in the fuel coupling ring or holding the
shifter (always by removing the pin to disassemble) if it coupling with a vise, mount the rest, and tighten the
is worn or scorched. governor weight nut.
(3) Disassemble and replace excess fuel springs that are
settled, broken ar corroded by pulling the spring pin.
(4) Check link parts for bends or kinks that will cause mal-
functioning, and replace any parts as necessary.
NOTE: 1. Side gap on top of governor lever shaft.

mm(in.)
Standard side gap 0.4(0.0157)
2. Replace the governor lever, tension bar,

bushing, shifter and throttle spring as an kg-m(ft-lb)
45-5.0
assembly. YPES type
(32.54-36.16)
(5) Inspection of springs

1) Check the governor spring and other springs and
replace if they are broken, settled or corroded.
64
DSL 601
(2) Open the governor weight to the outside, and insert the (6) Mount the governor lever assembly to the governor
sleeve in the end of the fuel pump camshaft. link.
NOTE: 1. Make sure that the correct governor link mount-

ing holes are used, and that it is mounted in the
correct direction.
2. Make sure that the governor link moves
NOTE: Make sure that the sleeve moves smoothly after smoothly.
inserting it.
(3) When the stop lever has been disassembled, mount (7) Put the governor lever shaft assembly in the governor
the stop lever return spring on the stop lever, tap the case, insert the governor lever shaft, and tap it in until
stop lever lightly with a wooden hammer to insert it, the O-ring groove comes out the opposite side of the
and tighten the stop lever stop pin. governor case.
(4) When the control lever shaft has been removed, light-
ly tap the control lever shaft and washer from inside
the governor case, using an appropriate plate.
(5) If the governor has been disassembled, tap in the NOTE: 1. Fit the O-ring to the side you have tapped in.
spring pin.
2. Make sure to insert the governor lever shaft in

the correct direction.
65
DSL 601
3. DonÕt forget to mount the washers to both sides (9) Fit the stop lever return spring to the end of the
of the governor lever. governor lever shaft.
(8) After you have mounted the O-ring, tape the governor
lever in the opposite direction, and mount the (10) Hook the governor spring on the control lever shaft
E-shaped stop rings on the grooves at both ends. and tension lever hook with radio pliers.
(11) Pull the governor link as far as possible towards the

governor case mounting surface, insert the governor
link pin in the fuel control rack pin hole and fit the
snap pin on it.
NOTE: After mounting the governor lever assembly, make

sure the governor lever assembly moves smoothly.
66
DSL 601
(12) Mount the governor case to the fuel pump unit while
lightly tapping it with a wooden hammer, and tighten
the bolts.
(13) Place the adjusting spring and adjusting rod on the
governor case cover adjusting bolt, and mount the
governor case cover.
(14) Insert the control lever in the control lover shaft, and
tighten the nut.
NOTE: Move the control lever back and forth to make sure
that the entire link moves smoothly.
67
DSL 601
00.3.3 Disassembly, Reassembly and Inspection of

Fuel Injection Pump
1. Fuel pump housing 17. Bearing holder 33. Stop screw

2. Delivery valve holder stop 18. *Oil seal 34. Control rack
3. Delivery valve holder 19. Adjusting packing (shim) 35. Aux. spring
4. O-ring 20. Tappet stopper 36. Control rack stopper
5. Delivery valve stopper 21. Tappet assembly 37. Plunger barrel stopper
6. Delivery valve spring 22. Pin 38. Deflector
7. Delivery valve assembly 23. Roller guide 39. Pump side cover
8. Delivery valve 24. Roller (outer) 40. Pump bottom cover
9. Delivery valve seat 25. Roller (inner)
10. Delivery packing 26. Adjusting shim
NOTE: 1. Some models are equipped with ball bearings
11. Plunger assembly 27. Adjusting bolt and some with taper roller bearings.
12. Plunger barrel 28. Plunger spring seat B 2. *Oil seal: Some models are equipped with oil
13. Plunger 29. Plunger spring seals and some are not. The shape of the
14. Fuel pump camshaft 30. Plunger spring seat A
15. Bearing 31. Control sleeve bearing holder differs for models with and
16. Bearing 32. Control pinion B without oil seals.
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3-1 Disassembly of fuel injection pump (2) Remove the fuel feed pump.
NOTE: Do not disassemble the fuel feed pump. See
When disassembling the fuel pump, separate the parts for instructions for fuel feed pump for details.
each cylinder and be careful not to get them mixed up.
Be especially careful to keep the plunger/plunger barrel,
delivery valve/delivery valve seat and other assemblies
separate for each cylinder (the parts of each assembly
must be kept with that assembly and put back in the same
cylinder).
Preparation
1. Wash off the dirt and grease on the outside of the

pump with cleaning oil (kerosene or diesel oil) before
disassembly.
2. Perform work in a clean area.
3. Take off the fuel pump bottom cover and remove lubri-
cant oil.
4. Turn the fuel pump upside down to drain fuel oil.
(1) Loosen the nut with a box spanner and take it off,
holding it with the hole in the fuel coupling ring or
holding the coupling with a vise and take out the
governor weight assembly.
(3) Remove the fuel pump side cover.
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(4) Turn the camshaft until the roller guide is at the (7) Turn the fuel pump upside down, move all the roller
maximum head, and insert the plunger spring support guides to the plunger side, and then put the pump on
plate in between the plunger spring washer B (lower its side. Turn the camshaft to a position so that none
side) and fuel pump unit. of the cylinder cams hit the tappets.
(8) Put a plate against the governor end side of the
camshaft and lightly tap it, and pull out the camshaft
and drive side bearing.
(9) Remove the roller guide stop.
NOTE: If the camshaft does not turn, put double nuts on

the end of the cam shaft or remove the coupling.
(5) Remove the camshaft woodruff key.
(6) Put a screwdriver in the two grooves on the camshaft (10) Use a hammer handle or the like to push up the roller
bearing holder mounting surface, and pull out the cam- guide from the bottom of the pump, and remove the
shaft bearing holder. plunger spring support plate.
NOTE: 1. Make sure not to damage the oil seal with the
threaded part of the camshaft. NOTE: The plunger spring may make the roller guide and
2. Be careful not to loose the shims in between the plunger, etc. fly out when the plunger support
pump and bearing holder. plate is removed.
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(11) Remove the roller guide. (13) Loosen the small screw on control pinion.
NOTE: When you stand the fuel pump up, all of the roller
guides drop out at one time. Therefore, first
NOTE: 1. Check to make sure the match marks on the
remove the stop bolt for one cylinder at a time, and
pinion/sleeve are correct before loosening the
then the roller guide for each cylinder---continue
small screw on the control pinion, as the pinion
this process.
and sleeve come apart when the screw is
loosened. If the mark is hard to read or off
center, lightly inscribe a new mark. This will
serve as a guide when adjusting injection
volume later.
(12) Remove the plunger, plunger spring and lower washer 2. Keep parts separate for each cylinder
from the lower part of the pump. (14) Remove the control pinion, sleeve and upper rest.
NOTE: Keep the parts separate for each cylinder. NOTE: Keep the parts separate for each cylinder.
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(15) Remove the control rack stop bolt and remove the (17) Remove the delivery valve holder.
rack.
(18) Remove the delivery valve assembly.
Note: Be careful not to lose the spring on the control rack.
NOTE: 1. Be careful not to lose the delivery valve pack-

ing, delivery valve spring, delivery valve stopper
or other small parts.
2. Keep the delivery valve assemblies for each
cylinder clearly separated.
(19) Take the plunger barrel out from the top of pump.
(16) Loosen the delivery valve retainer stop bolt, and
remove the delivery valve holder stop.
NOTE: Keep it as a set with the plunger that was

removed earlier.
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3-2 Inspection of fuel injection pump of key grooves and deformation of screws on both
(1) Inspection of plunger ends, and replace if necessary.
1) Thoroughly wash the plungers, and replace plungers 2) Bearings
that have scratches on the plunger lead or are dis- Replace if the taper rollers or outer race surface is
colored. flaked or worn.
2) The plunger is in good condition if it slides down
smoothly when it is tilted about 60%. Repeat this
several times while turning the plunger. Repair or
replace if it slides down too quickly or if it stops part
way.
NOTE: Replace fuel camshafts and bearings together.
(5) Inspection of roller guide assembly

1) Roller
(2) Inspection of delivery valve
Replace if the surface is worn or flaked.

2) Roller Guide
Replace if the outer roller pin hole is extensively worn
or there are many scratches.
3) Replace if the play of the roller guide assembly pin/
roller is 0.2mm (0.0078in.) or more.
4) Injection timing adjustment bolt
Replace if the surface in contact with the plunger side
is unevenly or excessively worn.
1) Replace as a set if the delivery valve suck-back collar
or seat is scratched, scored, scuffed worn, etc. (6) Inspection of rack and pinion
2) The valve is in good condition if it returns when 1) Rack
released after being pushed down with your finger
(while the holes in the bottom of the delivery guide
seat are covered). Replace if necessary.
3) Likewise, the valve should completely close by its own
weight when you take your finger off the holes in the
bottom of the delivery guide sheet.
Inspect for bending of rack and wear or deformation
NOTE: When fitting new parts, wash with diesel oil and of fit with pinion.
perform the above inspection. 2) Pinion
Inspect for wear or deformation of fit with rack.
(3) Inspection of pump
1) Inspect for extreme wear or roller guide sliding surface. NOTE: If the tooth surface or sliding surface is not in
Scratches on the roller pin sliding surface are not a good working order, rack resistance increases,
problem. affecting the condition of the engine (rough rpm,
2) Inspect the plunger barrel seat. over running, etc.).
If there are burrs or discoloration, repair or replace as (7) Inspection of plunger spring and delivery spring
this will lead to dilution of the lubricant. Inspect springs for scratches, cracks, breakage,
(4) Inspection of fuel camshaft and bearings uneven wear and rust.
1) Fuel camshaft
Inspect for scratches or wear of camshaft, deformation
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DSL 601
(8) Inspection of oil seals (3) Place the control rack, and tighten the control rack
Inspect oil seals to see if they are burred or scratched. stop bolt.
(9) Inspection of roller guide stop
Inspect the side of the tip, replace if excessively worn.
(10) Inspection of O-rings
Inspect and replace if they are burred or cracked.
3-3 Reassembly of fuel injection pump
Preparation
After inspection, put all parts in order and clean.
See inspection of Fuel Pump for inspection procedure.
(1) Put in the plunger barrel from the top of pump.
NOTE: 1. Do not forget the rack aux. spring.

2. Make sure the rack moves smoothly through a
full cycle.
(4) Place the rack set screw (using the special tool) in the
rack stop bolt screw hole to fix the rack.
(5) Looking from the bottom of pump, align the match
marks on the rack and pinion.
NOTE: Make sure the barrel key groove is fitted properly (6) While holding the pinion with one hand and keeping it
to the barrel stop pin. aligned with the match mark, fit in the sleeve, and
lightly tighten the small pinion screw.
(2) Place the delivery valve assembly, packing, spring and
stopper from the top of the pump, in this order.
NOTE: Fitting of sleeve; Face towards small pinion

screws and align with match mark.
NOTE: Replace the delivery valve packing and O-ring.
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(7) Mount the plunger spring upper rest. (10) Insert the plunger spring support plate between the
plunger spring seat B (lower) and fuel pump, by put-
ting the handle of a hammer in the lower part of pump
and pushing the roller guide up.
NOTE: 1. Make sure to mount the upper rest with the

hollow side facing down.
2. Recheck to make sure that the rack moves
easily.
(8) Mount the plunger spring.
(9) Mount the lower rest on the head of the plunger, and NOTE: 1. Face the roller guide stop groove up, and align
fit the plunger in the lower part of pump while aligning with stop screw hole on pump.
the match marks on the plunger flange and the sleeve.
2. Check movement of rack. The plunger spring

may be out of place if movement is heavy-
insert a screwdriver and bring to correct posi-
tion.
3. When replacing the roller guide assembly, fit
shims and lightly tighten:
Standard shim thickness

Part code number
(11) Make sure that roller guide stop groove is in correct

position, and tighten roller guide stop bolt.
NOTE: If the plunger is mounted in the opposite direction,

the injection volume will increase abnormally and
cannot be adjusted.
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(12) Fit the bearings to both ends of the camshaft, and (15) Turn the camshaft, and pull out the plunger spring
insert from drive side by lightly tapping. support plate.
NOTE: Turn pump upside down, and tap camshaft in while

moving roller guide to plunger spring side. (16) Mount the fuel pump side cover.
(17) Tap in the camshaft wood ruff key.
(13) Fit the oil seal on the inside of the bearing retainer
and mount the bearing retainer.
NOTE: Coat the camshaft and oil seal with oil to prevent
the oil seal from being scratched.
(14) Fix the pump, lightly tap both ends of the cam shaft
with a wood hammer, and adjust the cam shaft side
clearance with the adjustment shims while checking
with side clearance gauge.
mm(in.)
0.02~0.05
Camshaft side clearance
(0.0007~0.0019)
Adjusting
Pull out adjusting shims if clearance is too small, and add NOTE: Fit double nuts to turn the camshaft.
adjusting shims if it is too large.
mm(in.)
0.50(0.0196)
Adjusting shim thickness 0.40(0.0157)
0.30(0.0118)
0.15(0.0059)
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(18) Tighten delivery valve retainer. (20) Mount the fuel feed pump
kg-m(ft-lb)
Tightening torque 3.5 ~ 4.0(25.31 ~ 28.93)
NOTE: See the item explaining reassembly of the fuel
NOTE: 1. Tighten the retainer as far as possible by handÐ feed pump.
if the bolt gets hard to turn part way, the packing
or delivery valve are out of place. Remove,cor-
rect, and start tightening again.
2. Overtightening can result in malfunctioning of
the rack.
(19) Fit the delivery retainer stop and tighten the stop bolt.
kg-m(ft-lb)
Tightening torque 0.3(2.16)
NOTE: Overtightening can upset the delivery retainer and

cause oil leakage.
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00.3.4 Adjustment of Fuel Injection Pump and Governor

Adjust the fuel injection pump after you have completed mm(in.)
reassembly. The pump itself must be readjusted with a Tester used 11 12 Part code number
special pump tester when you have replaced major parts Yanmar
110 150
158090-51010
such as the plunger assembly, roller guide assembly, fuel (4.3307) (5.9055)
camshaft, etc. Procure a pump tester like the one illus- 125 165
Robert Bosch 158090-51020
(4.9212) (6.4960)
trated below.
(4) Remove the control rack blind cover and fit the rack
4-1 Preparations (YPES type) indicator.
Next, turn the pinion from the side of the pump until the
Prepare for adjustment of the fuel injection pump as fol- control rack is at the maximum drive side position, and
lows: set it to the rack indicator scale standard position.
(1) Adjusting nozzle assembly and inspection of injection Then make sure that the control rack and rack indicator
starting pressure. slide smoothly.
kg/cm2(lb/in.2)
Adjusting nozzle type YDN-12SD12
165~175
Injection starting pressure
(2346.85~2489.08)
mm(in.)
2.0/6.0 x 600
Inner dia./outer dia.x length
(0.0787/0.2362 x 23.6220)
Minimum bending radius 25(0.9842)
(3) Mount the fuel injection pump on the pump tester plat-
form.
Part code number 158090-51500
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(5) Check control rack stroke Relation between top clearance, standard shim thickness
Make sure the rack position is at 11.5~12.5mm (0.4527 and pre-stroke.
~ 0.4921 in.) on the indicator scale when the governor
mm(in.)
control lever is set at the maximum operating position. 1.0(0.0394)
If it is not at this value, change the link connecting the 1.2(0.0472)
1.3(0.0512)
governor and control rack to adjust it. Adjusting shim thickness
1.4(0.0551)
1.5(0.0591)
1.6(0.0630)
NOTE: Links are available in 1mm (0.0394 in.) increments. Part Code Number 129155-51600
(6) Remove the plug in the oil fill hole on the top of the (1) Place the top clearance gauge on a level surface and
governor case, and fill the pump with about 200cc of set the gauge to zero.
pump oil or engine oil.
(7) Complete fuel oil piping and operate the pump tester to
purge the line of air.
(8) Set the pressure of oil feed from pump tester to injec-
tion pump at 0.2-0.3 kg/cm≈ (2.84-4.26 lb/in≈)
(2) Remove the injection pump delivery retainer, take out

the delivery valve assembly, insert the top clearance
gauge and tighten by hand.
4-2 Adjustment of top clearance
Adjust the top clearance (clearance between top of

plunger and top of barrel with cam at top dead point) of
each cylinder plunger to bring it to the specified value by
changing the thickness of the shims.
(3) Turn the camshaft, and bring cam to top dead point
while watching gauge needle.
mm(in.)
Top clearance
Pre-stroke
(Page 3-51)
Standard shim thickness
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(4) Read the gauge at this position, and adjust until the (1) Set the governor control lever to the operating position
clearance is at the specified value by changing adjust- and fix (bring plunger to the effective injection range),
ing shims. turn the camshaft clockwise, and check the injection
Tighten the adjusting screw after completing adjust- starting time (FID) of cylinder No.1 (start of discharge
ment. of fuel from the delivery retainer).
Cylinder No. Count from the drive side
Direction of rotation Right looking from drive side
(2) In the above state, set the tester needle to a position

easy to read on the flywheel scale, and check the
injection timing several times by reading the flywheel
scale, according to the injection order.
(Greater shim thickness decreases top clearance and

smaller shim thickness increases top clearance).
No. of cylinder 4 3
Injection order 1-3-4-2-1 1-3-2-1
Injection timing 90˚ 120˚
Allowable deviation +30´ +30´
NOTE: Adjust while watching gauge, and then tighten. (3) Readjust the top clearance of cylinders that are not
within the allowable deviation (increasing adjusting
(5) After adjustment is completed, insert the delivery valve shim thickness makes injection timing faster, and
assembly and tighten the delivery retainer. decreasing makes it slower).
kg-m(ft-lb) The change in injection timing effected by adjusting
3.5 ~ 4.0 shims is as follows:
Delivery retainer tightening torque
(25.31 ~ 28.93)
Change in injection timing
Repeat the above procedure to adjust the top clearance of Change in shim thickness
Cam angle Crank angle
each cylinder.
0.1mm(0.0039in) 0.5˚ 1.0˚
4-3 Adjusting of injection timing (4) When you have readjusted top clearance, make sure it
is within allowable values after completing adjustment.
After adjusting the top clearance for all cylinders, mm(in.)
check/adjust the injection timing. Allowable top clearance 0.3(0.0118)
NOTE: 1. All cylinders must be readjusted if one shows

less than the allowable value.
2. If the top clearance is less than the allowable
value, the plunger will hit the delivery valve or
the plunger flange will hit the plunger barrel.
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4-4 Plunger pressure test 4-6 Adjusting injection volume

(uniformity of each cylinder)
(1) Mount the pressure gauge to the delivery retainer of
the cylinder to be tested. The injection volume is determined by the fuel injection
pump rpm and rack position. Check and adjust to bring to
specified value.
4-6.1 Measuring injection volume
(1) Preparation
Set the pump rpm, rack position and measuring stroke
to the specified value and measure:
Pump RPM See separate service data
Pump rotating direction Right looking from drive side
Rack indicator scale See separate service data
reading (Page 3-51)
Remove the rack stop bolt behind the pump and screw in
1000 kg/cm2
the rack fixing bolt to fix rack.
Max. pressure gauge reading
(14223 lb/in.2)
Connecting screw dimensions M12 x 1.5
(2) Set the governor control lever to the stop position,

operate the injection pump at about 200rpm, and make
sure that the pressure gauge reading is 500 kg/cm≈
(7110 lb/in.≈) or more while lightly moving the control
pinion gear towards full throttle (drive side) from the
pump.
Replace the plunger if the pressure does not reach this
value.
(3) Immediately release the gear after pressure rises to
stop injection.
At the same time, check to see that oil is not leaking
from the delivery retainer or fuel injection piping, and
that there is no extreme drop in pressure.
4-5 Delivery valve pressure test
(1) Perform the plunger pressure test in the same way,

bringing the pressure to about 120 kg/cm≈ (1706 lb/in.≈),
and then stopping injection.
Part Code Number 158090-51510
(2) Measuring injection volume

Measure the injection volume at the standard stroke,
and adjust as follows if it is not within the specified
value.
Measuring stroke 1,000 st
Specified injection volume See injection pump
at standard rack position service data(Page 3-51)
Nonuniformity of cylinders ± 3%
(2) After pressure rises to the above value, measure the

time it takes to drop from 100~90 kg/cm≈ (1422~2702 4-6.2 Adjustment of injection volume
lb/in≈).
Compare the injection volume collected in measuring cylin-
100 ~ 90 kg/cm2 5 seconds ders for each cylinder, and adjust if necessary to obtain
(1422 ~ 2702 lb/ in2) (to drop 10 kg/cm2 (142 lb/ in2)
specified value.
If the pressure drops faster than this, wash the deliv- (1) Push the control rack all the way to the drive side, stop
ery valve, and retest. Replace the delivery valve if with rack fixing body, and loosen the pinion/sleeve fix-
the pressure continues to drop rapidly. ing bolt 1/3 revolution.
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(2) When the control sleeve is turned to the right or left, (2) Measure fuel injection volume at rack position (R ). 1
the plunger is turned through the same angle to in- Tightening of fuel limit bolt.
crease or decrease injection volume. (3) If the injection volume is at the specified value, tighten
The injection volume is increased when the control the fuel limit bolt lock nut at that position.
sleeve is turned in the direction of the right arrow on
fig. and is decreased when turned in the direction of 4-7.2 Adjusting RPM limit bolt
the left arrow on the figure.
(1) Gradually loosen the governor control lever while
keeping the pump drive condition in the same condition
as when the fuel limit bolt was adjusted, and adjust the
tightness of the RPM limit bolt to the point where the
rack position just exceeds the specified value (R ). 1
(3) Measure the injection volume of each cylinder again.

Repeat this process until the injection volume for every
cylinder is the same (within specified limit).
(4) Next, measure the injection volumes under different
conditions, and make sure the injection volume for
every cylinder is within specifications.
Replace the plunger if the injection volume is not with-
in specifications.
NOTE: See adjustment data for the specified injection vol-

ume value at other measurement points.
(5) After completing measurement, firmly tighten the pin-

ion/sleeve fixing screw. (2) Check maximum RPM at no load
(6) If not aligned with match mark, make a new match Further increase rpm, and make sure that rack position
mark. (R2 = R1 - L) corresponding to maximum rpm at no
load is within specified value (N2).
4-7 Adjustment of governor
No load max. RPM See separate service data
(Pump RPM) (Page 3-51)
4-7.1 Adjusting fuel limit bolt 4-7.3 Adjusting idling
(1) Adjust the tightness of the fuel limit bolt to bring the
rack position to the specified value (R ) with the gov-
1
(1) Maintain the pump rpm at specified rpm (N ). 3
ernor control lever all the way down towards the fuel
increase position, while keeping the pump at rated rpm
N.
1
Idling rpm(Pump RPM) See separate service data

(Page 3-51)
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DSL 601
(2) Measure the injection volume while lowering the

governor control lever to the idling position, and adjust
the position of the control lever with the idling adjust-
ment bolt to bring it to specified valve.
Measuring stroke See separate service data

Idling injection volume (Page 3-51)
4-7.4 Check injection volume when starting
(1) Make sure the control rack moves smoothly while

gradually reducing idling rpm.
(2) Next, fix the governor control lever at full load position
with the pump at specified rpm (N ). Make sure that
4
control rack is at maximum rack position.

Measure the injection volume and check to make sure
it is within the specified value.
Pump rpm(N4) 200 rpm
Rack indicator scale 11.5 ~ 12.5 mm(0.4527 ~ 0.4921 in.)
(4) After completing above, tighten lock nut to specified
Measuring stroke 1000st
torque, and mount governor case cover.
Injection volume See separate service data
(Page 3-51) kg-m(lb-ft)
Lock nut tightening torque 2.5 ~ 3.0(18.08 ~ 21.69)
4-8 Adjustment of torque rise
NOTE: Make sure that the angleich bolt does not turn
There are some models which obtain torque rise with with the locknut when tightening it.
angleich and torque springs incorporated in the fuel injec-
tion pump as an injection volume increasing mechanism. (5) Bring fuel injection pump to rated speed again, make
sure that control rack smoothly displaces torque rise
stroke, and that rack position (R ) and injection value
1
are with inspecified value at (N ) rpm.

1
4-8.2 Models with torque spring
The torque rise spring is corporated in the fuel limit bolt,

and is used as an assembly.
4-8.1 Models with angleich spring

Use the dummy nut during adjustment as shown in fig.,
For models with angleich spring, perform, this adjustment without torque rise stroke, and remove it after completing
after finishing speed limit bolt adjustment. adjustment.
(1) The angleich spring is used as an assembly.
(2) Bring the governor control lever to the full load position, Check injection stop
and keep pump speed at the specified peak torque Drive the pump at rated rpm (N ) and standard rack posi-
1
(N ).
5
tion (R ) with governor control lever at full load position,
1
(3) Remove governor case cover in this state and screw operate the stop lever on the back of the governor case,
angleich spring assembly to tension lever. Screw in and make sure that injection to all cylinders is stopped.
from contact position with governor lever (when control
lever starts to move), so that injection volume at torque NOTE: Be sure to remove the rack fixing bolt when doing
this.
rise is within specified values (0 deg.)
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DSL 601
00.3.5 Fuel Feed Pump

The fuel feed pump pumps fuel from the fuel tank, passes
it through the fuel filter element, and supplies it to the fuel
injection pump.
The fuel feed pump is mounted on the side of the engine,
and is driven by the (eccentric) cam of the fuel pump
camshaft. It is provided with a manual priming lever so
that fuel can be supplied when the engine is stopped.
5-1 Construction of fuel feed pump

(Fuel feed pump for YPES type)
1. Bottom body 6. Pin 11. Top body assembly

2. Piston spring 7. Lever return spring 12. Packing
3. Piston 8. Lever assembly 13. Cover
4. Diaphragm spring 9. O-ring 14. Small screw
5. Diaphragm assembly 10. Stop pin 15. Cap
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DSL 601
5-2 Fuel feed pump specifications (2) Attach a vinyl hose to the fuel feed pump intake, keep
the pump at the specified depth from the fuel oil sur-
Suction head 0.8 mm (2.57 ft) face, move the priming lever by hand and check for
230 cc/min (14.03 in. 3/min) sudden spurts of fuel oil from the discharge port.
Discharge volume at 1500 cam rpm, discharge pressure If oil does not spurt out, inspect the diaphragm and
of 0.2 kg/cm2 (2.84 lb/in2)
0.3 kg/cm2 (4.26 lb/in2)
diaphragm spring and repair/replace as necessary.
Closed off pressure (3) Diaphragm inspection
or more (at 400 cam rpm)
Parts of the diaphragm that are repeatedly burned will
5-3 Disassembly and reassembly of fuel feed become thinner or deteriorate over a long period of
pump time. Check diaphragm and replace if necessary.
5-3.1 Disassembly
(1) Remove the fuel feed pump mounting nut, and take the
fuel feed pump off the fuel injection pump.
(2) Clean the fuel feed pump assembly with fuel oil.
(3) After checking the orientation of the arrow on the cover,
make match marks on the upper body and cover,
remove the small screw, and disassemble the cover,
upper body and lower body.
5-3.2 Reassembly
(1) Clean all parts with fuel oil, inspect, and replace any
(4) Valve contact/mounting
defective parts.
Clean the valve seat and valve with air to remove any
(2) Replace any packings on parts that have been
foreign matter.
disassembled.
(3) Make sure that the intake valve and discharge valve on
upper body are mounted in the proper direction, and
that you don’t forget the valve packing.
(4) Assemble the diaphragm into the body, making sure
the diaphragm mounting holes are lined up (do not
force).
(5) Align the match marks on the upper body of the pump
and cover, and tighten the small screw evenly.
kg-cm(ft-lb)
Tightening torque 15 ~ 25(1.08 ~ 1.80)
5-4 Fuel feed pump inspection (5) Inspect the diaphragm spring and piston spring for set-
tling and the piston for wear, and replace as necessary.
(1) Place the fuel feed pump in kerosene, cover the dis-
charge port with your finger, move the priming lever NOTE: Replace parts as an assembly.
and check for air bubbles (Repair or replace any part
which emits air bubbles).
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DSL 601
00.3.6 Fuel Injection Nozzle

When fuel oil pumped by the fuel injection pump reaches 6-1 Functioning of fuel injection nozzle
the injection nozzle, it pushes up the nozzle valve (held
down by spring), and is injected into the combustion cham- Fuel from the fuel injection pump passes through the oil
ber at high pressure. port in the nozzle holder, and enters the nozzle body reser-
The fuel is atomized by the nozzle to mix uniformly with the voir.
air in the combustion chamber. How well the fuel is mixed When oil reaches the specified pressure, it pushes up the
with high temperature air directly affects combustion effi- nozzle valve (held by the nozzle spring), and is injected
ciency, engine performance and fuel economy. through the small hole on the tip of the nozzle body.
Accordingly, the fuel injection nozzles must be kept in top The nozzle valve is automatically pushed down by the noz-
condition to maintain performance and operating efficien- zle spring and closed after fuel is injected.
cy. Oil that leaks from between the nozzle valve and nozzle
body goes from the hole on top of the nozzle spring
through the oil leakage fitting and back into the fuel tank.
Adjustment of injection starting pressure is effected with
the adjusting shims.
6-2 Type/construction of fuel injection nozzle The YPES-CL fuel injection pump is designed for use with
both direct and indirect injection engines. The hole type/
There are two types of fuel injection nozzles. Direct injec- pintle type of fuel injection nozzles are used according to
tion engines are equipped with the hole type, and indirect the engine type.
injection engines with the pintle type. The type of fuel injection nozzle used depends on the type
of engine.
(1) Hole type fuel injection nozzle
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DSL 601
Nozzle opening
pressure
Nozzle angle
No. of nozzles x dia.
(Page 3-51)
Identification No.
(Nozzle type)
Engine model
(2) Pintle type fuel injection nozzle
Nozzle type YDN - PD
Nozzle opending pressure 120 kg/cm2
Identification number YDN - OPD2
87
DSL 601
(3) Nozzle body identification number 6-3 Fuel injection nozzle disassembly
The type of nozzle can be determined from the number
inscribed on the outside of the nozzle body. NOTE: 1. Disassemble fuel injection nozzle in a clean
1) Hole type fuel injection nozzles area as for fuel injection pump.
2. When disassembling more than one fuel injection
(Sample) nozzle, keep the parts for each injection nozzle
separate for each cylinder (i.e. the nozzle for
cylinder 1 must be remounted in cylinder 1).
(1) When removing the injection nozzle from the cylinder

head, remove the high pressure fuel pipe, fuel leakage
pipe, etc., the injection nozzle retainer nut, and then the
fuel injection nozzle.
Pintle type fuel injection nozzles

(Sample)
Hole Type
88
DSL 601
(2) Put the nozzle in a vise (4) Clean the nozzle seat with cleaning spray.
NOTE: Use the special nozzle holder for the hole type
injection nozzle so that the high pressure mounting
threads are not damaged.
(3) Remove the nozzle nut
(5) Clean off the carbon on the tip of nozzle with a piece of
wood.
(6) Clean hole type nozzles with a nozzle cleaning needle.
NOTE: Use a special box spanner for the hole type (the
thickness of the two nozzle nuts is 15mm
(0.5906in.)).
(4) Remove the inner parts

Part Code Number 28210 - 000010
NOTE: Be careful not to loosen the spring seat, adjusting

shims or other small parts.
6-4 Fuel injection nozzle inspection
6-4.1 Washing
(1) Make sure to use new diesel oil to wash the fuel injec-
tion nozzle parts.
(2) Wash the nozzle in clean diesel oil with the nozzle
cleaning kit.
6-4.2 Nozzle inspection
(1) Inspect for scratches/wear

Inspect oil seals for abnormal scratches or wear and
replace nozzle if the nozzle sliding surface or seat are
scratched or abnormally worn.
(2) Check nozzle sliding
1) Diesel Kiki nozzle cleaning key: Wash the nozzle and nozzle body in clean diesel oil,
Type NP-8486B No. 5789-001 and make sure that when the nozzle is pulled out about
2) Anzen Jidosha Co., Ltd. nozzle cleaning kit: half way from the body, it slides down by itself when
Type NCK-001 released.
(3) Clean off the carbon on the outside of the nozzle body
with a brass brush.
89
DSL 601
Rotate the nozzle a little; replace nozzle/nozzle body as a (4) Inspecting nozzle spring
set if there are some places where it does not slide Replace the nozzle spring if it is extremely bent, or the
smoothly. surface is scratched or rusted.
(5) Nozzle holder

Check oil seal surface for scratches/wear; replace if
wear is excessive.
6-5 Fuel injection nozzle reassembly
The fuel injection nozzle is reassembled in the opposite

order to disassembly.
(1) Insert the adjusting shims, nozzle spring and nozzle

spring seat in the nozzle holder, mount the stop plate
with the pin, insert the nozzle body/nozzle set and
tighten the nut.
(2) Use the special holder when tightening the nut for the
hole type nozzle as in disassembly.
(3) Inspecting stopper Nozzle nut tightening torque

kg-m (ft-lb)
Check for scratches/wear in seals on both ends, check Hole type nozzle 4 ~ 4.5(28.9 ~ 32.5)
for abnormal wear on the surface where it comes in Pintle type nozzle 4 - 4.5(28.9 - 32.5)
contact with the nozzle; replace if stop plate is exces-
sively worn. 6-6 Adjusting fuel injection nozzle
6-6.1 Adjusting opening pressure
Mount the fuel injection nozzle on the nozzle tester and

use the handle to measure injection starting pressure. If it
is not at specified pressure, use the adjusting shims to
increase/decrease pressure (both hole and pintle types).
mm(in.)
Nozzle contact surface wear limit 0.1(0.0039)
90
DSL 601
Injection starting pressure 2) Pintle nozzle

2 2
kg-cm (lb/in. )
Slowly operate nozzle tester and observe spray con-
Hole type 195 ~ 205 (2773 ~2915) dition.
Pintle type 115 - 125 (1635 - 1778) (1) The injection should not come in a stream or be
off center.
6-6.2 Injection test (2) A straight conical spray pattern should form along
the center line of the nozzle. The cone angle
After adjusting the nozzle to the specified starting pres- should be 5-10 degrees.
sure, check the fuel spray condition and seat oil tightness. (3) Place a sheet of white paper 30cm below the
(1) Check seat oil tightness nozzle. The injection spray should form a perfect
After two or three injections, gradually increase the circle.
pressure up to 20 kg/cm≈ (284lb/in.≈) before reading (4) No oil should drip from the nozzle after injection.
the starting pressure, maintain the pressure for 5 sec- (5) Oil should not spread from the injection hole
onds, and make sure that no oil is dripping from the tip when pressure is brought to a little less than 10
of the nozzle.
kg/cm2.
Test the injection with a nozzle tester; retighten and
(6) Test the injection with a nozzle tester; retighten
test again if there is excessive oil leakage from the
and test again if there is excessive oil leakage
overflow coupling.
from the Overflow coupling.
Replace the nozzle as a set if oil leakage is still exces-
Replace the nozzle as a set if oil leakage is still
sive.
excessive.
(2) Injection spray condition
Operate the nozzle tester lever once or twice a second
and check for abnormal injection.
1) Hole type nozzles
Replace hole type nozzles that do not satisfy the fol-
lowing conditions:
•Proper spray angle (0)
•Correct injection angle(a)
•Complete atomization of fuel
•Prompt starting/stopping of injection
91
DSL 601
00.3.7 Troubleshooting
1. Troubleshooting of fuel injection pump Basic check points
Complete repair means not only replacing defective • Check for breaks or oil leaks throughout the fuel system,
parts, but finding and eliminating the cause of the trou- from the fuel tank to the nozzle.
ble as well. The cause of the trouble may not neces- • Check the injection timings for all cylinders. Are they
sarily be in the pump itself, but may be in the engine or correctly adjusted? Are they too fast or too slow?
the fuel system. If the pump is removed prematurely, • Check the nozzle spray.
the true cause of the trouble may never be known. • Check the fuel delivery. Is it in good condition? Loosen
Before removing the pump from the engine, at least go the fuel pipe connection at the injection pump inlet, and
through the basic check points given here. test operate the fuel feed pump.
2. Major faults and troubleshooting
Fault Cause Remedy
(1) No fuel in the fuel tank. Resupply

(2) Fuel tank cock is closed. Open
(3) Fuel pipe system is clogged. Clean
(4) Fuel filter element is clogged. Disassemble and clean,
1. Engine won’t Fuel not delivered or replace element
start. to injection pump (5) Air is sucked into the fuel due to defective connections in the Repair
piping from the fuel tank to the fuel pump.
(6) Defective valve contact of feed pump. Repair or replace
(7) Piston spring of feed pump is broken. Replace
(8) Inter - spindle or tappets of feed pump are stuck. Repair or replace
(1) Defective connection of control lever and accel. rod of injection Repair or adjust
. pump.
Fuel delivered to (2) Plunger is worn out or stuck. Repair or replace
injection pump (3) Delivery valve is stuck. Repair or replace
(4) Control rack doesn’t move. Repair or replace
(5) Injection pump coupling is damaged, of the key is broken. Replace
(1) Nozzle valve doesn’t open or close normally. Repair or replace

(2) Nozzle seat is defective. Repair or replace
Nozzle doesn’t (3) Case nut is loose. Inspect and tighten
work. (4) Injection nozzle starting pressure is too low. Adjust
(5) Nozzle spring is broken. Replace
(6) Fuel oil filter is clogged. Repair or replace
(7) Excessive oil leaks from the nozzle sliding area. Replace the nozzle assembly
(1) Inject timing is retarded due to failure of the coupling. Adjust

Injection timing is (2) Camshaft is excessivelly worn. Replace camshaft
defective (3) Roller guide incorrectly adjusted of excessively worn. Adust or replace
(4) Plunger is excessively worn. Replace plunger assembly
(1) Fuel pipe is clogged. Clean

(2) Fuel filter is clogged. Disassemble and clean,
2. Engine starts, but immediatelly or replace the element.
stops. (3) Improper air - tightness of the fuel pipe conncetion, or pipe is Replace packing ; repair pipe
broken and air is being sucked in.
(4) Insufficient fuel delivery from the feed pump. Repair or replace
92
DSL 601
Fault Cause Remedy
3. Engine’s Defective injection (1) Knocking sounds caused by improper (too fast) injection timing. Inspect ans adjust
output is timing, and other (2) Engine overheats or emits large amount of smoke due to Inspect and adjust
insufficient failures. improper (too slow) injection timing.
(3) Insufficient fuel delivery from feed pump. Repair or replace
Nozzle movement (1) Case nut is loose Inspect and adjust

is defective (2) Defective injection nozzle performance Repair or replace nozzle
(3) Nozzle spring is broken. Replace
(4) Excessive oil leaks from nozzle. Replace nozzle assembly
(1) Max. delivery limit bolt is screwed in too far. Adjust

(2) Plunger is worn. Replace
(3) Inject amount is not uniform. Adjust
(4) Inject timings are not even. Adjust
Injection pump is (5) The 1st and 2nd levers of the governor and the control rack of Repair
defective the injection pump are improperly lined up.
(6) Delivery stopper is loose. Inspect and retighten
(7) Delivery packing is defective. Replace packing
(8) Delivery valve seat is defective. Repair or replace
(9) Delivery spring is broken. Replace
4. lding is rough. (1) Movement of control rack is defective.

1) Stiff plunger movement or sticking. Repair or replace
2) Rack and pinion fitting is defective. Repair
3) Movement of governor is improper. Repair
4) Delivery stopper is too tight. Inspect and adjust
(2) Uneven injection volume. Adjust
(3) Injection timing is defective. Adjust
(4) Plunger is worn and fuel injection adjustment is difficult. Replace
(5) Governor spring is too weak. Replace
(6) Feed pump can’t feed oil at low speeds. Repair or replace
(7) Fuel supply is insufficient at low speeds due to clogging of Disassemble and clean,
fule filter. or replace element
5. Engine runs at high speeds, but (1) The wire or rod of the accelerator is caught. Inspect and repair
cuts out at low speeds. (2) Control rack is caught and can’t be moved. Inspect and repair
(1) Governor spring is broken or excessively worn. Replace

6. Engine doesn’t reach max. rpm.
(2) Injection performance of nozzle is poor. Repair or replace
7. Loud knocking (1) Injection timing is too fast or too slow. Adjust
(2) Injection from nozzle is improper. Adjust
Fuel drips after each injection.
(3) Injection nozzle starting pressure is too high. Adjust
(4) Uneven injection. Adjust
(5) Engine overheats or insufficient compression. Repair
8. Engine emits (1) Injection timing is too fast. Adjust

too much When exhaust (2) Air volume intake is insufficient. Inspect and repair
smoke. smoke is black: (3) The amount of injection is uneven. Adjust
(4) Injection from nozzle is improper. Repair or replace
(1) Injection timing is too slow. Adjust

(2) Water is mixed in fuel. Inspect fuel system,
When exhaust
and clean
smole is white:
(3) Shortage of lube oil in the engine. Repair
(4) Engine is over - cooled. Inspect
93
DSL 601
00.3.8 Fuel Filter

The fuel filter, which is located between the fuel feed pump Specifications
Applicable
and the fuel injection pump, removes any impurities from 4TNE84
model
the fuel. It has a replaceable paper type element to ensure Type Paper
consistent fuel filtration. Filtration area 900cm2
The sucking action of the fuel injection pump draws fuel (139.5in 2)
from the fuel tank and into the filter element to remove dirt Filtration grain
8 - 9u
dia.
particles. Clean fuel flows to the interior of the filter ele-
Air venting method Auto - air venting
ment, up through the central passage, into the outlet pas-
Element code 129100 - 55650
sage, and to the fuel injection pump.
Inspection
Check and completely clean the fuel filter with clean fuel oil
if it is contaminated with deposits, water, etc. The filter ele-
ment should be replaced every 500 service hours, or soon-
er if it is stained or broken. If the fuel appears to be cont-
aminated, check the filter carefully and replace it even if
the maximum number of service hours has not been
reached.
Cleaning the inside Every 300 service
filter hours 100 hours
(First time)
Replacing of filter Every 500 hours
element
94
DSL 601
00.3.9 Air Venting System

[DI engine]
The DI engine is equipped with an automatic air venting

system. The check valve attached between the fuel filter
and the fuel injection pump has an air venting hole. The
air accumulated in the fuel line when fuel is fed by the
fuel feed pump is vented through the air venting hole out
of the fuel line. For the IDI engine, air is vented with an
air venting plug.
95
DSL 601
00.3.10 Service Data

Model 4TNE84
VM
Fuel injection equipment
assembly (1) + (2) + (3) -
code number
(1) Fuel Assembly code
-
injection number
pump Plunger
mm ø7.5
Plunger diameter
barrel 35˚ lower
Lead
assembly deg lead
angle
(right)
Suck back
mm3/st 23.6
Delivery volume ; Q
valve Angleich
mm 0.1
assembly cut
Identification GM
(2) Governor Spring kg/
0.253
Governor constant mm
spring Free
mm 40
lenghth
Type B
Tension lever (length between the supporting points)
(R=67)
Torque
Torque
rise Type
spring
devie
Engine stop device Type A
(3) Fuel
Diaphragm
feed Type
type
pump
96
DSL 601
00 Engine, 4TNE84 00.4 Lubricating System
00.4 LUBRICATING SYSTEM

00.4.1 LUBRICATION SYSTEM ...........................................................................98
00.4.2 LUBE OIL PUMP........................................................................100

00.4.2.1 LUBE OIL PUMP CONSTRUCTION .......................................100
00.4.2.2 SPECIFICATIONS OF LUBE OIL PUMP................................101
00.4.2.3 LUBE OIL PUMP DISASSEMBLY ....................................102
00.4.2.4 LUBE OIL PUMP INSPECTION ......................................1 0 2
00.4.3 LUBE OIL FILTER & OIL PRESSURE CONTROL VALVE .............103
00.4.3.1 LUBE OIL FILTER CONSTRUCTION ..............................1 0 3
00.4.3.2 LUBE OIL FILTER REPLACEMENT.................................104
00.4.3.3 OIL PRESSURE CONTROL VALVE REPLACEMENT .......104
00.4.4 SERVICE DATA .........................................................................105
97
DSL 601
00.4.1 Lubrication System

Lubricating oil is important for lubricating the reciprocating The lubricating oil in the main gallery is distributed among
or moving parts of the crankshaft, camshaft, cylinder-pis- the crank journal, idle gear shaft, and fuel injection pump.
ton, etc. The lube oil also cools, cleans and prevents cor- (1) The lubricating oil in the crank journal lubricates the
rosion of these parts. The engine’s durability is largely crank pin, and is partly fed to the camshaft bearing on
dependent on the quality and viscosity of the lube oil. the gear housing side. The lubricating oil which has
Since the lube oil degenerates according to the use of the passed through the drill hole of the cylinder body and
engine, it is important to replace the oil periodically. of the cylinder head is fed to the valve rocker arm shaft
Lubricating oil is pumped up from the oil pan through the and to lubricate the rocker arm and valve actuating
lubricating oil strainer and suction pipe by the lube oil system.
pump, and is fed to the lubricating oil filter through drilled (2) The lubricating oil fed to the idle gear shaft through the
hole of the cylinder block and the filter bracket. drill hole lubricates idle gear faces through idle gear
The lubricating oil is filtered by the filter element and pres- bearing.
sure controlled by the oil pressure control valve, and then (3) The lubricating oil in the main gallery is also fed to the
fed to the main gallery of the cylinder. fuel injection pump through piping.
98
DSL 601
99
DSL 601
00.4.2 Lube Oil Pump

2-1 Lube oil pump construction
The trochoid type lube oil pump is mounted on the gear

case side engine plate, and the rotor shaft gear is driven
by the crankshaft gear.
The lube oil flows from the intake filter mounted on the bot-
tom of the cylinder body through the holes in the cylinder
body and engine plate, and out from the holes in the
engine plate and cylinder body to the discharge filter.
100
DSL 601
2-2 Specification of lube oil pump

Engine speed
Gear ratio
(crank gear/pump gear) See separate service data
pump speed (Page 105)

Discharge volume
Discharge pressure
Recommended lube oil : SAE #30, temperature 55 - 65˚C(131 - 149D)
101
DSL 601
2-3 Lube oil pump disassembly

(1) Remove the lube oil pump assembly from the engine
plate.
(2) The lube oil pump cover may be disassembled, but do
not disassemble the rotor, rotor shaft or drive gear.
The oil pressure regulating valve plug is coated with
adhesive and screwed in, so it cannot be disassem-
bled. These parts cannot be reused after disassembly.
Replace if necessary as an assembly.
2-4 Lube oil pump inspection
(1) Clearance between outer rotor and pump body mm(in.)

Insert a feeler gauge between the outer rotor and Standard Wear limit
pump body to measure the clearance, and replace if it Outer rotor and See separate service data
exceeds the limit. inner rotor clearance (Page 4-8)
(3) Clearance between pump body and inner rotor side of
outer rotor
Place a straight-edge against the end of the pump body
and insert a feeler gauge between the straight-edge
and the rotor to measure side clearance. Replace the
assembly if the clearance exceeds the limit.
mm(in.)
Standard Wear limit
Outer rotor and See separate service data
pump body clearance (Page 4-8)
(2) Clearance between outer rotor and inner rotor

To measure clearance, insert a feeler gauge between
mm(in.)
the top of the inner rotor tooth and the top of the outer
rotor tooth, and replace if it exceeds the limit. Standard Wear limit
Pump body and inner rotor, See separate service data
outer rotor clearance (Page 4-8)
(4) Clearance between rotor shaft and side cover
Measure the rotor shaft outer diameter and the side
cover hole diameter, and replace the entire assembly if
the clearance exceeds the limit.
mm(in.)
Standard Wear limit
Rotor shaft and See separate service data
body clearance (Page 4-8)
(5) Check for looseness of driver gear/rotor shaft fitting,
and replace the entire assembly if loose or wobbly.
(6) Push the oil pressure regulating valve piston from the
oil hole side, and replace the assembly if the piston
does not return due to spring breakage, etc.
(7) Make sure that the rotor shaft rotates smoothly and
easily when the drive gear is rotated.
Turning torque less than 1.5 kg - cm (0.108 ft - lb)
102
DSL 601
00.4.3 Lube Oil Filter & Oil Pressure Control Valve

3-1 Lube oil filter construction
The lube oil filter is a full-flow paper element type, mount-

ed to the side of the cylinder body with the filter bracket. It
is an easy to remove cartridge type filter.
To prevent seizure in the event of the filter clogging up, a
bypass circuit is provided in the oil filter. The bypass valve
in the filter element opens when the difference in pressure
in front and behind the paper element reaches 0.8 ~ 1.2
kg/cm2 (11.38 ~ 17.06 lb/in2).
103
DSL 601
Type
3-3 Oil pressure control valve replacement
Filtration area
The control valve has been adjusted and assembled at the
Discharge volume See separate service data
factory, so it should not be disassembled without good rea-
Pressure loss (Page 4-8) son.
By-pass valve If the oil pressure control valve is disassembled due to
regulating pressure spring trouble, etc., mount a pressure gauge to the cylin-
der body main gallery, and adjust the pressure with adjust-
ment shims until it is at the specified value.
3-2 Lube oil filter replacement

Regulating pressure See separate service data
(1) Period (Page 4-8)
The paper element will get clogged up with dirt after

long hours of usage, and eventually unfiltered oil will
be fed to the engine through the bypass circuit.
Replace the filter according to the following standard,
as the dirt in unfiltered oil will of course have a
detrimental affect on the engine.
Oil filter replacement period Every 300 hours of
engine operation
(2) Replacement
1) Remove the lube oil filter with the special tool.
2) Clean the filter mounting surface on the filter bracket
and mounting screws.
3) Coat the filter rubber packing with lube oil.
4) Screw in the filter until the rubber packing comes in
contact with the bracket mounting surface, and then
2 ~ 3 turns more.
5) Run the engine after mounting the filter, and make
sure that there is no oil leakage.
104
DSL 601
00.4.4 Service Data

Model 4TNE84
Application code S/VM
Unit Standard Wear limit
Engine
rpm 3000 -
speed
Gear ratio - 28/29 -
Specifications Pump
rpm 2897 -
of lube speed
oil pum Discharge L/min 30.0 -
volume (US gal/min) (7.923) -
2
Discharge kg/cm 3 -
pressure (PSI) (42.66) -
Outer rotor and pump mm 0.10 - 0.17 0.25
body clearance (in) (0.0039 - 0.0067) (0.0098)
Outer rotor and inner mm 0.05 - 0.105 0.15
rotor tip clearance (in) (0.0019 - 0.0041) (0.0059)
Pump body and inner

mm 0.03 - 0.09 0.15
rotor, outer rotor side
(in) (0.0011 - 0.0035) (0.0059)
clearance
Rotor shaft and body mm 0.015 - 0.048 0.2
clearance (in) (0.0006 - 00035) (0.0078)
Full flow, paper

Type - -
element
Filtration m2
0.10(155) -
area (in2)
Lube oil Max.

L/min
filter discharge 30(7.923) -
(US gal/min)
volume
Pressure kg/cm2 0.3 - 0.5

-
loss (PSI) (4.27 - 7.11)
By pass
kg/cm2 0.8 - 1.2
-
valve
(PSI) (11.38 - 17.06)
regulating
pressure
kg/cm2 3.0 - 4.0 -

Regulatingpressure
(PSI) (42.66 - 56.88)
105
DSL 601
106
DSL 601
00 Engine, 4TNE84 00.5 Cooling System
00.5 COOLING SYSTEM

00.5.1 COOLING SYSTEM .................................................................................108
00.5.2 RADIATOR ................................................................................109

00.5.2.1 RADIATOR SPECIFICATIONS.................................................109
00.5.2.2 CAP CHECK ...............................................................................109
00.5.2.3 CHECK FOR LEAKS IN THE RADIATOR AND
COOLING WATER SYSTEM ....................................................109
00.5.3 RADIATOR FAN BELT .............................................................................110

00.5.3.1 FAN BELT TENSION..................................................................110
00.5.4 THERMOSTAT ............................................................................111

00.5.4.1 THERMOSTAT INSPECTION ...................................................111
00.5.4.2 TESTING THERMOSTAT.................................................111
00.5.4.3 THERMOSWITCH ...........................................................111
00.5.5 COOLING WATER PUMP .......................................................................112

00.5.5.1 COOLING WATER PUMP INSPECTION...........................112
00.5.5.2 WATER PUMP DISASSEMBLY ....................................... 112
00.5.6 SERVICE DATA..........................................................................114
107
DSL 601
00.5.1 Cooling System

The engine employs the forced circulation radiator
cooling system, which includes a thermostat in the cir-
cuit. Cooling water is forcibly circulated by the cooling
water pump. Cooling water cooled by the radiator is
sucked from the radiator lower tank by the cooling
water pump and is circulated to each part under pres-
sure.
(1) Cooling water pump

If the drain plug leaks, replace the mechanical
seal.
(2) Sub-tank
As the engine is operated, cooling water
temperature rises. Water temperature rise is
inhibited by the radiator. Overload operation or
extended continuous operation further raises cool
ing water temperature and steam pressure in the
cooling system. When the steam pressure
exceeds 0.9 kg/cm2 the pressure cap opens,
exhausts steam, and consumes cooling water
consumption. Supply the sub-tank with fresh
water so that the sub-tank water level is kept
between the LOW mark and FULL mark in cold
state.
108
DSL 601
1-3 Check for leaks in the radiator and cooling water

00.5.2 Radiator system
1-1 Radiator specifications
It is advisable to perform this check with the engine
Engine warmed up.
Coolant capacity
Radiator
Cooling water pump type
(1) Wait until the engine is cooled, then carefully remove
Radiator capacity See separate service
the radiator cap.
(2) Fill the radiator with coolant up to the normal water
Thermostat data
level.
Radiator fan pusher (Page 5 - 6)
(3) Connect the adapter furnished with a tester unit.
Radiator cap working pressure
Connect the tip to the adapter to the water filler port.
Fan belt tension (4) Operate the pump and apply the amount of pressure
Thermoswitch indicated on the radiator cap. Excessive pressure may
break the radiator and/or hose.
1-2 Cap check
0.9kgf/cm2
Applied pressure
(1) Attach the cap to the tester. (0.9 Bar / 12.8psi)
(2) Operate the water pump of the tester to build up water
pressure. The cap is working if the gauge needle stays (5) With pressure applied, check the following:
within the normal pressure range for 6 seconds. If the • Hose connections
water pressure does not rise, or if it drops immediately • Radiator cooling water pump packing
after it has risen, either the cap packing is worn, • Radiator coolant drain plug
cracked or broken, or the cap spring has deteriorated.
Replaced the cap
(6) If the gauge indicates a drop in pressure, but no cool-

ant leakage is detected, coolant may be leaking from
the cooling water system and/or gaskets of the cylinder
block and cylinder head. The engine must be disas-
sembled for the check.
(3) Remove the cap, turn it 180°, and retest it. This is to
eliminate any possibility of an inaccurate measure-
ment. Remove and test the cap twice.
0.9kgf/cm2
Cap working pressure
(0.9 Bar / 12.8psi)
109
DSL 601
00.5.3 Radiator Fan Belt

The radiator fan belt is subject to stretching, due to the wet
and other possible damage after a long period of service.
3-1 Fan belt tension
(1) If the belt is loose, it will slip, causing the battery to be

undercharged, the cooling system to malfunction, and
the V-belt groove to wear abnormally. Check the ten-
sion periodically and adjust it if required.
Press hard with the fingers to get

Belt Tension
a play of 10 - 15 mm(0.4 - 0.6in.)
Measuring belt tension
(2) Loosen the charging generator bolts and shift the

generator until the belt has the proper tension. When
the belt has been replaced, check the tension for any
damage after 20 and 50 hours.
110
DSL 601
(3) Heat the water and measure the water temperature

00.5.4 Thermostat with a thermometer. Check temperature at which the
thermostat first opens and at full lift.
4-1 Thermostat inspection
Note: Do not let the thermostat touch the bottom of the
Remove the thermostat cover and take out the thermostat.
hot container.
Clean off scale and rust, then inspect the thermostat.
Replace with new one, if the characteristics (performance)
(4) Measure the lift height of the thermostat when fully
have changed, and check the spring etc. for damage and
open.
corrosion.
4-3 Thermoswitch
Thermoswitch inspection
(1) Connect the lead wires and suspend the thermoswitch
in a container with oil.
(2) Heat the oil and measure the oil temperature with a
thermometer when the continuity occurs.
Temperature for continuity 110°C (230°F)
(3) After the measurement, remove extraneous oil away
on the thermoswitch.
4-2 Testing Thermostat
(1) Replace the thermostat is it opens at room tempera-

ture.
(2) Suspend the thermostat in a container filled with water.
111
DSL 601
00.5.5 Cooling Water Pump

5-1 Cooling water pump inspection
(1) Make sure that the pump shaft rotates smoothly.
(2) Make sure that there is no “play” on the pump shaft.
If there is excessive play, disassemble the pump and
replace the pump shaft with bearing.
(3) Make sure that cooling water does not leak from the
hole in the lower section of the pump unit during
operation. If there is leakage, the mechanical seal in
the hole may be broken. Disassemble the pump and
replace the mechanical seal.
(4) Measure the clearance between the impeller and the
pump body.
Checking meachanical seal leakage
Measuring clearance between impeller and pump body
mm(in.)
Standard Wear limit
Clearance between 0.3~1.1 1.5
Impeller and body (0.0118~0.0433) (0.0590)
112
DSL 601
5-2 Water pump disassembly
(1) Remove the water pump

(2) Remove the impeller using a gear puller.
Removing impeller
(3) Remove the mechanical seal.

(4) Remove the fan pulley flange using a gear puller.
Removing pulley flange
(5) Remove the snap ring.

(6) Press the pump shaft and bearing assembly out from
the impeller end to the fan pulley end.
(7) Reassemble in the reverse order of disassembly.
(8) Install the water pump.
113
DSL 601
00.5.6 Service Data

Model 4TNE84
Application code S/VM
Engine L(US qt.) 2.7(2.85)
Coolant
3.5
Capacity Radiator L(Us qt.)
(3.7)
Cooling water pump type - Centrifugal
Radiator Capacity K cal/h 29200
Wax pellet type, open : 71˚C(160˚F)
Thermostat - Full open : 85˚C(185˚F)
Left height Min. 8mm(0.31in.)
Type,
Pusher
blade,
Radiator Fan 6370
mm dia.
Ident.E
Identification
Radiator cap working kg/cm2
0.9(12.8)
pressure (PSI)
Deflection
Fan belt tension mm(in.)
10 - 15(0.4 - 0.6)
Thermoswitch
ON : 107 -113˚C(225 - 235˚F)
(Water temperature
Hysteresis 10˚C or less(50˚F or less)
sender switch)
114
DSL 601
00 Engine, 4TNE84 00.6 Air Induction System
00.6 AIR INDUCTION

SYSTEM
00.6.1 AIR CLEANER ...........................................................................116
00.6.1.1 DESCRIPTION ............................................................................116
00.6.1.2 MAINTENANCE ..........................................................................116
115
DSL 601
00.6.1 Air Cleaner

1-1 Description
The air cleaner is an important engine component that pro-

motes longer diesel engine life. The engine intakes air into
the air cleaner, and the filter element removes dust and grit
from the air to prevent cylinder and piston wear.
(4) Cleaning the filter element

1) From the inside of the element blow a stream of dry,
clean compressed air upwards and downwards
against the folds of the element to blow away dust
that has collected. If the air pressure is too high, the
element may break, therefore do not exceed
2 kgf/cm2 (2 Bar/28 psi) air pressure.
2) After cleaning the element with compressed air, be
sure to check it for pinholes, as well as for breakdown
or deformation.
3) Do not use any oil in the dry-type air cleaner’s dust-
1-2 Maintenance cup.
(1) If the outer surface of the filter element is clogged with (5) Precautions for replacing the element
dust, there will be a reduction in the amount of air and 1) Check the rubber-lined washer and rubber packing.
a drop in horsepower. If the engine is operated in a If the rubber part of the rubber-lined washer or
dusty area, clean the air element every-50 hours. rubber packing is broken or deformed, replace the
(2) If the engine is used in a relatively dust free area, clean defective part.
it every 100 hours. 2) Check for damage to the suction port pipe on the
(3) Replace the filter element as follows: air cleaner, which is coupled to the engine, and be
1) Every 250 hours of operation in dusty area. sure the hose band is tight.
2) Every 500 hours in relatively dust free areas. 3) Check the condition of the suction port pipe on the air
3) Replace it yearly whether or not the specified duration cleaner which is coupled to the engine, and be sure
has been reached. the hose band is tight.
116
DSL 601
Caution on maintenance
1. Perform the maintenance of the air cleaner at appro- 6. Check the element with cyclon vanes for larger dust
priate intervals. (If the air cleaner is equipped with particles deposited on the element and vanes and for
the dust indicator, maintenance should preferably be deformation.
performed after a clogging alarm is raised.)
7. Never remove the cyclon vane from the element
Note that unnecessary maintenance is useless and may when cleaning the element.
rather cause damage. Carefully clean the element, until dust on the element
• For example, dust is introduced while the element is is sufficiently removed.
mounted or removed.
• The element is flawed or deformed. 8. In the case of the element with the unloader valve,
check for trouble such as hardened rubber parts.
2. Be sure to stop the engine before removing the element.
Do not start the engine with the element left removed. 9. Check to see if: –
1) the element is tightly sealed in the body.
3. Carefully prevent dust deposits on the element from 2) the seal washer (tightening the element) is sufficient-
entering the secondary side (the air cleaner outlet) ly air-tight.
when taking out the element. 3) the paper element is securely bonded to plates on
both ends. (Poor bonding may cause dust to leak.)
4. If the element has pinholes, replace it with a new one. 4) there is an excessive clearance between the body
and the periphery of the element. (The allowable
5. To clean the element, blow into the element or flush the clearance is 1mm or less.)
element. (some elements allow flushing with the An excessive clearance causes the element to run
specified detergent.) out under vibration, and dust may leak along the
Do not strike the air cleaner to protect the element packing of the element.
from a shock or impact. 5) the unloader valve is properly attached in the down-
Be sure to blow air from the inside of the element to ward direction.
the outside. After flushing the element, rinse it careful- 6) the notch of the baffle plate properly faces upward.
ly and allow it to thoroughly dry before use.
117
DSL 601
118
DSL 601
00 Engine, 4TNE84 00.7 Electrical System
00.7 ELECTRICAL SYSTEM

00.7.1 ELECTRICAL SCHEMATIC..........................................................122
00.7.2 STARTER MOTOR ......................................................................125

00.7.2.1 SPECIFICATION AND PERFORMANCE................................125
00.7.2.2 CONSTRUCTION .......................................................................126
00.7.2.2.1 Conventional type starter motor ...............................126
00.7.2.3 ADJUSTMENT AND PERFORMANCE TEST ........................129
00.7.2.3.1 L-size measurement (gap between pinion
and pinion stopper).....................................................129
00.7.2.3.2 Pinion movement .........................................................129
00.7.2.3.3 Plunger movement ......................................................129
00.7.2.3.4 Mesh Clearance...........................................................129
00.7.2.4 DISASSEMBLY ...........................................................................130
00.7.2.4.1 Magnetic switch ...........................................................130
00.7.2.4.2 Rear cover ....................................................................130
00.7.2.4.3 Brush holder .................................................................130
00.7.2.4.4 Yoke ...............................................................................130
00.7.2.4.5 Armature .......................................................................130
00.7.2.4.6 Pinion ............................................................................131
00.7.2.5 INSPECTION ..............................................................................132
00.7.2.5.1 Armature .......................................................................132
00.7.2.5.2 Field coil .......................................................................133
00.7.2.5.3 Brush .............................................................................133
00.7.2.5.4 Magnetic switch ...........................................................134
00.7.2.5.5 Pinion ............................................................................135
00.7.2.6 REASSEMBLY PRECAUTIONS ...............................................135
00.7.2.7 TESTING .....................................................................................135
00.7.2.7.1 No load test ..................................................................135
00.7.2.8 MAINTENANCE STANDARD ...................................................136
00.7.2.9 VARIOUS PROBLEMS AND THEIR REMEDIES ..................137
00.7.3 CHARGING EQUIPMENT ........................................................................139

00.7.3.1 FEATURES ..................................................................................139
00.7.3.2 SPECIFICATIONS ......................................................................139
00.7.3.3 CHARACTERISTICS .................................................................139
00.7.3.4 CONSTRUCTION .......................................................................140
00.7.3.5 ALTERNATOR FUNCTIONING ................................................141
00.7.3.6 HANDLING PRECAUTIONS.....................................................141
119
DSL 601
00.7.3.7 DISASSEMBLING THE ALTERNATOR...................................142

00.7.3.8 INSPECTION AND ADJUSTMENT..........................................143
00.7.3.9 REASSEMBLING THE ALTERNATOR ....................................145
00.7.3.10 PERFORMANCE TEST .............................................................146
00.7.3.11 TROUBLESHOOTING ................................................................149
00.7.4 STARTING AIDS.......................................................................................150
00.7.5 BATTERY ...................................................................................................151

00.7.5.1 BATTERY CAPACITY AND BATTERY CABLES ...................151
00.7.5.1.1 Battery capacity ...........................................................151
00.7.5.1.2 Battery cable ................................................................151
00.7.5.2 BATTERY INSPECTION ...........................................................152
00.7.5.3 BATTERY CHARGING ..............................................................153
00.7.6 SERVICE DATA ........................................................................................154
120
DSL 601
121
DSL 601
00.7.1 Electrical Schematic
122
DSL 601
WIRING SCHEMATIC-ELECTRIC
MODEL : 1340XL / DSL602
122.1
123
DSL 601
Instrument panel layout
Front
9 10 8 11 14 13 12 15
E F
2 3 4 5 6 7 1 16 17 18 19
For more information about the instrument panel, see sec-

tion 06 Electrical System, 2-5, Instrument Panel.
1) Key Switch
2) Water temperature warning light
3) Engine oil pressure warning light
4) Charge warning light
5) HST oil temperature warning light
6) HST pressure warning light
7) Oil filter warning light
8) Warning light
9) Stop light
10) Buzzer
11) Light switch
12) Pre-heat light
13) Parking brake light
14) Fuel gage
15) Hour meter
16) Fuse-lamp
17) Fuse-instrument panel
18) Fuse-start
19) Fuse-horn
NOTE: The left-hand instrument panel is a sealed unit.

Warning lamps cannot be replaced individually. In the right-
hand unit, the pre-heat light (12) and parking brake light (13)
can be replaced from the back.
124
DSL 601
00.7.2 Starter Motor

The starter motor is installed on the flywheel housing. (1) Identification of the starter motor.
When the starting key switch is turned on, the starter motor
pinion flies out and engages the ring gear of the flywheel. Engine Model Srarter model (Mfg.) Type
Then the main contact is closed, current flows, and the 4TNE84 VM S13-41C (Hitachi) Conventional
engine is started.
After the engine starts, the pinion automatically returns to
its initial position when the starting key switch is released.
Once the engine starts, the starting key switch should be
released immediately. Otherwise, the starter motor may
be damaged or burned out.
2.1 Specification and Performance.

Engine Model
Model
Rating (sec.)
Output (kW)
Direction of rotation
(viewed from pinion side)
Weight kg (lb.)
Clutch system
Engagement system See separate service
No. of pinion teeth data
Pinion coming out voltage (page 154)
Terminal voltage (V)
No-load Current (A)
Speed (rpm)
Terminal voltage (V)
Loaded
Current (A)
characteristics
Torque kg-m (ft-lb.)
S13-41C
current(A)
125
DSL 601
2-2 Construction
The started motor described in this section is a conven- (2) Motor

tional pre-engaged 4-bush 4-pole starter motor with a A continuous current series motor which generates ro-
screw roller drive clutch. tational drive power.
The starter motor is composed of three major parts, (3) Pinion
as follows: Transfers driving power from motor to ring gear.
(1) Magnetic switch An over-speed clutch is employed to prevent damage
Moves plunger to engage and disengage pinion and, if the engine should run too fast.
through the engagement lever, opens and closes the
main contact (moving contact) to stop the starter
motor.
2-2.1 Conventional type starter motor
126
DSL 601
To prevent the motor receiving a shock when the engine

starts and over-runs, the starter motor has an over-running
clutch.
127
DSL 601
(2) Operation
Key switch ON
Series coil } are energized

Shunt coil } are energized
Plunger is attracted. Pinion and

pinion shaft are pushed out by
shift lever.
Pinion is normally
engaged. Pinion strikes ring gear.
Pinion is engaged with ring gear
Pinion is engaged with Pinion is not engaged

ring gear. with ring gear.
Torsion spring
and plunger moves
again.
Main contractor closes to Main contactor closes

carry a large current to carry a large current
to motor. to motor.
Rotated armature turns Rotated armature turns

pinion through reduce- pinion through reduce-
tion gears. tion gears.
Ring gear is rotated. Pinion is released from

ring gear, and engaged Ring gear is rotated
with ring gear by
torsion spring to rotate
ring gear.
Check if engine has started.

Turn key switch OFF.
Magnetic switch no longer attracts

pinion. Main contactor opens.
Plunger and shift lever are returned

to the original position by torsion
spring; pinion by pinion return
spring.
Motor (armature) stops. Key switch is turned OFF
128
DSL 601
2-3 Adjustment and performance test
2-3.1 L-size measurement (gap between pinion and 2-3.3 Plunger movement
pinion stopper)
Adjustment made by adjusting stroke of magnetic plunger
[Conventional starter motor] to the prescribed value. Adjust the l dimension installing
shim (Adjust plate) at the magnetic switch section.
When the pinion is at the projected position, measure gap There are two kind of shim [Thickness 0.5 mm (0.0197 in.),
between pinion and pinion stopper. This check should be 0.8mm (0.0315 in.)]
made with the pinion pressed back lightly to take up any
play in the engagement linkage.
mm (in.)
Starter motor M diminsion
(Page 154)
2-3.4 Mesh clearance
Mesh clearance is the distance between the flywheel ring

gear and starter motor pinion in the rest position. This
clearance should be between 3mm (0.1181in.)to 5mm
(0.1969in.).
2-3.2 Pinion movement
After complete assembly of the starter motor, connect up

the motor as in following figures.
129
DSL 601
2-4 Disassembly
[Conventional starter motor]
2-4.1 Magnetic switch 2-4.3 Brush holder
(1) Disconnect magnetic switch wiring. (1) Lift (-) brush from the commutator.
(2) Remove magnetic switch mounting bolt. (2) Remove (+) brush from the brush holder.
(3) Remove magnetic switch. (3) Remove brush holder.
(4) Separate the switch shift lever.
(5) Remove the torsion spring. (for Reduction type Starter For Reduction type:
Motor) Pull out torsion spring on magnetic switch.
(1) Removing yoke, armature, and brush holder.
Pull out yoke, armature, and brush holder simultane-
ously. Gently pull out brush and commutator so that
they may not interfere with the surrounding section.
2-4.2 Rear cover
(1) Remove dust cover.
2-4.4 Yoke
(1) Remove yoke. Pull it out slowly so that it does not

strike against other parts.
(2) Remove E-ring, and remove thrust washer (be careful

not to lose the washer and shim).
(3) Remove the two through bolts holding the rear cover
and the two screws holding the brush holder.
(4) Remove rear cover.
130
DSL 601
2-4.5 Armature
(1) Slide pinion stopper to pinion side.
(2) Remove the pinion stopper clip.
2-4.6 Pinion
(1) Slide the pinion stopper to the pinion side.

(2) Remove the pinion stopper clip.
(3) Remove the pinion from the armature.
131
DSL 601
2-5 Inspection
2-5.1 Armature
(1) Commutator (2) Mica undercut

Inspect the surface of the commutator. If corroded or Check the mica undercut, correct with a hacksaw
pitted, sand with #500 ~ #600 sandpaper. Replace blade when the undercut is too shallow.
the commutator if damage is irreparable.
mm (in.)
Maintenance Repair limit
Standard
Mica undercut
(Page 154)
(3) Armature coil ground test

Using a circuit tester, check for the insulation between
Maintenance Wear limit the commutator piece and the shaft (or armature core).
Standard
Commutator
If there is continuity, replace the armature.
outside diameter
Commutator run - out See separate service data
Difference between (Page 154)
maximum diameter and
minimum dianeter
132
DSL 601
Armature coil short test (3) Cleaning the inside of the yoke
Place the iron piece on the armature fitted to the layer If any carbon powder or rust has collected on the
short tester and turn the armature. If the iron piece inside of the yoke, blow the yoke out with dry
vibrates, there is a short circuit and the armature should be compressed air.
replaced. *Do not remove the field coil from the yoke.
(4) Armature shaft outside diameter

Measure the outside diameter of the armature shaft at
four locations: front, center, end, and pinion. Replace
the armature if the shaft is excessively worn. 2-5.3 Brush
Check the bend of the shaft; replace the armature if the
bend exceeds 0.08mm (0.0031in.) The brushes are quickly worn down by the motor. When
the brushes are defective, the output of the motor will drop.
2-5.2 Field coil
(1) Open test

Check for continuity between the terminals of the field
coil. If there is no continuity, the coil is open and must
be replaced.
(1) Brush dimensions

Replace brushes which have been worn beyond the
specified wear limit.
mm (in.)
Brush standard height See separate service data
(2) Short test
Wear limit (page 154)
Check for continuity between the yoke and any field
coil terminal. If there is continuity, the coil is shorted
and it must be replaced.
133
DSL 601
(2) Brush appearance and movement in brush holder 2-5.4 Magnetic switch
If the outside of the brush is damaged, replace it. If the
movement of the brushes in the brush holder is hamp- (1) Shunt coil continuity test
ered because the holder is rusted, repair or replace the Check for continuity between the S terminal and the
holder. magnetic switch body (metal part). If discontinuity,
(3) Brush spring the coil is open and the switch must be replaced.
Since the brush spring pushes the brush against the
commutator while the motor is running, a weak or
defective spring will cause excessive brush wear,
resulting in sparking between the brush and the
commutator during operation. Measure the spring
force with a spring balance; replace the spring when
the difference between the standard value and the
measured value exceeds ± 0.2kg.

Coil resistance (at 20 ûC) (page 154)
Standard spring load (page 154)
(2) Series coil continuity test

(4) Brush holder ground test Check for continuity between the S terminal and M
Check for continuity between the insulated brush hold- terminal. If discontinuity, the coil is open and that it
er and the base of the brush holder assembly. Cont- must be replaced.
inuity indicates that these two points are grounded and
that the holder must be replaced.

Resistance value (at 20 ûC) (page 154)
134
DSL 601
(3) Contactor contact test (2) Mounting the magnetic switch

Push the plunger with your finger and check for Attach the shift lever to the pinion; assemble the gear
continuity between the M terminal and B terminal. case as shown below.
If discontinuity, the contact is faulty and the Do not forget to install the dust cover before assem-
contactor must be replaced. bling the gear case.
After reassembly, check by conducting no-load opera-
tion.
(3) Lubrication
Lubricate each bearing and spline (points indicated in
the figure below) with high quality “Hitachi Electrical
Equipment Grease A”
The following lubricants may be used in place of Hitachi
Electrical Equipment Grease A.
2-5.5 Pinion Magnetic switch plunger Shell Aeorshell No. 7
Bearing and slpine Shell Albaria Grease No. 2
(1) Inspect the pinion teeth and replace the pinon if the
teeth are excessively worn or damaged.
(2) Check if the pinion slides smoothly; replace the pinion
2-7 Testing
if faulty.
(3) Inspect the springs and replace if faulty. 2-7.1 No load test
(4) Replace the clutch if it slips or seizes.
Test procedure
(1) Connect the positive side of the ammeter (A) to the
2-6 Reassembly precautions
positive terminal of the battery, and connect the
negative side of the ammeter to the B terminal of the
Reassemble the starter motor in the reverse order of dis-
starter.
assembly, paying particular attention to the following:
(1) Torsion spring and shift lever
Hook the torsion spring into the hole in the magnetic
switch and insert the shift lever into the notch in the
plunger of the magnetic switch (through the torsion
spring).
(2) Connect the negative terminal of the battery to the

body of the starter.
(3) Connect the positive side of the voltmeter (V) to the B
terminal of the starter, and connect the negative side
of the voltmeter to the body of the starter.
(4) Attach the tachometer.
(5) Connect the switch between the B terminal and S
terminal of the starter.
135
DSL 601
• The magnetic switch should begin operation, and the

speed, current, and voltage should be at the prescribed
values.
• A fully charged battery must be used.
• Since a large current flows when the starter is operat-
ed, close the protection circuit switch before initial
operation, then open the switch and measure the cur-
rent after the starter reaches a constant speed.
• The test should be carried out immediately because
the rating of the starter motor is 30 seconds.
2-8 Maintenance standard
Standard spring load kg (lb)

Brush Standard height mm (in.)
Wear limit mm (in.)
Series coil resistance A
Magnetic switch
Shunt coil resistance A
Outside diameter Maintenance standard mm (in.)
Wear limit mm (in.)
Difference between
minimum diameter Repair limit mm (in.)
Commutator
and maximum
diameter Repair accuracy mm (in.)
Maintenance standard mm(in.)
Mica undercut
Repair limit mm (in.)
Shaft diameter mm (in.)
Rear side bearing
Bearing inside diameter mm (in.)
Intermediate bearing
Standard dimension Shaft diameter mm (in.)
Pinion Sliding section
Pinion inside diameter mm (in.)
Pinion side bearing
136
DSL 601
2-9 Various problems and their remedies
(1) Pinion fails to advance when the starting switch is closed

Problem Cause Corrective action
Wiring Open or loose battery or switch terminal Repair or retighten
Threaded part connected to pinion section of armature shaft Repair contacts
Starting switch
is damaged, and the pinion does not move or replace switch
Threaded part connected to pinion section of amature shaft
Starter motor Replace
is damaged, and the pinion does not move
Magnetic switch Plunger of magnetic switch malfunctioning or coil shorted Repair or replace
(2) Pinion is engaged and motor rotates, but rotation is not transmitted to the engine

Starting motor Faulty over-running clutch Replace
(3) Motor rotates at full power before pinion engages ring gear

Starting motor Torsion spring permantly strained Replace
(4) Pinion engages ring gear, but starter motor fails to rotate

Wires connecting battery and magnetic switch open or wire connecting
Wiring Repair, retighten, or replace wire
ground, magnetic switch and motor terminal loose
Faulty pinion and ring gear engagement Replace
Faulty motor mounting Remount
Starter motor Dirty commutator Repair
Faulty armature, field coil Repair or replace
Loose field coil and brush connection Retighten
Faulty contactor contact Replace
Magnetic switch
Pitted contactor contact Replace
(5) Motor fails to stop when starting switch is opened after engine starts

Starting switch Faulty switch Replace
Magnetic switch Faulty switch Replace
137
DSL 601
Check Item Troubleshooting

3. Troubleshooting for Starting Motor
Engine will
not turn
*1
Check battery for
charge level. Poor Check or replace battery.
Engine Turns Yes Starter No Check battery termi- Repair connection and corrosion
by crank? turns? nals for connection and corrosion of battery terminals.
and corrosion
Check starter relay for wiring

Good
system.
Repair if necessary.
Starter relay sounds No • Key swich
when operating? • Starter relay
Yes • Connection
Yes
Check wiring up to magnetic
switch.
Starter magnetic Repair if necessary.
No
switch sounds when Repair or replace magnetic switch.
operating?
Yes • Adjust L-dimension

Yes • Check shift lever for deforma-
Yes Check pinion roller Pinion is normally tion, return spring for fatigue,
Gear shaft Poor
clutch for breakage. engaged with ring and pinion for sliding condition.
turns? Repair if broken. gear?
• Check pinion and ring gear for
engagement. Correct or replace
Good if necessary.
Check reduction gears Connect battery

(armature and gear shaft) directly to starter No Replace motor
for breakage. terminal M. Motor (field coil or armature)
Replace if necessary. turns?
Yes
Check battery for
charging level. Check magnetic If any trouble is found, remove
Motor turns Poor wiring at the battery terminal on
Check battery termi- switch contact.
normally? nal for connection Replace if defective. the side.
and corrosion.
Good Motor does not stop
even if key switch is
Good
OFF.
Check fuel system
Check engine oil Poor
for viscosity Replace engine oil
Repair or replace key switch,

Good starter relay, or magnetic switch.
Replace a new
Yes Repair or replace
starter motor.
starter
Motor turns?
No
Check engine
internally
138
DSL 601
00.7.3 Charging Equipment

[A] Alternator (12V-20A/12V-35A)
The alternator serves to keep the battery constantly charg- 3-2 Specifications
ed. It is installed on the cylinder block by a bracket, and is
driven from the V-pulley at the end of the crankshaft by a Model of alternator LR120 - 15C LR135 - 91
V-belt. Model of IC regulator TRIZ - 63 TRIZ - 63
The type of alternator used in this engine is ideal for high Battery voltage 12 V 12 V
speed engines with a wide range of engine speeds. It con- Norminal output 12 V / 20 A 12 V / 35 A
tains diodes that convert AC to DC, and an IC regulator Earthpolarity Negative earth Negative earth
that keeps the generated voltage constant even when the Direction of rotation
engine speed changes. (Viewed from pulley end) Clockwise Clockwise
Weight 3.4kg 3.5kg

3-1 Features Rated speed 5000 rpm 5000rpm
Operating speed 1000 - 13500 1000 - 13500
The alternator contains a regulator using an IC, and has Speed at 13.5 V 1000 or less 1000 or less
the following features.
Output current at 20ûC over 20A 35 L 2A
(1) The IC regulator is self-contained, and has no moving
14.5 L 0.3 V (Standard temperature)
parts (mechanical contact points). It therefore has Regulated voltage
Voltage gradient, -0.01/ ûC)
superior features such as freedom from vibration, no Permissible ambient -30ûC- + 80ûC (-22ûF - 176ûF)
fluctuation of voltage during use, and no need for read-
justment.
Also, it is of the over-heating compensation type and
can automatically adjust the voltage to the most suit- Pulley ratio
able level depending on the operating temperature.
(2) The regulator is integrated within the alternator to
simplify external wiring. Specification Pulley ratio
(3) It is an alternator designed for compactness, lightness 4TNE84 G1 1.76
of weight, and high output.
(4) A newly developed U-shaped diode is used to provide
increased reliability and easier checking and mainten-
ance.
3-3 Characteristics
139
DSL 601
3-4 Construction
This is a standard rotating field type three-phase alternator.

It consists of six major parts: the pulley, fan, front cover,
rotor, stator and rear cover. The IC regulator is an integral
part of the alternator.
140
DSL 601
3-5 Alternator functioning 3-6 Handling precautions
(1) IC regulator (1) Be careful of the battery’s polarity (+, - terminals), and
The IC regulator is the transistor (Tr1) which is series- do not connect the wrong terminals to the wrong
connected with the rotor. The IC regulator controls the cables, or the battery will be short-circuited by the
output voltage of the generator by breaking or conduc- generator diode.
ting the rotor coil (exciting) current. In this case too much current will flow, the IC regulator
When the output voltage of the generator is within the and diodes burn out, and the wire harness will burn.
standard value, the transistor (Tr1) turns on. When the
(2) Make sure of the correct connection of each terminal.
voltage exceeds the standard value, the Zener diode
goes on and the transistor (Tr1) turns off. (3) When quick-charging, etc., disconnect either the bat-
With the repeated turning on and off of the transistor, tery terminal on the AC generator or the terminal on
the output voltage is kept at the standard value. (Refer the battery.
to the circuit diagram below.) (4) Do not short-circuit the terminals.
(2) Charge lamp (5) Do not conduct any tests using high tension insulation
When the transistor (Tr1) is on, the charge lamp key resistance. (The diodes and IC regulator will burn out.)
switch is turned to ON, and current flows to R1, R1 and
to Tr1, to light the lamp. When the engine starts to run
and output voltage is generated in the stator coil, the
current stops flowing to this circuit, turning off the
charge lamp.
(3) Circuit diagram
141
DSL 601
3-7 Disassembling the alternator
(1) Remove the through-bolt, and separate the front (4) Remove the nut, the brush-holder, and diode fixing nut
assembly from the rear assembly. at the BAT, and the terminal screws of the rear cover.
Separate the rear cover from the stator (with the diode
and brush holder.)
(2) Remove the pulley nut, and pull out the rotor from the (5) Disconnect the soldered joint of the stator lead wire,
front cover. and remove the diode and brush regulator assemblies
from the stator at the same time.
(3) Remove the screw from the front cover, and then (6) Separating the regulator
remove the ball bearing. 1) To separate the regulator, remove the rivet which
keeps the diode assembly and the brushless regula-
tor in place, and the soldered joint of the L-terminal.
142
DSL 601
2) To replace the IC regulator, disconnect the soldered After repeating the above test, if any diode is found to
joint of the IC regulator and pull out the two bolts. Do be defective, replace the diode assembly. Since there is
not remove these two bolts except when replacing the no terminal on the auxiliary diode, check the continuity
IC regulator. between both ends of the diode.
3-8 Inspection and adjustment
(1) Diode
CAUTION: Do not use high tensile insulation resistance
Between terminals Bat (+side diode)
instrument such as meggers, etc. for testing.
Tester wire + side - side
The diode may burn out.
+ side No continuity
U.V.W.
- side continuity
(2) Rotor
Inspect the slip ring surface, rotor coil continuity and
Between terminals E (- side diode)
insulation.
Tester wire + side - side
1) Inspecting the slip ring surface
+ side No continuity
U.V.W. Check if the surface of the slip ring is sufficiently
- side continuity
smooth. If the surface is rough, grind the surface with
No. 500-600 sand paper. If it is contaminated with
oil, etc., wipe the surface clean with alcohol.
Standard Wear limit
Slip ring outer dia ø31.6mm ø30.6mm
(1.2441in) (1.2049in)
2) Rotor coil continuity test

Check the continuity in the slip ring with the tester. If
there is no continuity, there is a wire break. Replace
the rotor coil.
Current flows only in one direction in the diode as shown

above. Accordingly, when there is continuity between each
terminal (e.g. BAT and U), the diode is in normal condition.
When there is no continuity, the diode is defective.
When the tester is connected in the reverse of above,
there should be no continuity. If there is, the diode is Approx. 5.17 Ω at 20ûC (LR120)
defective. Resistance value
Approx. 3.1 Ω at 20ûC (LR135)
143
DSL 601
3) Rotor coil insulation test 2) Stator coil insulation test

Check the continuity between the slip ring and the Check the continuity between the terminals and the
rotor core, or the shaft. If there is continuity, insula- stator core. If there is continuity, insulation of the
tion inside the rotor is defective, causing a short with stator coil is defective. This will cause a short-circuit
the earth circuit. Replace the rotor coil. with the earth core. Replace the stator coil.
4) Check the rear side ball bearing. If the rotation of the

bearing is heavy, or produces abnormal sounds,
replace the ball bearing. (4) Brush
The brush is hard and wears slowly, but when it is worn
beyond the allowable limit, replace it. When replacing
the brush, also check the strength of the brush spring.
To check, push the spring down to 2mm (0.0787in.)
from the end of the brush holder, and read the gauge.
(3) Stator
1) Stator coil continuity test
Check the continuity between each terminal of the
stator coil. If there is no continuity, there is a wire
Brush spring strength 255 - 345g (0.56 ~0.76lb.)
break in the stator coil. Replace the stator coil.
(5) Brush wear
Check the brush length.
The brush wears very little, but replace the brush if
worn over the limit line printed on the brush.
Approx. 0.21 Ω at 20ûC (LR120)

Resistance value
Approx.0.14 Ω at 20ûC (LR135)
mm (in.)
(1-phase resistance)
Maintenance standard wear limit
Brush length 16 (0.6299) 9(0.3543)
144
DSL 601
(6) IC regulator
Connect the variable resistance, two 12V batteries,
resistor, and voltmeter as shown in the following wiring.
1) Use the following measuring devices.
Resistor (R1) 100 W ,2W, 1pc.

Variable resistor (Rv) 0–300 W ,12W,1pc.
Battery (BAT1, BAT2) 12V, 2pcs.
DC voltmeter 0–30V, 0.5 class 1pc.
(measure at 3 points)
2) Check the regulator in the following sequence,
according to the diagram. NOTE: 1. Use non-acid type paste.
a) Check V3 (BAT1 and BAT2 voltage). If the voltage 2. The soldering iron temperature is 300 ~ 350¡C.
is 20–26V, both BAT1 and BAT2 are normal. 2) Mount the IC regulator on the brush holder as illust-
b) While measuring V2 (F-E terminal voltage), move rated, and press in the M5 bolt. Do not forget to
Rv gradually from the 0-position. Check if there is assemble the bushing and the connecting plate at the
a point where the V2 voltage rises sharply from same time.
below 2.0V to over 2.0V. If there is no such point, (If the bushing is left out; the output terminal will be
the regulator is defective. Replace the regulator. If earthed and the battery short-circuited).
there is a sharp voltage rise when testing, return
the Rv to the 0-position, and connect the voltmeter
to the V1 position.
c) While measuring V1 (voltage between L-E termi-
nals), move Rv gradually from the 0-position.
There should be a point where the voltage of V1
rises sharply by 2–6V. Measure the voltage of V1
just before this sharp voltage rise. This is the
regulating voltage of the regulator. If this voltage of
V1 is within the standard limit, the regulator is
normal. If the voltage deviates from the limit, the
regulator is defective. Replace the regulator.
NOTES: 1. Insertion pressure is 100kg (220.5 lbs.)

2. Insert vertically.
(2) Connecting the brush regulator assembly and diode

1) Check the rivets
Place the rivets as shown in the figure, and then caulk
them using the caulking tool.
Calking torque 500kg (1102 lbs.)
2) Connect the brush to the diode.

Insert the brush side terminal into the diode terminal,
caulk it, and then solder into place.
3-9 Reassembling the alternator
Reassembly is done in the reverse order of disassembly.

For reassembly, be careful of the following points. (Refer
to 3-7 disassembling alternator).
(1) Assembling the brush regulator
1) Solder the brush.
Position the brush as shown in drawing and solder
it. Be careful not to let the solder drip into the pig Rivetting Pressure 500kg (1102 lbs.)
tail (lead wire).
145
DSL 601
(3) Assembling the rear cover 3-10 Performance test

Insert pins from the outside of the rear cover. Install
the brush on the brush holder, then attach the rear Conduct a performance test on the reassembled AC gen-
cover. After assembly, pull out the pins. erator as follows. The following is the circuit for the per-
formance test.
(1) Measuring devices

Battery Fully charged 12 V battery
DC voltmeter 0 -30 V, 0.5 Class, 1 pc.
DC ammeter 0 -50 V, 1.0 Class, 1 pc.
Variable resistor 0 - 1 Ω, 1 kW, 1 pc.
Lamp 12 V, 3 W
Switch Capacity 40 Amps.
(2) Speed measurement at 13.5V

1) Start the alternator slowly after opening SW1 and
closing SW2.
2) After the alternator has reached a speed of approxi-
mately 500 rpm, open switch SW2.
3) Gradually increase the alternator speed while watch-
ing the voltmeter, and read the speed on the tacho-
meter when the voltage reaches 13.5V.
(4) Tightening torques 4) The speed at this time is 1,000 rpm ar less, and is
Tightening torque the 13.5 V rise speed.
Positions
kg-cm (ft-lb)
Brush holder fixing (M5) 32 - 40 (2.31 ~ 2.89) (3) Output measurement
Diode fixing (M5) 32 - 40 (2.31 ~ 2.89) 1) Set the variable resistor to the maximum resistance
Bearing retainer fixing (M4) 16 - 20 (1.16 ~ 1.45) value, close the SW1 and SW2, and start the alterna-
Pulley nut tightening (M14) 450 - 550 (32.5 ~ 40) tor.
Through-bolt tightening (M5) 32 - 40 (2.31 ~ 2.89) 2) Revolve the alternator at 5,000 rpm while keeping a
voltage 13.5 V with the variable resistor.
3) Measure the current with an ammeter when the
alternator speed at 5,000 rpm.
4) The current at this time is the standard value. (20A
or more at 13.5 V)
(4) Performance test precautions

1) Connect the alternator BAT terminal and battery (+)
terminal, and the E terminal and battery (-) terminal
using 2.5 m or less of wiring having a crosssectional
area of 8 mm2 or more.
2) Check the wires for correct or loose connection.
146
DSL 601
[B] Magneto-Generator
The magneto-generator is standard to the VM, CL and CH

specifications, through the standard alternator 12V/20 A is
furnished to the S, G1, and G2 specifications.
1. Specifications
Output (V/A) 12/15 12/20

Manufacturer Kokusan Kokusan
Manufacturer GP8138 GP9165
Yanmar code 171301 - 77201 129150 - 77202
RS5118 K2A34
Manufacturer’s code
Combinated A 119660 - 77710 129150 - 77710

regulator
Yanmar code * B 171301 - 77700 119640 - 77710
Regulated voltage (V) 14 - 15 14 - 15
- -
Combinated safety relay * 121522 - 77701 121522 - 77701
A - -
Combinated charge indicator * B 121522 - 77721 121522 - 77721
Usable speed (rpm) 900 - 6500 1300 - 4800
Max speed (rpm) 7000 4800
Output current (A)/Voltage (V)-speed (rpm) 14 - 15/12 - 7000 20/12 - 4500
-40 - +80 -25 - +65
Permissible ambient temperature ûC ( ûF)
(-40 - 176) (-13 - 149)
Ground polarity / Weight<kg(lb)> Negative/1.6 (3.5) Negative
Belt/Pulley A single/65 (2.56) A single/65 (2.56)
Pulley <mm (in.)>
Outer dia. or HM single or HM single
Drive end Outer dia. <mm(in.)>/Bearing
Shaft 12 (0.47)/6201ZZC3 12 (0.47)/6201ZZC3
Rear end Outer dia. <mm(in.)>/Bearing
* marks: Use regulator B in combination with safety relay B and charge indicator B.
147
DSL 601
(2) Construction
The magneto-generator is composed of the starter coil,
rotor magnet, drive shaft/pulley, bearings, etc.
The magneto-generator is kept excited by the magne-
to. This requires the regulator to limit a greater cur-
rent as compared with the alternator.
In addition, the magneto-generator must be sufficiently-
cooled because of a greater calorific value developed.
The magneto-generator shows a little larger horsepower
loss than the alternator. The magneto-generator has a
simple configuration, smaller size, lighter weight, and
is less expensive than the alternator.
(3) Disassembly procedure

1) Disconnect the generator from the engine.
2) Remove the cap and the M10 hexagonal nut.
3) Fix the end of the shaft. Do not fix the flywheel.
4) Pull out the rotor magnet. (6) Stator coil continuity test
Tap the threaded end (M10) of the shaft with a mallet 1) Connect a wire of the megger to the terminal.
or the like. 2) Contact the other wire of the megger to the housing-
5) Clamp the lead-wire to the coil plate. for not more than 1 second, and check the indicator
Remove an M4 screw and the coupler. of the megger.
6) Remove the stator coil from the coil plate. If there is continuity (the resistance is zero), replace
Remove 2-M4 screws. the stator coil.
(4) Reassembly procedure

1) To reassemble the magneto-generator, reverse the
steps indicated in Disassembly procedure.
2) Tighten the M10 hexagonal nut to a torque of 300–
350 kg-cm.
(5) Generator check

Follow the next directions to check if the generator
works abnormally.
1) Disconnect the generator output wiring to the regulator,
with the generator left coupled with the engine.
2) Extend the generator output wiring and connect it to a
volt/ammeter.
3) Set the volt/ammeter to the 100 VAC range.
4) Start the engine and check the volt/ammeter for
readings.
5) When the specified voltage is proven on the volt/
ammeter, the generator is in normal operation.
GP8138: Approx. 15.7 V(AC) at 3000 rpm (gen.)

GP9165: Approx. 24.8 V(AC) at 3000 rpm (gen.)
148
DSL 601
3-11 Troubleshooting
(1) Charging failure
Doesn’t Defective
Does the charge lamp go off go off
o Replace fan belt.
when the key switch is turned Check fan belt o Adjust fan belt.
(after engine starting)?
Goes off OK
After stopping the engine, turn on the key switch.
Remove generator coupler (R-L).
Defective o Check electrical wiring for defective

continuity of the BAT, and R
Measure the voltage between BAT
terminals.
terminal, and coupler terminal
o Check the key switch and charge
(R-L).
lamp for defective continuity of the
L-terminal.
OK
BAT, R-L terminal
Voltage:9–12V
Insert coupler (R-L) to generator.
Turn on the key switch for engine starting.
Defective
o In case of defective continuity of
*Measure the voltage between BAT terminal, replace IC regulator.
generator BAT, and L terminal. o In case of defective continuity of
* Measuring condition L-terminal, check or replace diode,
Generator rpms: 5,000 stator, and rotor.
149
DSL 601
00.7.4 Starting Aids

4-1 Air heater (DI engine)
An air heater is available for warming intake air during

starting in cold weather. The air heater is mounted on the
end of the intake manifold.
The device is operated by the key switch on the instrument
panel.
A timer is equipped for the pre-heating. When this device

is initially turned ON by the key switch, the pilot lamp lights.
The timer is set so that the pilot lamp goes off 15 sec after
the system is turned ON. When the pilot lamp goes off,
once turn the key switch to OFF. Then, turn the key switch
to START to start the engine.
Air heater system circuit: Air heater Pilot lamp Timer Air heater circuit (with Timer)
Rated output 400W

Rated current 33.3A
Rated voltage DC 12 V
Pre-heating: 15 sec.
Rated operating time Engine operating: 30 sec. max.
Engine Stop: 30 sec.
Range of operating
-30 ûC (-22ûF ) or higher
temperature
Earth polarity Negative earth/Body earth
150
DSL 601
00.7.5 Battery
5.1 Battery capacity and battery cables
5.1.1 Battery capacity
Recommended battery capacity

Standard (recommended) For cold starting
Atmospheric temperature More than -5ûC (23ûF) See TN series

Application manual
20 hrs. rating (AH) 100
(Use battery more than
4TNE84 O standard battery capacity)
5.1.2 Battery cable Wire thinner than specified Single conductor wire
Wiring must be performed with the specified electric wire. Wire longer than specifed
Thick, short wiring should be used to connect the battery
to the starter, (low-voltage cables for automobile [AV wire]).
Using wire other than that specified may cause the follow- High wiring resistance
ing troubles:
Open circuit caused
The starter motor circuits, excluding motor, relay, and sole- by vibrations
noid, shall be designed so that the difference between the Low current
voltage at the storage battery terminals and the starter
motor terminals including connections shall not exceed
those shown in the following table. Faulty starting Faulty charging
Permissible length of battery cable (m) Max.
Rated voltage 12 V Conductor

Nominal
conductor Starter capacity Below 2 KW 2 Kw (incl.) and more resistance of
Cable
cross section Battery switch cable
area Present
or not None Present
(mm2) ( ): calculated area (Ohm/m)
15 (13.36) <0.86 m 0.001380
20 (20.61) <1.30 m 0.000887
30 (35.19) <2.30 m <1.5 m <0.76 m 0.000520
40 (42.73) <2.80 m <1.8 m <0.90 m 0.000428
50 (54.29) <3.50 m <2.3 m <1.20 m 0.000337
*AV vable 60 (63.84) <4.10 m <2.7 m <1.40 m 0.000287
85 (84.96) <5.50 m <3.7 m <1.80 m 0.000215
100 (109.1) <7.10 m <4.7 m <2.40 m 0.000168
Permissible resistance of cable (Ohm) 0.0012 0.0008 0.0004
Permissible resistance of starter 0.002 0.002

moter circuit (Ohm) (0.2V/100A) (0.2V/100A)
* JIS C 3406, Low-voltage cables for automobile.
Notes: 1. Find the cable length in the following equation:

permissible cable resistance
Cable length =
permissible cable conductor resistance
151
DSL 601
5.2 Battery inspection
The quality of the battery governs the starting performance

of the engine. Therefore the battery must be routinely
inspected to ensure that it functions perfectly at all times.
Check the electrolyte level in each cell. If the level is low,
add distilled water to bring the level to the UPPER level.
Check the battery case for loose parts, cracked case or top.
Check the battery terminals for looseness or rusting.
Check the battery cap for the clogged vent holes.
Test each cell by drawing electrolyte into the hydrometer.
SPECIFIC GRAVITY: 1.270-1.290 (Type II)

1.260-1.280 (Type I)
WARNING
The battery contains sulfuric acid. Avoid contact with skin,

eyes, or clothing.
Antidote: Flush with water and get prompt medical atten-
tion.
NOTE: Check the electrolyte level every 7 to 10 days. The elec-

trolyte must always be 10 – 20 mm (0.3937 – 0.7874 in.)
• Do not overfill the battery. Wipe up spilled electrolyte over the top of the plates.
at once and flush well with water.
• The specific gravity varies with the temperature as
shown in the accompanying table.
• The battery must be replaced if sulfation is evident.
• The battery must be replaced if there are pastes
settled on the bottom of each cell.
Variation of Specific Gravity with Temperature
152
DSL 601
5.3 Battery Charging
Remove the battery; remove the cap from each cell.

Connect the charger positive (+) cable to the battery posi-
tive terminal.
Connect the charger negative (-) cable to the battery neg-
ative terminal.
Charging current:
Battery current 20 hrs. rating – 10 hrs. rating.
Example: 20 hrs. rating 45 AH, battery

(45 ÷ 20) – (45 ÷ 10) = 2.25A – 4.5A
Charging:
Charging the battery until specific gravity is 1.270 – 1.290
at 20°C (68°F). (Incase of the battery of Type 1: 1.260 –
1.280)
Warning
¥ Before charging remove the cap from each cell.

¥ Keep fire and sparks from a charging battery.
¥ Turn power ON/OFF at the charger, not at the battery
terminals.
¥ Discontinue charging if the electrolyte temperature
exceeds 45¡C (117¡F).
CAUTION:
Quick-charging should only be done in an emergency;

slow-charging is preferred.
After installing the battery, coat the terminals with clean

grease.
153
DSL 601
00.7.6 Service Data

Applicable Model 4TNE84
Standard Wear limit
Starter motor model S13-41C
Rating sec 30
Output kW 2.5
Direction of rotation - Clockwise
(viewed from pinion side)
Weight kg(lb) 5.3(11.7)
Clutch system - Over running
Engagement - Magnetic shift
No. of pinion teeth - 15
Pinion flyout voltage V 8
Terminal voltage V 11
No-load Current A <140
Speed rpm >3900
Terminal voltage V 8.76
Loaded
Current A 300
characteristics
Torque/rpm kg-m/rpm(ft/lb) 0.7(5.062)/>1700
L-dimension(gap between mm 0.3-1.5
pinion and pinion stopper) (in) (0.012-0.059)
Commutator outside mm 36.5 35.5
diameter (in) (1.437) (1.398)
Commutator run-out mm 0.03 0.2
(in) (0.001) (0.008)
Mica undercut mm 0.5-0.8 0.2
(in) (0.020-0.032) (0.008)
Brush height mm 15 9
(in) (0.591) (0.354)
Standard spring load kg 2.7-3.3
(lb) (5.592-7.275)
Shunt coil resistanceat 20˚C(68˚F) ohm 1.74
Series coil resistance at 20˚C ohm 0.20
Shaft mm 6903 Z
Rear side diameter (in)
bearing Bearing mm 608 Z
inside diameter (in)
Shaft mm 6004 Z
Intermediate diameter (in)
bearing Bearing mm 6904 Z
inside diameter (in)
Shaft mm 16.35-16.368
Pinion sliding diameter (in) (0.6437-0.6444)
section Pinion inside mm 15.6-15.7
diameter (in) (0.614-0.618)
Shaft mm 15.55-15.58
Pinion side diameter (in) (0.612-0.613)
bearing Pinion inside mm 15.6-15.7
diameter (in) (0.162-0.618)
154
DSL 601
00 Engine, 4TNE84 00.8 Disassembly And Reassembly
00.8 DISASSEMBLY AND

REASSEMBLY
00.8.1.1 DISASSEMBLY ...........................................................................156
00.8.1.2 REASSEMBLY ............................................................................156
00.8.2 DISASSEMBLY AND REASSEMBLY ....................................................157

00.8.2.1 DISASSEMBLY ...........................................................................157
00.8.2.2 REASSEMBLY ............................................................................162
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
155
DSL 601
00.8.1 Disassembly and Reassembly Precautions

1-1 Disassembly • Prepare a cleaner and cleaning can.
• Take sufficient time to accurately pin-point the cause • Clear an adequate area for parts and prepare con-
of the trouble, and disassemble only those parts tainer(s).
which are necessary. • Drain cooling water and lube oil.
• Be careful to keep all disassembled parts in order.
• Prepare disassembly tools. 1-2 Reassembly
• Sufficiently clean and inspect all parts to be assem-
bled.
• Coat sliding and rotating parts with new engine oil
when assembling.
• Replace all gaskets and O-rings.
• Use a liquid packing agent as necessary to prevent
oil/water leaks.
• Check oil and thrust clearances, etc. of parts when
assembling.
• Make sure you use the correct bolt/nut/washer.
Tighten main bolt/nuts to specified torque. Be
especially careful not to overtighten the aluminum
alloy part mounting bolts.
• Align match mark (if any) when assembling. Re-
assemble bearings, pistons, and other parts in the
proper position.
156
DSL 601
00.8.2 Disassembly and Reassembly

2-1 Disassembly
Disassembly procedure should be undertaken only after

the following parts have been removed.
• Battery cables
• Fuel pipe (Fuel tank to fuel feed pump)
• Control panel
• Power take off shaft
• Electrical wiring
• Cable (for speed control and for engine emergency
stop)
(1) Cooling water

1) Remove the water drain plug on the cylinder block
side and drain the cooling water.
2) Drain the water in the radiator.
3) Tighten the drain plug and close the drain cock.
(2) Lubricating oil

1) Remove the drain plug on the oil pan, and drain the (9) Removing the fuel injection nozzles
lubricating oil. Remove the fuel injection nozzle retainer nut, and pull out
2) Tighten the drain plug after draining the lubricating the fuel injection nozzle retainer and fuel injection nozzle.
oil.
(3) Radiator
1) Disconnect the cooling water hoses.
2) Remove the radiator mounts and stay.
3) Remove the radiator.
(4) Removing the turbocharger (turbocharged engine

only)
1) Remove the air hose.
2) Remove the lube pipe for the turbocharger.
3) Remove the turbocharger.
(5) Exhaust silencer

Remover the silencer.
(6) Air cleaner

Remove the air cleaner together with the bracket and
intake hose.
(7) Exhaust manifold

Remove the exhaust manifold.
(8) Removing the high pressure fuel pipe.

1) Loosen the box nuts on both ends of the fuel injec-
tion pipe and remove the fuel injection pipe.
2) Remove the fuel oil return pipe.
(fuel injection nozzle-fuel injection pump)
(10) Removing the valve rocker arm shaft assembly

1) Remove the valve rocker arm cover.
2) Remove the valve rocker arm shaft mounting bolts,
and remove the rocker arm shaft assembly.
157
DSL 601
3) Pull out the push rods. (13) Intake manifold

1) Remove the fuel pipe.
NOTE: Verify the cylinder No., and indicate intake or (fuel filter-fuel injection pump)
exhaust (for reassembly purposes) 2) Remove the fuel filter
3) Remove the intake manifold.
(14) Removing the cooling water pump

1) Loosen the water hose clamp and disconnect the
hose.
2) Remove the thermostat cover.
3) Remove the cooling water pump.
(11) Alternator
1) Remove the radiator fan bolt and radiator fan.
2) Remove the belt adjusting bolt and loosen the (15) Removing the cylinder head
alternator pivot bolt. (1) Remove the cylinder head bolts with a torque wrench,
3) Remove the fanbelt. and remove the cylinder head.
4) Remove the alternator pivot bolt and alternator. (2) Remove the cylinder gasket packing.
(12) Removing the lube oil filter

1) Remove the filter bracket with lube oil filter element
from the cylinder block.
2) Remove the lube oil dipstick.
158
DSL 601
(16) Removing the crankshaft V-pulley (19) Removing the lube oil pump
Remove the hex bolts holding the crankshaft V-pulley, and Remove the lube oil pump and gasket packing from the
remove the crankshaft V-pulley with an extraction tool. gear case flange.
(20) Removing the idling gear

Remove the two hex bolts holding the idling shaft, and pull
(17) Removing the gear case
out the idling gear and idling shaft.
Remove the gear case mounting bolts, and remove the
gear case from the cylinder block.
(18) Removing the fuel injection pump

1) Remove the nut, and pull out the fuel injection
pump driving gear with an extraction tool.
2) Remove the fuel injection pump and O-ring from (21) Removing the starting motor
the gear case flange. Remove the starting motor from the flywheel housing.
159
DSL 601
(22) Removing the flywheel (25) Removing the oil pan

Remove the flywheel mounting bolts and then the flywheel. Remove the oil pan and oil pan spacer.
(26) Removing the camshaft

(1) Loosen the thrust rest mounting bolts out of the holes
in the camshaft gear, and remove.
(2) Pull out the camshaft gear and camshaft assembly
from the cylinder block.
NOTE: The camshaft gear and camshaft are shrunk fit.

They must be heated to 180 Ð 200¡C to disassem-
ble.
NOTE: Be careful not to scratch the ring gear.
(23) Removing the flywheel housing

Remove the flywheel housing from the cylinder block.
(27) Removing the tappets

Remove the tappets from the tappet holes in the cylinder
block.
(28) Removing the gear case flange

(1) Remove the gear case flange from the cylinder block.
(2) Remove the two O-rings from the lube oil passage.
(24) Remove the oil seal and oil seal case.
160
DSL 601
(29) Removing the oil strainer (31) Removing the main bearing
Remove the lube oil intake pipe and gasket packing. (1) Remove the main bearing bolts.
(2) Remove the main bearing cap and lower main bearing
metal.
NOTE: The thrust metal (lower) is mounted to the stan-

dard main bearing cap. Be sure to differentiate
between mounting surfaces.
(30) Removing the piston and connecting rods

(1) Remove the connecting rod bolt and the large end cap.
(2) Push the connecting rod from the bottom and pull out
the piston connecting rod assembly.
(32) Removing the crankshaft

(1) Remove the crankshaft
NOTE: 1. The thrust metal (upper) is mounted to the stan-

dard main bearing. However, in some cases the
thrust metal (upper) may be mounted to the
crankshaft.
2. Remove the main bearing metal (upper) from
the cylinder block.
NOTE: Place a tool against the piston cooling nozzle to

make sure the nozzle position does not change
and it doesnÕt get scratches.
161
DSL 601
2-2 Reassembly
(1) Inserting the tappets

Coat the inside of the cylinder block tappet holes and the
outside circumference of the tappets with engine oil, and
insert the tappets in the cylinder block.
• Insert the tappets before inserting their camshaft.
NOTE: Separate the tappets to make sure that they are

reassembled in the same cylinder, intake/exhaust
manifold as they came from.
(2) Mounting the crankshaft

1) The crankshaft and crankshaft gear are shrink fitted. If
the crankshaft and crankshaft gear have been disass-
embled, they have to be shrink fitted [heat the crank
shaft gear to 180° – 200°C (356–392°F) in the hot oil
and press fit].
2) Coat the cylinder block crank journal holes and upper
part of the main bearing metal with oil and fit the upper
main bearing metal onto the cylinder block.
NOTE: 1. Be sure not to confuse the upper and lower

main bearing metals. The upper metal has an (3) Mounting the main bearing metal with engine oil,
oil groove. and mounting the main bearing cap.
2. When mounting the thrust metal, fit it so that the NOTE: 1. The lower main bearing metal does not have an
surface with the oil groove slit faces outwards, oil groove.
(crankshaft side). 2. The standard bearing thrust metal is fitted with
the oil groove slit facing outwards.
3) Coat the crank pin and crank journal with engine oil
and place them on top of the main bearing metal. 1) Coat the main bearing cap bolt washer contact surface
and thread with engine oil, place them on the crank-
NOTE: 1. Align the crankshaft gear and camshaft gear shaft journal, and tighten the main bearing bolts to the
with the ÒAÓ match mark. specified torque.
2. Position so that the crankshaft gear is on the
gear case side. kg-m (ft-lb)
3. Be careful not to let the thrust metal drop. See separate service data
Main bearing bolt tightening torque
(Page 8 - 23)
NOTE: 1. The main bearing cap should be fitted with the

arrow near the embossed letters ÒFWÓ on the
cap pointing towards the flywheel.
2. Make sure you have the correct cylinder align-
ment no.
2) Measure the crankshaft side clearance.

mm(in.)
0.090 ~0.271
Crankshaft side clearance
(0.0035 ~ 0.0107)
3) Make sure that the crankshaft rotates smoothly and

easily.
162
DSL 601
(4) Mounting the gear case flange. 3) Measure the camshaft side gap.
mm(in.)
Mount the gear case flange, and the O-ring for oil line onto
the cylinder block. Crankshaft side gap
(Page 2- 32)
NOTE: 1. When mounting the gear case flange, match up 4) Make sure that the camshaft rotates smoothly.
the two cylinder block knock pins.
2. Be sure to coat the cylinder block lube O-ring (6) Mounting the piston and connecting rod
with grease when assembling, so that it does 1) Reassemble the piston and connecting rod.
not get out of place.
3. Seal with the Three Bond 1212 between NOTE: When reassembling the piston and connecting
cylinder block and gear case flange. rod, make sure that the parts are assembled with
the correct orientation.
2) Each ring opening (piston/oil rings) should be stag-

gered at gaps of 120°.
3) Coat the outside of the piston and the inside of the

connecting rod crank pin metal with engine oil and in-
(5) Mounting the camshaft sert the piston with the piston insertion tool.
1) If the camshaft and camshaft gear have been disass-
embled, shrink fit the camshaft and camshaft gear
[heat the camshaft gear to 180–200°V (356–392°F) in
the hot oil and press fit].
NOTE: When mounting the camshaft and camshaft gear,

be sure not to forget assembly of the thrust rest.
Also make sure they are assembled with the cor-
rect orientation.
2) Coat the cylinder block camshaft bearings and cam-

shaft with engine oil, insert the camshaft in the cylinder
block, and mount the thrust plate with the bolt.
163
DSL 601
Note: DI engine (9) Mounting the lube oil suction pipe

1. Before inserting the piston, confirm that both the Mount the lube oil intake pipe on the bottom of the cylinder
piston size mark and the connecting rod match block, using new packing.
mark are located at fuel pump side, and the
identification mark is at the connecting rod
section I with the mark facing the flywheel.
2. After inserting the piston, make sure the piston
size mark is facing the fuel injection pump, look-
ing from the top of the piston.
4) Align the large end match mark, mount the cap, and
tighten the connecting rod bolts.
kg-m (ft-lb)
Connecting rod bolt tightening torque
(Page 8 - 23)
NOTE: If a torque wrench is not available, match up with

the mark made before disassembly.
(7) Mounting the oil seal case

1) Press fit the oil seal in the oil seal case, and coat the
(10) Mounting the oil pan
lip of the oil seal with engine oil.
1) Mount the oil pan and oil pan spacer.
2) Mount the oil seal case, matching them up with the
2) Seal with the Three Bond 1212 among the cylinder
cylinder block positioning pins.
block, oil pan spacer and oil pan.
(11) Mounting the lube oil pump

(8) Mounting the flywheel housing
1) Mount the lube oil pump on the gear case flange.
Mount the flywheel housing, matching them up with the
2) Measure the backlash of the lube oil pump drive gear.
cylinder block positioning pins.
(12) Mounting the fuel injection pump

Lightly fit the fuel injection pump on the gear case.
NOTE: 1. Be careful not to scratch the O-ring between

the fuel injection pump and gear case flange.
2. Tighten the fuel injection pump all the way
after adjusting injection timing.
164
DSL 601
Tighten the nut for the fuel injection pump gear to (14) Mounting the gear case
the specified torque. 1) Coat the inside and outside of the seals with engine
oil, and press fit them into the gear case.
2) Position the two pipe knock pins, and tighten the
bolts holding the gear case.
kg-m (ft-lb)
3) Seal with Three Bond 1212 between the gear case
Nut tightening 6 - 7(43.3 - 50.6)
flange and gear case.
(13) Mounting the idling gear

1) Fit the idling gear so that the side of the idling shaft
with two oil holes faces up.
2) Align the “A” and “C” camshaft gear and crankshaft
gear match marks, match up with idling shaft retaining
plate, and tighten the bolts.
3) Measure the idling gear, camshaft gear and crankshaft
gear backlash.
4) Align the “B” match marks on the fuel injection pump
drive gear and idling gear.
5) Measure the back lash of the fuel injection pump drive
gear.
165
DSL 601
(15) Mounting the crank V-pulley (17) Mounting the cooling water pump
(1) Coat the oil seal and the section of the shaft with 1) Thoroughly coat both sides of the packing with
which it comes in contact with oil. adhesive.
(2) Fit the pin pressed into the crank gear in the pin 2) Replace the O-ring for the connecting pipe which is
(3) Tighten to the specified torque. inserted in the cylinder block, and tighten the cool-
ing water pump to the specified torque.
kg-m (ft-lb)
Cooling water pump
kg-m (ft-lb) 1.8 - 2.3(13 - 16.7)
tightening torque
V-pulley tightening torque
(Page 8 - 23)
3) Mount the thermostat case.

(16) Mounting the flywheel 4) Mount the V-pulley.
(1) Coat the flywheel mounting bolt threads with engine oil.
(2) Align the positioning pins, and tighten the flywheel bolts
to the specified torque. (18) Mounting the cylinder head
(1) Fit the gasket packing against the cylinder block, align-
ing it with the cylinder block positioning pins.
NOTE: The side on which the engine model is inscribed

should face up (cylinder head side).
(2) Lift the cylinder head horizontally and mount, aligning

with the cylinder head gasket.
(3) Coat the mounting bolt washers and threads with
engine oil, and lightly tighten the bolts in the specified
order. Then tighten completely, in the same order.
kg-m (ft-lb)
Flywheel mounting bolt See separate service data
tightening torque (Page 8 - 23)
166
DSL 601
(3) Adjust valve clearance.
kg-m (ft-lb)
Partial Complete
Cylinder bolt See separate service data
tightening torque (Page 8-23)
(4) Measure the top clearance.

mm(in.)
Top clearance
(Page 8-23)
(19) Mounting the valve rocker arm shaft assembly, mm(in.)

Intake/exhaust valve clearance 0.2 (0.0079)
pushrod
(1) Fit the pushrod to the tappet.
(2) Mount the valve rocker arm shaft assembly. (4) Coat the valve rocker arm and valve spring with engine
oil, and mount the valve rocker arm chamber cover.
kg-m (ft-lb)
Valve rocker arm shaft

2.3 - 2.9 (16.6 - 21)
support tightening torque
167
DSL 601
(20) Mounting the injection nozzle

1) Insert the fuel injection nozzle assemblies into the
nozzle holes.
2) Tighten the fuel injection nozzle retainer nut to the

specified torque. (23) Mounting the lube oil filter
kg-m (ft-lb) (1) Mount the filter bracket and packing on the cylinder
Fuel injection nozzle See separate service data block.
ratainer tightening torque (Page 8 - 23)
(2) Mount the filter element with the filter remover mount-
ing tool.
(21) Mounting the intake manifold
Thoroughly clean the inside of the intake manifold, and
mount the gasket packing and intake manifold.
(24) Mounting the Alternator

1) Mount the adjuster, the distance piece on the gear
case, and then the Alternator.
2) Adjust V-belt tension with the adjuster, and tighten
the mounting bolts.
(22) Mounting the high pressure fuel pipe and fuel oil
return pipe
Mount the high pressure fuel pipe and then the high pres-
sure fuel pipe vibration stop.
NOTE: Lightly tighten the box nuts on both ends of the

high pressure fuel pipe. Completely tighten after
adjusting the injection timing.
168
DSL 601
(30) Check the fuel injection timing

1) Check injection timing by turning the flywheel and
looking through the inspection hole in the flywheel
housing.
(25) Mounting the starting motor

Fit the starting motor in the flywheel housing.
(26) Mounting the fuel oil filter & fuel oil pipe
(27) Mounting the turbocharger

2) If injection timing is off, change the mounting posi-
(28) Filling with lube oil tion using the long hole in the injection pump mount-
Fill the engine with lube oil from the filter port on top of ing flange.
the gear case. Turning the fuel feed pump towards the cylinder
3
L(in ) block slows timing down, while movement in the
Lube oil capacity
See separate service data other direction makes it faster.
(Page 1 - 2)
Fuel injection timing(FID)
(Page 1 - 2)
(29) Filling with cooling water

1) Open the radiator cap and fill with water.
2) Fill with water until the level in the sub tank is bet-
ween the full and low marks.
169
DSL 601
00.8.3 Bolt/Nut Tightening Torque

1. Main bolt/nut tightening torque
kg-m(ft-lbs)
Item 4TNE84
M10 B 1.25
Thread dia. x pitch
Cylinder head clamping bolta 7.5 - 8.5
Tighting torque
(54.2 - 65.1)
M9 B 1
Thread dia. x pitch
Connecting rod clamping bolta 4.5 - 5.0
Tighting torque
(32.6 - 36.2)
M10 B 1.25
Thread dia. x pitch
Flywheel clamping bolta 8.5 - 9.0
Tighting torque
(61.5 - 65.2)
M12 B 1.25
Thread dia. x pitch
Main bearing clamping bolta 9.5 - 10.5
Tighting torque
(68.7 - 76.0)
M14B 1.5
Crankshaft V-Pully Thread dia. x pitch
11 - 13
clamping bolta Tighting torque
(79.6 - 94.1)
Fuel injection nozzle case Thread dia. x pitch

4 - 4.5
nut/Holder Tighting torque
(29.0 - 32.6)
M6B 2
Thread dia. x pitch
Fuel injection nozzle 0.4 - 0.5
Tighting torque
(2.9 - 3.6)
Thread dia. x pitch

Fuel pump driving gear nuta 5.0 - 7.0
Tighting torque
(36.2 - 50.7)
Thread dia. x pitch
Glow pulg -
Tighting torque
Thread dia. x pitch
Stub shaft bolt -
Tighting torque
Thread dia. x pitch

Governor weight support nuta 4.5 - 5
Tighting torque
(32.5 - 36.2)
a
Apply lubricating oil to the seat of bolt and threads of bolts and nuts before tightening. Do not apply molybdeum
disulfide lubricants to bolts and nuts.
b
In case of the steel mode V-pulley : 11.5 - 12.5kg-m(83.1 - 90.3 ft-lbs)
2. Standard bolt tightening torque

NOTE: 1. Tighten all other clamping bolts not specified in the
Tapered screw plug
preceding Table in accordance with the following
Table. kg-m(ft-lbs)
2. When bolting the aluminum parts, tighten the bolts Thread
about 80% of the tightening torque specified in the PT 1/8 1.0(7.2)
Table.
Hexagon headed bolt (7T)/Nut PT 1/4 2.0(14.4)
kg-m(ft-lb) PT 3/8 3.0(21.5)

All models PT 1/2 6.0(43.3)
Thread dia. x pitch M6 B 1
Tighting torque 1.0 - 1.2(7.2 - 8.7) Ball joint bolt
Thread dia. x pitch M8 B 1.25
Tighting torque 2.3- 2.9(16.6 - 21) kg-m(ft-lbs)
Thread dia. x pitch M10 B 1.5 Thread
Tighting torque 4.5 - 5.5(33 - 40) 1.3 - 1.7
M8
Thread dia. x pitch M12 B 1.75 (9.4 - 12.2)
Tighting torque 8.0 - 10.0(58 - 72) 2.5 - 3.5
Thread dia. x pitch M14 B 1.5 M12
(18 - 25)
Tighting torque 13.0 - 15.0(94 -108)
4-5
Thread dia. x pitch M16 B 1.5 M14
(29 - 36)
Tighting torque 21.5 - 24.5(155 - 177)
5-6
M16
(36 - 43)
170
DSL 601
00.8.4 Troubleshooting
The following description summarizes the probable Immediate countermeasures should be taken before
cause of and remedy for general failure by item. a failure is inflamed if any symptom is detected.
Hard to start the engine
Fuel system admits air Bleed air. (Check feed pump)
Clogged fuel supply piping or clogged air vent Detect the cause and remove clogs or
pipe in tank. obstacles.
Clogged fuel filter Replace filter element with a new one.
Fuel feed pump failure Check for function. Service fuel pump or
replace with a new one if less discharge
volume is found.
Insufficient compression Check according to “Insufficient output.”
Improperly adjust valve stick or clearance in Adjust clearance of intake/exhaust valves.

intake/exhaust valves. Check valve, valve guide, spring, and rocker
arm mechanism for damage.
Improper injection timing or valve timing. Check for injection timing and valve timing.
Clogged exhaust pipe (too high back pressure) Totally check exhaust system (for dented or
twisted pipes and clogged silencer, etc.)
Fuel injection valve failure or errors in selecting Check for part type No.
types. Service or replace fuel injection valves.
Fuel injection pump failure Check, service, or adjust.
Does starting-aid in cold weather function Check whether a proper voltage continuously
normally? occurs in low temperature starting-aid circuit
while switch is turned ON.
When thermostat (air heater) unit is used, air

cleaner or intake air hose is removed, and switch
is turned ON, air heater is red-heated,
and fuel valve opens and sets fire. If not, no
fuel feeds or air heater fails.
If fire once occurs, and goes out if starter motor is

switched ON, voltage is insufficient or circuit is
defective (such as erroneous selection of starter
switch).
171
DSL 601
Insufficient output
Hydraulic pressure Set relief pressure of

Driven machine normal?
source control valve
Clogged
Excessive intake
Clogged air cleaner intake
air resistance
air pipe
Clean Clean
Clogged Clogged cylinder

Excess exhaust Clogged
exhaust head exhaust
resistance muffler
pipe outlet
Clean or replace Clean Clean
Air intrusion
Fuel system failure into fuel Clogged fuel filter Clogged fuel pipe
system
Air bleeding Clean or replace Clean
Clogged air vent in fuel tank
Clean
Insufficient fuel
volume from
feed pump
Repair or replace
Governor Improper Fuel Clogged fuel

adjustment injection injection Fuel injection
pressure valve nozzle valve seizure
Adjust Clean or replace Replace
Lever link
malfunction Improper Worn
Fuel pump rack Faulty delivery
fuel injection plunger
malfunction valve
timing barrel
Repair or replace
Adjust Repair or replace Repair or replace Replace
Improper clearance Defective Intake/exhaust

Reduced compression Fatigued or broken
of intake/exhaust intake/exhaust valve stem
pressure valve spring
valves valve seat seizure
Adjust Reshape or replace Replace Replace
Pressure leak through

cylinder
Replace
Seizure, breakage and Flaws or wear Flaws or wear

wear of piston ring of piston of liner
Overheat Refer to “Overheating” Replace Replace Replace
172
DSL 601
Overheating
Hydraulic pressure Set relief pressure of

Driven unit normal? source control valve
Cooling Insufficient cooling Sagged fan Broken or worn Increased

Clogged radiator
system water belt fan belt exhaust pressure
Add water Replace

Adjust Clean Clean
Reduction in cooling
Radiator cap clogging Thermostat (air Clogged radiator
water pump
and malfunction heater) malfunction hose
performance
Replace Clean Replace

Clean or replace
Radiator
Clogged malfunction
Excessive intake Clogged air cleaner intake air
air resistance
pipe Clean
Clean or replace Clean
Clogged cylinder
Excessive exhaust Clogged Clogged
head exhaust
resistance muffler exhaust pipe
outlet
Clean Clean Clean
Leakage through head Cracked cylinder

Cylinder head gasket head
Replace Replace
Improper fuel Defective fuel

Fuel system injection injection valve
timing
Repair Clean or replace
Improper Improper valve

Injection OPEN/ valve OPEN/CLOSE
CLOSE timing clearance timing
Adjust Adjust
Seizure
Piston
likeliness
Replace
173
DSL 601
Black smoke is produced.
Driven machine properly? Hydraulic pressure Set relief pressure of

source control valve
Insufficient Refer to “Insufficient output”

output
Fuel Improper
fuel
Replace
Too early
Fuel pump injection Excess injection Uneven injection
volume volume
timing
Adjust or replace Adjust Adjust or replace
Governor Improper Malfunction of lever

adjustment and linkage
Adjust
Repair or replace
White smoke is produced.
Intrusion of low-
Fuel Water intrusion
in fuel quality fuel or
impurities
Replace
Replace
Lube oil Improper SAE grade
Replace
Excessive intake Clogged Clogged

air resistance air cleaner intake air
pipe
Repair or replace Clean or replace
Too late
Fuel pump injection
timing
Adjust
Oil down Defective valve Damaged or worn Damaged or worn

stem sealing valve stem valve guide
Replace Replace Replace
Seizure, breakage, or Flaws or wear Flaws or wear

Oil up
wear of piston ring of pistons of liner
Replace Replace Rebore/Rehone

Leakage through cylinder
head gasket
Over-cooling Thermostat malfunction
Replace
Replace
174
DSL 601
Starter motor will not turn

or output less power. [ Except engine seizure and
trouble of driven machine ]
Disconnection Grounding
& faulty Battery terminal Disconnected wiring Coupler connection
terminal
connection
Repair Repair Repair Repair
Specific Voltage Damaged battery

Battery gravity
Charging Add electrolyte Replace
or charge
Damaged or rusted starter

Key switch motor terminal Switch inner contactor Damaged switch
Replace or repair Replace Replace
Damaged or Faulty really

Safety relay functioning
rusted terminals
Replace or repair Replace
Damaged
Starter motor or rusted Magnet switch, malfunction Defective Burnt coil Short-circuited
terminal & defective contactor brush
Replace starter motor
Replace or repair Replace Replace or repair
Clutch slip
Replace
Hydraulic system will not operate

or to slow function.
Lube oil Deterioration Viscosity

Insufficient
quantity
Add lube oil Replace Recommended Hydro-oil
Trouble in
Piping (Aeration cavitation)
piping
Correct
Worn gears and

Gear pump Worn spline in flange Broken shaft housing
Replace
Replace
Replace
Filter Clogging
Clean or replace
175
DSL 601
Battery is dead or not

[During operation]
chargeable.
Poor charging Discharged
Defective Discon-
Battery Grounding Coupler
wiring and nected
terminal terminal connection ON
connection wiring Key Switch
condition
Correct Correct Correct Correct
Turn OFF
Damaged Wiring Short-circuit

Battery
battery
Replace
Replace
Electric
Alternator
Damaged Switch appliance
Key switch ON or rusted inner
terminals contactor
Turn ON.
Repair or replace Replace
Damaged
Short-circuit or diode
Electric
Alternator disconnected lead
appliance
wire Replace
Replace
Short-circuited
Sagged fan belt coil
Adjust
Replace alternator
Faulty IC regulator
Damaged diode
Replace alternator
Replace
Defective
brush
Repair or replace
Burnt coil
Replace alternator
Short-circuited
Replace alternator
176
DSL 601
00.8.5 Identification of Parts for each Application
IDENTIFICATIONS OF PARTS FOR EACH APPLICTION

Model 4TNE84
Applicaition VM CL CH
Cylinder head M M SH
Valve seat - - O
Radiator fan E NF E
Fuel injection nozzle EC EA GB
Turbocharger - - -
Driving gear,
B B b
F.I. Pump
Piston - - -
177
DSL 601
00.8.6 Conversion Tables

Unit To convert Into Multiply by Referecne
Length mm inch 0.03937 1 ft = 12 in

cm foot 0.03281 1 yd = 3 ft
m yard 1.09361 = 36 in.
km mile 0.62137
inch mm 25.4
foot cm 30.48
yard m 0.9144
mile km 1.6093
Area cm2 in.2 0.155 1 ft.2 = 144 in.2

m2 ft2 10.76 1 yd2 = 9 ft2
km2 mile2 0.3861 = 1296 in.2
are acre 0.0247
in.2 cm2 6.4516
ft 2
m2 0.0929
mile2 km2 2.59
acre are 40.4686
Volume cm3 in.3 0.06102 *Great Britain(UK)

dm3 (liter) in.3 61.0236 1 fl oz = 0.028413 dm3
dm3 (liter) ft3 0.03531 1 pt = 4 gills
m3 ft3 35.315 = 0.56826 dm3
m 3
yd 3
1.30795 1 qt = 2 pt
in.3 cm3 16.3871 = 1.13652 dm3
in. 3
dm (liter)
3
0.01639 1 gal = 34 qt
ft3 m3 0.02832 = 4.5461 dm3
yd3 m3 0.76456
*United States(US)
1 fl oz = 0.029574 dm3
1 liq pt = 4 gills
= 0.47318 dm3
1 liq qt = 2 lip pt
= 0.94635 dm3
1 gal = 231 in.3
= 4 liq qt
= 3.7854 dm3
Weight(Units of mass) g oz 0.03527

kg lb 2.2046 1 lb = 16 oz
oz g 28.3495 = 453.592 g
lb kg 0.45349 = 0.45359 kg
Force gf N(Newton) 0.009807 1 pd 1(poundal)

kgf N 9.80665 = 0.138255N
lbf N 4.44822 = force which accelerates
N gf 101.972 a mass of lb by ft/s2
N kgf 0.101972
N lbf 0.224809
178
DSL 601
Unit To convert Into Multiply by Referecne
Pressure and stress kgf/cm 2

Bar 0.98066 1 at = 1 kgf/cm 2
kgf/cm2 N/m2(Pa) 98066.5 1 Pa = 1 N/m2

kgf/cm2 lbf/in.2 14.2233 10m H O = 1 kgf/cm2
2
lbf/in.2 Bar 0.0689 1 mmHg = 1 Torr

lbf/in.2 N/m2(Pa) 6894.76
Bar kgf/cm2 1.01972
N/m2(Pa) kgf/cm2 1.0197 x 10-5
lbf/in.2 kgf/cm2 0.07031
Bar lbf/in.2 14.5037
N/m2(Pa) lbf/in.2 1.4504 x 10-4
Energy J kcal 238.8 x 10-6

J kwh 277.8 x 10-9
J BTU 947.8 x 10-6
kcal BTU 3.9683
BTU kcal 0.252
Work kgf-m N-m 9.80665

lbf-ft N-m 1.356
kgf-m lbf-ft 7.233
lbf-ft kgf-m 0.138
N-m kgf-m 0.102
N-m lbf-ft 0.738
Power kw PS 1.3596 1PS = 75 kg-m/sec

kw HP 1.3410 1HP = 550 lb-ft/sec
PS kw 0.7355
HP kw 0.7457
PS HP 0.98632
HP PS 1.01387
Velocity m/sec ft/min 196.86

ft/min m/sec 0.0051
km/h mile/h 0.62137
mile/h km/h 1.09361
Acceleration m/sec 2
ft/sec 2
3.281
ft/sec2 m/sec2 0.3048
Fuel consumption g/PS-h g/kw-h 1.3596

g/HP-h g/kw-h 1.3410
lb/PS-h g/kw-h 599.96
lb/HS-h g/kw-h 608.277
g/kw-h g/PS-h 0.7355
g/kw-h g/HP-h 0.7457
g/kw-h lb/PS-h 0.00167
g/kw-h lb/HS-h 0.00164
Temperature ˚C ˚F C = 5/9(F - 32)

˚C K(Kelvin) C = K - 273.15
˚F ˚C F = 1.8 X C + 32
˚F ˚R(Rankine) F = R - 459.67
K ˚C K = C + 273.15
˚R ˚F R = F + 459.67
179
DSL 601
180
DSL 601
00 Engine, 4TNE84 00.9 Engine Removal And Installation Procedures
00.9 ENGINE REMOVAL

AND INSTALLATION
PROCEDURES
00.9.1 ENGINE/HYDROSTATIC PUMP REMOVAL.................................................182
00.9.1.1 Disconnect the battery .....................................................................182
00.9.1.2 Remove the flexible tube, muffler, and tail tube assembly
(the exhaust system)........................................................................182
00.9.1.3 Remove the oil cooler ......................................................................182
00.9.1.4 Remove the radiator assembly ........................................................183
00.9.1.5 Remove the air cleaner....................................................................183
00.9.1.6 Disconnect all electrical wiring to the engine...................................183
00.9.1.7 Disconnect the fuel line hoses at the fuel filter ................................183
00.9.1.8 Disconnect the throttle cable ...........................................................184
00.9.1.9 Remove the drive control links ........................................................184
00.9.1.10 Disconnect the hydrostatic pump hydraulic lines at the
pump ................................................................................................184
00.9.1.11 Remove engine mounting bolts .......................................................184
00.9.1.12 Remove the engine and hydrostatic pump assembly ......................185
00.9.1.13 Remove the hydrostatic pump and pump housing from
the engine ........................................................................................185
00.9 2 ENGINE/HYDROSTATIC PUMP INSTALLATION .........................................186

00.9.2.1 Install the HST pump to the engine .................................................186
00.9.2.2 Install the engine and HST pump assembly into the
frame ................................................................................................186
00.9.2.3 Connect the HST pump lines at the pump ......................................186
00.9.2.4 Make miscellaneous control connections ........................................186
00.9.2.5 Install the air cleaner........................................................................186
00.9.2.6 Install the radiator assembly ............................................................186
00.9.2.7 Install the oil cooler to the frame with 4 bolts ..................................186
00.9.2.8 Install the exhaust system ...............................................................186
00.9.2.9 Double-check all electrical wiring connections. ................................187
00.9.2.10 Bleed the air from the fuel system ...................................................187
00.9.2.11 Make final checks.............................................................................187
00.9.2.12 Warm the engine..............................................................................187
181
00.9.1 Engine/Hydrostatic Pump Removal

00.9.1 Engine/Hydrostatic pump removal 00.9.1.2 Remove the flexible tube, muffler, and tail tube
assembly (the exhaust system).
The engine and hydrostatic pump can be removed as a unit.
Then the hydrostatic pump is removed from the engine.
NOTE: For removal of the hydrostatic pump only (engine

remains in the loader), disconnect the battery as described
in 00.9.1.1, then turn to 9-1.9 in this section, below. Also refer
to section 05 in this manual, 2. Removal and Installation
Procedures.
CAUTION
Allow time for the exhaust system parts, radiator, and
hydraulic oil cooler to cool BEFORE attempting to
remove or work around any of them. These parts get
extremely HOT during operation and can burn you.
00-1
Before removing the engine/hydrostatic pump, drain the
hydraulic fluid from the hydraulic tank into a clean container
if it is to be reused. Also drain the antifreeze from the radi- 1) Remove 4 lock nuts holding the flexible tube assembly
ator and engine into a suitable container. Fluids that are not to the engine exhaust manifold.
going to be reused should be disposed of in accordance 2) Remove the 4 bolts and hard washers holding the
with all federal, state, and local ordinances and laws. muffler band assembly to the mast cross member.
The exhaust system can now be removed.
00.9.1.1 Disconnect the battery.
00.9.1.3 Remove the oil cooler.
00-5
1) Disconnect the negative ( - ) battery cable.
CAUTION 00-2
Always disconnect the negative ( - ) battery cable

before disconnecting the positive ( + ) battery cable. 1) Disconnect the 2 hydraulic lines at the top of the cooler.
2) Remove the 4 bolts that mount the oil cooler to the
2) Disconnect the positive ( + ) battery cable. frame and remove the oil cooler.
182
00.9.1.4 Remove the radiator assembly. 00.9.1.6 Disconnect all electrical wiring to the
engine.
1) Place an appropriate receptacle beneath the radiator See the Engine Wiring diagram in section 06 of this machine
drain cock. Service Parts Manual.
2) Loosen the radiator cap.
3) Loosen (do not remove) the radiator drain cock and
drain the radiator coolant completely. 1) At alternator.
4) Tighten the drain cock. 2) At oil pressure switch.
5) Disconnect the overflow hose at the radiator filler neck. 3) At water temperature sender.
6) Loosen the clamps and disconnect the radiator inlet 4) At intake air heater.
and outlet hoses at the engine side. 5) At starter motor.
7) Remove the radiator mounting bolts (2 top and bottom, 6) At engine ground.
each side). The radiator with hoses attached can now
be removed. 00.9.1.7 Disconnect the fuel line hoses at the fuel
00.9.1.5 Remove the air cleaner. filter.
00-8
Band Assembly
Clamp 1) Disconnect feed hose.
2) Disconnect return hose.
Hose
Clamp
00-6
1) Loosen the clamp and disconnect the air cleaner

hose on the engine side.
2) Loosen the 1 bolt that adjust the band assembly.
With the bands sufficiently loose, the air cleaner and
hose can now be removed.
3) Remove the 2 bolts that mount the band assemblies
to the mast. Remove the band assemblies.
183
00.9.1.8 Disconnect the throttle c able. 00.9.1.10 Disconnect the hydrostatic pump hydraulic
lines at the pump (8 hoses total).
00-11
Throttle cable Bracket
1) Disconnect the charge hose.

2) Disconnect the drain hose.
A
3) Disconnect the high pressure hoses.
4) Cap off and mark for reinstall.
00.9.1.11 Remove the mounting bolts.
A
Clevis-pin
00-9
1) Disconnect the throttle cable at the fuel injection pump

(1 pin, cotter pin).
2) Loosen the 2 jam nuts that secure the cable to the
bracket.
00.9.1.9 Remove the drive control links.

00-12
1) Remove 1 bolt from the HST pump support bracket (C).

2) Remove 1 bolt each side, front (B).
3) Remove 1 bolt each side, rear (A).
Note: If removing the HST pump only, do not remove the

engine mounting bolts (steps 2 and 3)
00-10
1) Right side control: Remove the nut from the ball joint.
2) Left side control: Remove the nut from the ball joint.
184
If removing the HST pump only: 00.9.1.13 Remove the hydrostatic pump and pump
housing from the engine.
1) Support the rear of the engine with a block of wood.

Support the hydrostatic pump with a sling or other lifting
device.
00-15
1) Remove the 2 bolts that mount the hydrostatic pump

to the pump housing. The pump will separate from the
housing. Set the pump aside.
00-15
00.9.1.12 Remove the engine and hydrostatic pump 2) Remove the 2 bolts that mount the hydrostatic pump
assembly.
to the pump housing. The pump will separate from the
housing. Set the pump aside.
1) Attach chain hooks to the front and back engine hangers.
3) Remove the 6 bolts that attach the HST mounting bracket
To keep the engine as level as possible, set the front
to the pump housing and remove the bracket.
chain hook onto the rear chain 20 cm (7.8") above the
4) Remove the 8 bolts that mount the pump housing
rear hanger.
to the engine back plate and remove the housing.
CAUTION
Before hoisting the engine and hydrostatic pump assem-
bly, be sure that all wiring and piping are disconnected.
2) Hoist the engine and hydrostatic pump assembly.

Move the assembly out through the frame front and place
it in a stationary position.
00-16
5) Remove the bolts that mount the rubber coupling

to the engine flywheel and remove the coupling.
IMPORTANT
At reassembly, be sure the rubber coupling is mounted with
the toothed spline out to engage the hydrostatic pump shaft
properly.
185
00.9.2 Engine/Hydrostatic Pump Installation

For installation, refer to the photos and illustrations with the 00.9.2.3 Connect the HST pump lines at the pump.
removal steps, above.
Charge hose, drain hose, high pressure hoses (8 hoses).
00.9.2.1 Install the HST pump to the engine. Refer to the Fitting Installation information in section 10
General Information/Miscellaneous for standard
1) Support the rear of the engine with a block of wood. torque specifications.
Use a hoist and sling or other lifting device to support the
HST pump. 00.9.2.4 Make miscellaneous control connections.
2) Clean the flywheel before installing the rubber coupling
to the engine. 1) Attach the right and left side drive control links with the
3) Coat the seats of the coupling mounting bolts with nut and ball joint.
grease. Be careful NOT to coat the threads. Mount the 2) Connect the throttle cable at the fuel injection pump
coupling to the flywheel with the bolts. Tighten each bolt and
to 8.5 – 9.4 k•m (6 – 6.5 ft. lbs.) in a criss-cross bracket.
sequence. 3) Connect the fuel feed and return hoses at the fuel filter.
4) Connect all electrical wiring at the engine:
Notice: Coupling mounting bolts have a blue anti-torsion
coating. These bolts can be removed and installed At alternator.
up to three times. Replace the bolts after the third At oil pressure switch.
removal and installation. At water temperature sender.
At intake air heater.
4) Coat the spline portion of the rubber coupling with At starter motor.
molydisulfide grease. At engine ground.
5) Mount the HST pump housing to the engine with 8
bolts. Coat each bolt with Loctite No. 242. NOTE: For detailed procedures on control adjustments,
6) Mount the HST support bracket to the pump housing see the following topics in section 02 Control System of
with 6 bolts. this manual: 2-4 Drive Control System Installation and
7) Mount the HST pump to the pump housing with 2 bolts Adjustment and 2-6 Hydraulic Control System
and to the pump support bracket with 1 bolt. Coat each Reassembly, Installation, and Adjustment.
bolt with Loctite No. 242.
00.9.2.5 Install the air cleaner.
00.9.2.2 Install the engine and HST pump assembly into 1) Install the band assemblies to the boom mast.
the frame. 2) Install the air cleaner and hose into the bands.
3) Connect the air cleaner hose to engine and to indicator
1) Attach chain hooks to the front and back engine hangers. with clamps. Adjust fit and tighten as necessary.
To keep the engine as level as possible, set the front
chain hook onto the rear chain 20 cm (7.8") above the 00.9.2.6 Install the radiator assembly.
rear hanger. See the diagram with step 8-1.12, above.
2) Align the engine and frame mounting brackets and set 1) Install 2 bolts, top and bottom, each side.
the assembly carefully into position. 2) Connect and clamp the inlet and outlet hoses to the
3) Install the engine mounting bolts. engine.
3) Connect the overflow hose to the filler neck.
4) Tighten the drain cock.
5) Fill the radiator with to appropriate amount of coolant.
See the Periodic Maintenance instructions for coolant
specifications in section 10 General Information
/Miscellaneous.
00-12
186
00.9.2.11 Make final checks.
Before starting the engine, check hydraulic oil,

engine oil, and coolant levels. Fill to the specified levels.
See the Periodic Maintenance instructions for all refill spec-
ifications in section 10 General Information/
Miscellaneous.
00.9.2.12 Warm the engine
Warm it for at least five minutes at low idle. Then check the
operation of all systems.
WARNING
Shim spacer to adjust the even clearance between the fan AVOID INJURY
and shroud. Never service or adjust the machine when the engine
is running unless instructed to do so in the service
00.9.2.7 Install the oil cooler to the frame with 4 bolts. manual.
Connect the 2 coolant lines at the top of the cooler.
00.9.2.8 Install the exhaust system
Connect the flexible tube, muffler, and tail tube

assembly to the engine exhaust manifold and support
00.9.2.9 Double-check all electrical wiring connections.
Connect the positive battery cable, then the negative

battery cable.
00-17a 00-17b
Injection Pump Fuel Pump
00.9.2.10 Bleed the air from the fuel system
Bleed the system manually if necessary. Loosen the air

vent joint (A) on the injection pump and operate the priming
lever (B) of the fuel feed pump up and down to bleed out the
air. Tighten the air vent joint (A) when finished.
187
188
01 Fuel System Contents
01 Fuel System
01.1 GENERAL.........................................................................................................190
01.2 FUEL LINES .....................................................................................................191
189
01 Fuel System 01.1 General
01.1 General
The basic fuel system for the DSL 601 consists of the fol- Poor loader performance resulting from fuel system prob-
lowing components: lems can usually be traced to one of the following:
• Contaminated fuel, especially water in the tank
• Fuel tank, incorporated into the left rear frame • Dirty fuel
• Water separator • Improper fuel grade or poor quality fuel
• Fuel feed pump • Air in the system, the result of loose connections or leaks
• Fuel filter in hoses
• Fuel injection pump • Kinks, crushing, or other damage to fuel lines
• Fuel injection nozzles • Fuel injection pump wear or other damage
• Associated supply and return lines, clamps, retainers,
and joints For detailed service information about the fuel injection
pump, governor, fuel feed pump, and fuel injection noz-
A throttle control provides direct operator control of engine zles, including fuel system troubleshooting, see section
speed and fuel flow. Refer to section 03 Control System 00 Engine, Chapter 3, Fuel Injection Equipment.
for detailed service information.
The fuel injection pump is driven off the engine timing gear.
Mounted on the injection pump, a fuel feed pump draws fuel
out of the tank, through the water separator, through the
fuel filter, and then into the fuel injection pump where it is
distributed to the injection nozzles. See the diagram below.
190
01 Fuel System 01.1 General
01.2 Fuel Lines
01-1
The fuel lines (hoses) connect the components listed below.

Hoses are attached with worm-drive clamps. The water sep-
arator mounts to the fuel tank with 1 bolt and hard washer.
Hose connections include:
• Fuel tank to water separator (supply line)

• Water separator to fuel injection pump on engine
• Fuel filter on frame to fuel oil tank (return line)
Refer to the Fitting Installation information in section 10

General Information/Miscellaneous for standard clamp
tightening specifications.
IMPORTANT: Do not twist, bend, or distort fuel injection

lines. Engine performance will be affected. Lines that have
been bent from their original configuration must be replaced.
191
192
02 Control System Contents
02 Control System
02.1 GENERAL .........................................................................................................195
02.2 CONTROL SYSTEM REMOVAL, INSTALLATION AND

ADJUSTMENT PROCEDURES .......................................................................196
02.2.1 SEAT BAR SYSTEM REMOVAL ........................................................196
02.2.1.1 Remove the gas cylinders ....................................................196
02.2.1.2 Remove the seat bar assembly ............................................196
02.2.2 SEAT BAR SYSTEM INSTALLATION ................................................197
02.2.2.1 Install the seat bar assembly ................................................197
02.2.2.2 Install the gas cylinders .......................................................197
02.2.2.3 Adjust the seat bar hold-down block.....................................197
02.2.3 DRIVE CONTROL SYSTEM REMOVAL ............................................198
02.2.3.1 Disconnect the drive control lever linkage............................198
02.2.3.2 Disconnect and remove the centering control assembly......198
02.2.3.3 Remove the drive control lever assembly ............................199
02.2.4 DRIVE CONTROL SYSTEM INSTALLATION AND ADJUSTMENT...200
02.2.4.1 Install and adjust the drive control lever assembly...............200
02.2.4.2 Connect and install the centering control assembly .............200
02.2.4.3 Install the drive control lever linkage ....................................200
02.2.4.4 Make final adjustments .........................................................200
02.2.5 HYDRAULIC CONTROL SYSTEM REMOVAL ..................................202
02.2.5.1 Disconnect the rod assemblies.............................................202
02.2.5.2 Disconnect the links..............................................................202
02.2.5.3 Remove the bell crank assemblies from the shaft................202
02.2.5.4 Remove the pedal assemblies from the frame.....................202
02.2.5.5 Disassemble the pedal assemblies.......................................202
02.2.6 HYDRAULIC CONTROL SYSTEM REASSEMBLY AND
INSTALLATION ...................................................................................203
02.2.6.1 Assemble the pedal assemblies ...........................................203
02.2.6.2 Install the pedal assemblies onto the frame .........................203
02.2.6.3 Install the pedal lock .............................................................203
02.2.7 THROTTLE CONTROL SYSTEM REMOVAL ....................................204
02.2.7.1 Remove the throttle cable from the throttle lever .................204
02.2.7.2 Remove the throttle cable from the bracket assembly
and fuel injection pump control lever....................................204
02.2.7.3 Remove the throttle lever......................................................204
02.2.7.4 Remove the bracket assembly .............................................204
02.2.8 THROTTLE CONTROL SYSTEM INSTALLATION ..............................204
02.2.9 PARKING BRAKE SYSTEM REMOVAL...............................................205
193
02 Control System Contents
02.2.9.1 Remove the cable assemblies................................................205

02.2.9.2 Remove the parking brake assemblies (each side)................205
02.2.10 PARKING BRAKE SYSTEM INSTALLATION AND ADJUSTMENT ...206
02.2.10.1 Install and adjust the parking brake cables,
brake assembly and disk......................................................206
02.2.11 PEDAL LOCK SYSTEM REMOVAL INSTALLATION AND
ADJUSTMENT ...................................................................................208
02.2.11.1 Remove the pedal lock system .............................................208
02.2.11.2 Install the pedal lock system .................................................208
02.2.11.3 Adjust the pedal lock system.................................................209
194
02 Control System 02.1 General
02.1 General
The term "control system" actually groups together a num-
ber of discreet subsystems that each contribute to the oper- CAUTION
ation of the machine. These subsystems include:
Attempting to drive through this brake may damage the
• Seat Bar System loader.
• Drive Control System
• Centering Control System For specific removal, installation, and adjustment proce-
• Hydraulic Control System dures, refer to each system's section below. See the Table
• Throttle Control System of Contents on the preceding page.
• Parking Brake System
General functions of the systems are as follows:
Seat Bar System - A safety device, if not engaged (bar

pulled down in front of the operator and held securely in
place by a nylon block), the hydraulic control pedals are
mechanically locked in place and will not operate.
Drive Control System - Two levers that control the speed

and direction of the loader wheels through mechanical link-
ages to the hydrostatic pump.
Centering Control System - Two mechanical devices that

automatically position the drive control levers in the upright,
neutral position when the levers are released.
Hydraulic Control System - Three foot pedals that control

speed and directional movement of the bucket (RH pechal),
boom (LH pedal), and auxiliary equipment (center pedal).
Mechanical linkages run from the pedal assemblies to the
hydraulic control valve.
Throttle Control System - A left-side-mounted handle that

connects by cable to the fuel injection pump to control
engine speed.
Parking Brake System - A seatbar raised position engages

a pin into a cog mounted on the drive motors on each side.
195
02 Control System 02.2 Control System Removal, Installation And Adjustment Procedures
02.2 Control System Removal, Installation and

Adjustment Procedures
2-1 Seat bar system removal
The seat bar system includes the seat bar assembly and the
lock assembly.
2-1.1 Remove the gas cylinders and parking brake

cable (1 on each side).
02-1
1) Remove the nut that mounts the bottom cylinder stud

to the canopy. Remove the nut that holds the top stud of
the gas cylinder to the seat bar assembly if necessary.
2) Remove the clevis to disconnect the parking brake

cable.
2-1.2 Remove the seat bar assembly.
On each side, remove the bolt, washer, spacer and nut that
mount the seat bar to the frame. Note order for reassembly.
196
2-2 Seatbar system installation
2-2.1 Install the seatbar assembly
On each side, install the bolt, washer, spacer and nut that
mount the seat bar to the frame.
2-2.2 Install the gas cylinders (1 on each side).

1) Install the nut that mounts the bottom cylinder stud to the
frame.
2) Install the nut that holds the top stud of the gas cylinder
to the seat bar assembly.
3) Install the parking brake cable.
197
2-2.3 Adjust the seat bar hold-down block.
02-4
02-2E 2) Remove the nut and washer that connects the rear
ball joint of the linkage rod to the pump pintle lever.
1) Test the fit of the seat bar. There should be minimum 2-3.2 Disconnect and remove the centering control
wobble with the bar engaged. assembly. (Do for each side.)
2) If adjustment is necessary, loosen the two bolts that
secure the nylon block to the canopy. Adjust the block in
or out as needed to hold the seat bar in place.
3) Make fine adjustments with the bolt/jam nut on the
canopy frame if necessary.
2-3 Drive control system removal
The drive control system includes the right and left side
drive control assemblies and centering control.
WARNING 02-6
Wear safety glasses to prevent eye injury when any of
the following conditions exist:
Fluids are under pressure. 1) Remove the nut, pillow ball, and bolt that connect the
Flying debris or loose material is present. centering control cover to the tang on the lever assem-
Engine is running. bly.
Tools are in use. 2) Remove the nut from the centering control rod ball
joint where it attaches to its mounting bracket on the
2-3.1 Disconnect the drive control lever linkage. (Do frame.
for each side.) 3) Remove the two bolts that attach the centering control
housing to its mounting bracket.
02-3
1) Remove the nut that connects the front ball joint of the
linkage rod to the tang on the lever assembly.
198
2-3.3 Remove the drive control lever assembly. (Do

for each side.)
02-5
1) Remove the two nuts, washers, and bolts that mount

the end of the shaft assembly to the upper plate.
2) Remove the 4 bolts that mount the boot and plate to
the upper plate. Work the boot and plate back through the
hole in the upper plate.
3) Free the lever assembly from the "U" bracket on the
upper plate and pull the handle out through the hole.
199
2-4 Drive control system installation and adjustment 5) Adjust to two stop bolts on the lever assembly to bot-
tom out against the upper plate when the lever is
moved to the full FORWARD and full REVERSE posi-
WARNING tions. See the photo in the first column. This is just a
rough adjustment for the moment. For final adjust-
Wear safety glasses to prevent eye injury when any of ments, see the topic below, 2-4.4 Make final adjust-
ments.
the following conditions exist:
Fluids are under pressure.
Flying debris or loose material is present. 2-4.2 Connect and install the centering control
Engine is running. assembly. (Do for each side.)
Tools are in use.
1) Install the two bolts that attach the centering con-
Except as noted below, refer to the disassembly illustrations trol housing to its mounting bracket.
for installation. 2) Install the nut for the centering control rod ball
joint where it attaches to its mounting bracket on the
2-4.1 I n st al l an d a d ju s t th e d r iv e c o n tr o l lever hydrostatic pump.
assembly. (Do for each side.) 3) Install the nut, pillow ball, and bolt that connect
the centering control cover to the hydrostatic pump
pintle lever arm.
2-4.3 Install the drive control lever linkage. (Do for

each side.)
1) Install the nut and washer that connects the rear ball
joint of the linkage rod to the hydrostatic pump pintle
lever.
2) Install the nut that connects the front ball joint of the
linkage rod to the tang on the lever assembly.
2-4.4 Make final adjustments.

02-5A
NOTE: Adjusting the drive control involves three sets of
components:
1) Insert the handle through the upper plate. Fit the shaft 1. The neutral position in the HST pump.
into the the "U" bracket. 2. The linkage rods that connect the control to the
2) Work the boot and plate back through the hole in the drive control lever assembly, and
upper plate. Install the 4 bolts that mount the boot and 3. The centering control devices.
plate to the upper plate.
3) Install the two nuts, washers, and bolts that mount the Final operational check will be made after all static
end of the shaft assembly to the upper plate. adjustments are complete.
4) In the neutral position, the drive control levers should be IMPORTANT
90° in reference to the top surface of the upper plate. Before adjusting any mechanical linkages or devices (2
Make any necessary adjustment by lengthening or short- and 3) , you must be sure that the HST pump itself is
ening the control linkage rods. (When properly adjusted, adjusted to neutral (1). See the procedure for doing this
the centering controls will hold the levers in the straight- in section 05 Hydrostatic System.
up position.)
Linkage, HST control to drive control lever assembly
adjustment: (Do for each of the two linkage rods.)
02-5B
200
NOTE: This adjustment is made by sight and feel. Final

adjustments with the loader operation will be made later.
02-5D
1) To adjust the rod, loosen the jam nut and turn the adjust-
02-5C ing nut in or out as necessary.
2) Readjust the stop bolts on the drive control assembly to
bottom out at full FORWARD and full REVERSE if nec-
1) Lower the boom to the ground. essary.
2) Raise the canopy and lock it in position. 3) Recheck the adjustment of the control linkage rods.
3) Make sure the drive control handles are rough adjusted The neutral control must be static in its center position.
to the 90° vertical position. See the procedure above, 2- There should be NO TENSION ON THE ROD! At the
4.1, Install and adjust the drive control assembly. same time, there should be no play in the rod either.
4) Loosen the jam nut at the rod end.
5) Adjust the length of the rod by turning it so that the neu- Operational test:
tral control is static in its center position. There should be
NO TENSION ON THE ROD! At the same time, there 1) Lower the boom to the ground.
should be no play in the rod either. 2) Raise the canopy and lock it in position.
3) Jack the loader up off the ground so that all four tires are
Centering control adjustment: (Do for each of the two free to turn. Support the loader on jack stands.
centering controls.) 4) Start the engine and observe the wheels. If the drive con-
trol system is properly adjusted to the neutral position,
Adjust the centering control so that the wheel of the neutral none of the wheels should turn.
switch fits into the detent on the rod when the drive control
handle is at 90°, the neutral position. If any movement is detected in the wheels, STOP THE
ENGINE and check the adjustment of the control linkage
rods (right or left, depending on which wheels are turning).
Minor mechanical creep is adjusted out at the centering
device. If linkage adjustment is correct and there is still
wheel movement, the problem may be unequal pressure in
the HST neutral adjustment.
201
2-5 Hydraulic control system removal 2-5.3 Remove the bell crank assemblies from the
shaft.
The hydraulic control system includes the three foot pedal
assemblies and associated linkages.
2-5.1 Disconnect the rod assemblies.
02-7D
1) Remove the retaining ring, washers, spacers and bushings.
2-5.4 Remove the pedal assemblies from the frame.

02-7B
Bosses
1) At the control valve spools by removing the cotter pins
and clevis pins.
2) At the bell crank assemblies by removing the cotter
pins and clevis pins.
2-5.2 Disconnect the links.

Bosses
02-7E
2) Loosen the hex socket head bolts from the bosses.

3) Slide the pedal assemblies either direction out of
the bosses.
2-5.5 Disassemble the pedal assemblies.
02-7C Set Collar
Note: Disconnect the bell cranks by removing the clevis

pins. For removal, installation and adjustment of the pedal
lock assembly, see section 2-13.
Set Collar
Woodruff key
02-7F
1) Remove the woodruff key.

2) Loosen the set screw in the set collar and remove
the set collar.
3) Separate the pedals, bushings, and plate assembly.
202
2-6 Hydraulic control system reassembly and

installation
For reassembly and installation, refer to the illustrations with

the removal steps, above.
2-6.1 Assemble the pedal assemblies.
1) Assemble the pedals, bushings, and plate assembly.

2) Install the set collar and tighten the set screw.
3) Install the woodruff key.
2-6.2 Install the pedal assemblies onto the frame.
1) Slide the pedal assemblies into the bosses.

2) Tighten the hex socket head bolts on the bosses.
2-6.3 Install the pedal lock.
See section 2-13.
WARNING
Adjust the pedal lock cable so that lift, tilt & auxiliary
control pedals are locked in neutral when the seat bar is
up.
CAUTION
Adjust the yoke and nut on the bell crank end of the rod
assemblies so that the pedal assembly angle is 34¡ at
the neutral position in the control valve.
203
02 Control System 02.2 Control System Removal, Installation And Adjustment
2-7 Throttle control system removal
Cable
Upper plate Lever

Bracket
02-7G
The throttle control system includes the throttle lever, throt- 2-7.3 Remove the throttle lever.
tle cable assembly, and bracket assembly. Refer to the illus-
tration above for 2-7.1 through 2-7.4. 1) Remove the screw, washer and nut.
2) Remove the lever trom the upper plate.
2-7.1 Remove the throttle cable from the throttle lever.
2-7.4 Remove the bracket assembly.
1) Loosen the screw on the lever that holds the wire of cable
2) Remove the cable from the lever through the uppler 1) Remove the mounting bolt, washer, and bracket.
plate.
2-8 Throttle control system installation
2-7.2 Remove the throttle cable from the bracket
assembly and fuel injection pump control lever. For installation, refer to the illustrations with the removal
steps, above.
1) Remove the jam nut, washer, nut, and bolt from the
cable end clevis at the fuel injection pump control lever. Install thes thro throttle control system in reverse order of
2) Loosen the nut that holds the cable in the bracket removal mounting bolt, washer, and bracket.
assembly and lift the cable out of the bracket.
204
2-9 Parking brake system removal

The parking brake system includes the brake lever assem-
bly, 2 brake assemblies (1 on each side), 2 cable assem-
blies (1 set of 2 on each side), and associated linkages,
springs, and fasteners.
2-9.1 Remove the cable assemblies.
02-8
1) Remove the chain case covers to access the parking 9) Remove the remaining fasteners from the cable and
brake assemblies. remove the cable assembly from the frame.
2) Place the parking brake lever in the release position.
3) Remove the spring (A) to release tension.
4) Remove the cotter pin and clevis pin from the clevis at 2-9.2 Remove the parking brake assemblies (each side).
the brake lever.
5) Loosen the bolts and clamp that hold the cable assem- 1) Remove the 2 springs at bellcrank assembly (C).
blies to the frame bracket and slide the cables out of the 2) Remove the bolts and washers that mount the parking
bracket. brake assembly to the frame and lift out the brake assem-
6) Remove the cotter pin and clevis pin from the clevis at bly.
the end of the cable assembly where it attaches to the 3) For removal of the disc, remove the 4 bolts, washers, and
seat bar. spacers at (D).
7) Unscrew the clevis from the end of the cable.
8) Disconnect the cable where it attaches to the frame at (B).
205
2-10 Parking brake system installation and

adjustment
WARNING
Function and adjustment of the parking brake should
be checked on a routine basis to maintain proper oper-
ation at all times.
2-10.1 Install and adjust the parking brake cables,

brake assembly and disk.
m
76m
02-9
1) With the forward chain case covers removed, feed the 8) Lower the canopy. Raise the seat bar. Adjust the slack
cable assembly into the frame and install the fasteners. out of cable (E) and tighten the jam nuts.
2) Screw the clevis onto the end of the cable at the seat bar. 9) Lower the seat bar. Adjust the cable assembly yoke
3) Attach the clevis to the seat bar with the clevis pin and so that the brake disengages and there is a 10mm
cotter pin. clearance between the brake assembly lock and the
4) Clamp the cable assembly to the frame. disc.
5) Attach the clevis to the parking brake lever. 10) Move the brake lever to the engaged position.
6) Place the lever in the engaged position. Adjust the rod 11) Adjust cable (E) until the brake is fully engaged.
so that the top arm at the bellcrank is approximately 133o 12) Raise the seat bar. Move the brake lever to the
from horizontal. engaged position and verify that it is engaged. Then
7) Place brake lever in the disengaged position. move the lever to the disengaged position. Verify that
206
the brake is still engaged.

13) Lower the seat bar. Engage the brake and verify that it
is engaged. Disengage the brake and verify that it is dis-
engaged.
14) Adjust plate by nuts until the dimension between plate
and cable mtg.plate to 76mm for keeping the tension of
cable.
15) Set the parking lever to the unlock position.
16) Adjust S/W location until S/W lever should contact with
the plate.
17) Tighten all nuts.
18) Seal the chain case covers with sealant and install the
covers.
IMPORTANT
When replacing the chain case/parking brake area covers,
seal the covers with sealant.
SEE THE TOPIC "PARKING BRAKE ADJUSTMENT"

UNDER PERIODIC MAINTENANCE IN SECTION 10 GEN-
ERAL INFORMATION/MISCELLANEOUS FOR IN-SER-
VICE INSPECTION AND ADJUSTMENT OF THE PARKING
BRAKE.
207
2-11 Pedal lock system removal, installation,

and adjustment
The pedal lock system includes the cable assembly and

lock assembly and associated brackets and fasteners.
2-11.1 Remove the pedal lock system.
CAUTION
The lock assembly levers are under spring tension.
Restrain the springs if you disassemble the lock assembly
itself.
02-10
1) Disconnect the cable clevis fromt the seat bar. Remove 2-11.2 Install the pedal lock system.
the clevis.
2) Remove the jam nut and pull the cable through the 1) Mount the lock assembly to the frame with 2 bolts.
frame. 2) Mount the cable bracket to the frame with 2 bolts.
3) Disconnect the cable clevis from the plate guide in the 3) Connect the cable clevis to the plate guide.
lock assembly. 4) Feed the cable through the top of the frame and install
4) Remove the 2 bolts that mount the cable bracket to the the jam nut. Install the clevis and connect it to the seat
frame. The cable is now free. bar.
5) Remove the 2 bolts that mount the lock assembly to the
frame. The lock assembly is now free.
208
2-11.3 Adjust the pedal lock system.
02-11
209
The pedal lock is designed to prevent the three foot pedals

from being activated if the seat bar is up. Lowering the seat
bar pulls three spring loaded, notched levers away from the
bellcranks on the pedal shafts, making the pedals operable.
Raising the seat bar causes the springs to pull the notched
levers into a position that blocks the bellcranks, making the
pedals inoperable.
If adjustment is needed, do the following:

1) Check the positions of the levers when the seat bar is
raised and when it is lowered. Determine whether the
levers need adjustment toward or away from the bell-
crank ends.
2) Raise the seat bar to release tension from the linkage.
3) Loosen the jam nut (A), remove pin (B).
4) Rotate the clevis (C) to adjust cable length in or out, as
needed, until the pedal lock functions properly.
5) Re-attach the clevis and tighten the jam nut.
210
03 Power Train Contents
03 Power Train
03.1 GENERAL.........................................................................................................212
03.2 POWER TRAIN DISASSEMBLY AND ASSEMBLY.........................................213

03.2.1 POWER TRAIN DISASSEMBLY ........................................................213
03.2.1.1 Remove wheels and tires.....................................................213
03.2.1.2 Remove the chain case covers............................................213
03.2.1.3 Remove the parking brake components...............................213
03.2.1.4 Remove the disk and motor sprocket...................................213
03.2.1.5 Remove the chain .................................................................214
03.2.1.6 Remove the hydrostatic motor ..............................................214
03.2.1.7 Remove the axle shaft ..........................................................215
03.2.2 POWER TRAIN INSTALLATION ........................................................215
03.2.2.1 Install the axle shaft..............................................................215
03.2.2.2 Install the hydrostatic motor ..................................................216
03.2.2.3 Install the chain .....................................................................216
03.2.2.4 Install the parking brake disc and motor sprocket................216
03.2.2.5 Install the chain case covers and gaskets............................216
03.2.2.6 Install the wheels and tires ...................................................216
211
03 Power Train 03.1 General
03.1 General
The power train includes the tires, wheels, and axle assem-
blies as well as the sprockets, chains, and bearing assem-
bles inside the oil-filled chain cases. The parking brake
components and hydrostatic motors attach to and function
with the power train, but detailed discussions of these com-
ponents is covered in other sections of this manual (parking
brake - section 02 Control System; hydrostatic motor - sec-
tion 05 Hydrostatic System).
Access to the chain cases is gained by removing any nec-

essary covers with gaskets. Note that on reassembly, these
covers must be properly sealed to prevent entry of contam-
inants.
Most inspection, adjustment, or repairs of power train com-

ponents require that you drain the respective chain case. If
the oil is to be reused, store it in a clean and suitable con-
tainer. If it is to be disposed of, follow all federal, state, and
local ordinances and laws governing such disposal.
Typically, performance problems related to power train

operation are not subtle. Unusual noise and vibration, often
loud and pronounced, signal difficulties. Broken or loose
chains will drastically affect operation on one side of the
loader. This is also true of damaged bearings. Often these
problems can be traced to improperly tightened parts.
Assembly procedures require careful attention to fit and
torque specifications to prevent premature component wear
or failure.
Bear in mind that even slight amounts of dirt or water in the

oil can destroy bearings and score rotating surfaces on
shafts and sprockets. Chain case contamination must
always be guarded against.
212
03 Power Train 03.2 Power Train Disassembly And Assembly
03.2 Power Train Disassembly and Assembly

Before Removing any power train system components 1) Raise and securely lock the canopy.
(except when removing only wheels and tires), drain the oil 2) Remove the upper covers and gaskets on chain case.
from the chain case. See the Periodic Maintenance section 3) Remove the rectangular covers and gaskets on the out-
of this manual for the correct procedure. side frame, opposite the hydraulic motors.
The following procedures are presented in the order 2-1.3 Remove the parking brake components.
required to disassemble the entire power train system.
1) Follow the procedures under Parking Brake System
2-1 Power train disassembly Removal in section 02 Control System.
2-1.1 Remove wheels and tires. 2-1.4 Remove the disk and motor sprocket.
1) Working through the round access cover opening,

WARNING remove the bolt and washer from the motor sprocket.
2) Remove the disk from the motor sprocket, then remove

Be sure the skid steer loader is on a level surface before
the motor sprocket.
removing wheels and tires.
1) Lift the frame and support it with jack stands so that the
tires are off the ground.
2) Support the tire and remove the hub nuts.
3) Lift the wheel and tire by the rim and pull it free of the
wheel studs.
2-1.2 Remove the chain case covers.
WARNING
Be sure the canopy lock is securely latched whenever
the canopy is in the raised position. Failure to lock the
canopy securely may result in injury or death.
03-2
213
2-1.5 Remove the chain.
03-5
1) Turn the axle shaft until the chain connecting link is

accessible from the outside chain case opening.
2) Pull out the cotter pins, remove the connecting link, and
remove the chain from the case.
2-1.6 Remove the hydrostatic motor.
CAUTION
Do not attempt to disconnect hydraulic lines and hoses
when they are hot. Allow the system to cool before dis-
connecting lines and hoses.
03-6
1) Remove the floor plate.

2) Disconnect the motor lines and hoses from the hydrostatic
pump.
3) Remove the 4 bolts that attach the motor flange to the
frame. Remove the motor and gasket.
4) Remove the hoses from the motor.
IMPORTANT
When repairing hydrostatic and hydraulic systems, clean the
work area before disassembly and keep all parts clean.
Always use caps and plugs on hoses, tube lines and ports to
keep dirt out. dirt can quickly damage the system.
214
2-1.7 Remove the axle shaft.
03-10
1). Remove the bolt, washer and driven sprocket.

CAUTION
2). Remove the axle. Bearing cones are removed from
inside the chain case. Be sure to install the spacer between the bearing cone
and the sprocket.
CAUTION CAUTION
Check for damage to the oil seal when you pull out the axle.
Check the direction of sprocket installation. Install the
front and rear drive sprockets according to the marks
2-2 Power train installation you made on their faces at disassembly.
For installation, refer to the photos and illustrations with the 3) Install the inside bearing cone, spacer, drive sprocket,
removal steps, above. disc and washer. (Disc shall be installed on front axle)
4) Initially, tighten the bolt to 200 L 20 N•m (147 L 15 ft.-
2-2.1 Install the axle shaft.
lbs.).
5) Rotate the axle 1-2 times to be sure there is no binding.
1) Check the oil seal and the inside and outside bearing
6) Back off the bolt until it will turn by hand.
cups before installing the axle shaft. Replace any of
7) Retighten the bolt to 50 N•m (38 ft.-lbs.) with Loctite#271.
these components if damaged.
2) Install the axle shaft with outside bearing cone in place.
Take care not to damage the oil seal in the axle housing.
215
2-2.2 Install the hydrostatic motor. 2-2.6 Install the wheels and tires.
1) Install the motor flange with Loctite #2C to the frame 1) Install the tire and wheel onto the axle.
with 4 2) Place a wedge under the tire to stabilize it and fasten
bolts with 125 L 15N.m torque, Loctite#243. the hub nuts.
2) Install the lines and hoses to the hydraulic motor. 3) Tighten the nuts to 146 L 20 N•m (108 to 15 ft.-lbs.).
4) Check tire inflation: 3.2 kg/cm2 (45 psi).
2-2.3 Install the chain.
1) Through the chain case opening, fit the chain over the
sprockets.
2) Install the connecting link, link plate, and cotter pins.
Chain Slack
S
The each chain slack(s) is as follows

A-B : 17-26mm
C-D : 21~32mm
2-2.4 Install the parking brake disc and motor sprocket.
1) Fit the motor sprocket over the hydraulic motor shaft.

2) Install the sprocket with the washer and bolt with
Loctite#271
2-2.5 Install the chain case covers and gaskets.
Install the rectan gular covers opposite the hydraulic motor.

Tighten the bolts to 20 L 5 N•m (15 L 4 ft.-lbs.)
Install the upper covers and gaskets. Tighten the bolts to 20
L 5 N•m (15 L 4 ft.-lbs.)
IMPORTANT
When replacing the chain case/parking brake area covers,
seal the covers with sealant.
216
04 Hydraulic System Contents
04 Hydraulic System
HYDRAULIC SCHEMATIC.........................................................................................218
04.1 GENERAL.........................................................................................................219
04.1.2 HYDROSTATIC (HST) SYSTEM ........................................................219
04.2 REMOVAL AND INSTALLATION PROCEDURES ..........................................220
04.2.1 HYDRAULIC CHARGE PUMP ...........................................................220
04.2.1.1 Remove the hydraulic charge pump.....................................220
04.2.1.2 Install the hydraulic charge pump.........................................220
04.2.2 HYDRAULIC CONTROL VALVE.........................................................221
04.2.2.1 Remove the control valve .....................................................221
04.2.2.2 Disassemble and reassemble the control valve ...................222
04.2.2.3 Install the control valve .........................................................223
04.2.2.4 Check and set maximum system pressure ..........................224
04.2.3 BOOM AND BUCKET CYLINDERS ...................................................224
04.2.3.1 Disassemble the boom cylinder............................................224
04.2.3.2 Assemble the boom cylinder.................................................224
04.2.3.3 Disassemble the bucket cylinder ..........................................225
04.2.3.4 Assemble the bucket cylinder ...............................................225
04.2.4 HYDRAULIC LINES............................................................................226
04.2.5 BOOM AND BUCKET CYLINDER LINES ..........................................227
04.2.5.1 Remove and install the boom cylinder lines .........................227
04.2.5.2 Remove and install the bucket cylinder lines .......................227
04.2.6 ATTACHMENT LINES.........................................................................228
04.3.1 TEST EQUIPMENT ............................................................................229
217
04 Hydraulic System Hydraulic Schematic
Hydraulic Schematic
218
7
6
8 5
9
4
10
2 1 HST PUMP
2 HST MOTOR
3 CONTROL VALVE
4 BOOM CYLINDER
2 5 BUCKET CYLINDER
6 QUICK COUPLER(MALE)
7 QUICK COUPLER (FEMALE)
11 8 BY-PASS VALVE
9 OIL COOLER
10 HYD FILTER
11 DRAIN RELIEF VALVE
218.1
04 Hydraulic System 04.1 General
04.1 General
1-1 Hydraulic system
1-2 Hydrostatic (HST) system
The HYDRAULIC CHARGE PUMP is directly connected to
the hydrostatic pump. It draws hydraulic oil from the Through its manual control mechanisms, the HST PUMP
HYDRAULIC TANK and "charges" the hydraulic system with sends oil to the left and right side HST MOTORS. The HST
hydraulic power converted from engine power. PUMP drives the HST MOTORS forward or reverse accord-
ing to the position of the drive control levers.
From the hydraulic charge pump, hydraulic oil is sent under
pressure to the CONTROL VALVE. Spools in the control From the HST MOTORS, oil is returned to the HYDRAULIC
valve, operated by the drive control levers and control ped- TANK through the DRAIN RELIEF VALVE, which controls
als, distribute the oil to actuating devices – BOOM CYLIN- the drain flow.
DERS, BUCKET CYLINDERS, and AUXILIARY EQUIP-
MENT. Various HYDROSTATIC LINES, both metal tubing and
hose, carry hydraulic oil between the HST PUMP and the
Return oil from actuating devices is sent to the OIL COOL- HST MOTORS.
ER and HYDRAULIC FILTER, then on to the HYDROSTAT-
IC (HST) PUMP.
Various HYDRAULIC LINES carry hydraulic oil between the

control valve, oil cooler, filter, and actuating devices.
219
04 Hydraulic System 04.2 Removal And Installation Procedures
04.2 Removal And Installation Procedures

2-1 Hydraulic charge pump
04-1
2-1.1 Remove the hydraulic charge pump.
1) Remove the hydraulic lines connected to the charge

pump.
2) Remove the 2 bolts that mount the pump to the hydro-
static pump.
3) Remove the gasket.
2-1.2 Install the hydraulic charge pump.
1) Install the gasket.

2) Install the 2 bolts that mount the pump to the engine.
3) Install the hydraulic lines to the charge pump.

General Information/Miscellaneous for standard torque
specifications.
220
2-2 Hydraulic control valve
2-2.1 Remove the control valve.
04-4
3) Remove the tube assemblies and hose assemblies.
04-2 NOTE: It may be easier to break the hard lines loose at the
first junction from the control valve, then remove them from
the loader along with the control valve.
1) Remove the centering control device on the control valve
side of the HST pump.
04-5
04-3 4) Remove the 3 bolts that mount the control valve to the
frame and remove the control valve.
2) Remove the control linkages on the valve spools.
221
2-2.2 Disassemble and reassemble the control valve. Main Relief Valve: Assembly and Installation
Refer to the control valve exploded view in your DSL 601 1) Lubricate all new o-rings and backup rings with clean oil.
Parts Manual and the illustrations below. 2) Assemble the o-ring (43) and the seal nut (45) on the
adjustment bolt (46) with the body (44).
Main Relief Valve: Removal and Disassembly 3) Assemble the o-ring (37) with the ring (42) and insert into
the valve body.
AUX
04-5a
1) Locate the relief valve in the control valve. Remove any 4) Assemble the o-rings (33-31) and the backup ring (32)
dirt and grease in the area before removing. with the body (34). Insert the ring (35) and the spring
2) Unscrew the relief valve body assembly from the control (36).
valve assembly. 5) Assmble the o-ring (37) and the backup ring (38) with the
3) Remove and discard o-rings and backup rings. Take ring (39) and insert in the body (34).
care not to nick or scratch the cartridge. 6) Insert the pin (40), the spring (41) and install the body kit
4) Loosen the seal nut and remove the adjustment bolt and (44) into the body (34) and tighten to 40 N•m (30 ft.-
seal nut. Loosen and remove the screw kit. lbs.)
5) Clean the cartridge with a suitable solvent. 7) Insert the cartridge into the control valve and tighten to
6) Inspect the cartridge for damage and replace if necessary. 40 N•m (30 ft.-lbs.).
8) Adjust the maximum system pressure setting. (See pro-
cedure below in this section 2-3.4.)
222
Check Valve: Removal and Disassembly 7) Assemble the yoke and clevis pin to the spool.
See illustration above. Boom Raise/Lower or Auxiliary Spool Assembly (with

Detent): Removal and Disassembly
1) Locate the check valve (there are 3) on the top of the
control valve. Remove any dirt and grease in the area See illustration above.
before removing.
2) Remove the check valve kit. 1) Locate the tilt spool on the control valve. Remove any
dirt and grease in the area before removing.
Check Valve: Assembly and Installation 2) Remove the control cable clevis pin and yoke from the
spool.
1) Clean all parts with suitable solvent. Allow the parts to 3) Remove the end cap (20), the spring (19), the ring (18),
dry. and the ball (16).
2) Lubricate the new o-ring with clean oil and install into the 4) Remove the bushing (17) and the cap (14) by removing
valve kit. the four mounting screws.
3) Install the valve kit into the control valve and tighten to 30 5) While holding the spool, remove the detent spool (22) or (13).
N•m (22 ft.-lbs.). 6) Remove the bushes (9 and 12), the spring (11), and the
ring (10).
Tilt Spool Assembly (without Detent): Removal and 7) Carefully remove the spool from the valve body and
Disassembly inspect. If the spool shows any signs of wear or scoring,
the entire valve must be replaced.
See illustration above.
Boom Raise/Lower or Auxiliary Spool Assembly (with
1) Locate the tilt spool on the control valve. Remove any Detent): Assembly and Installation
dirt and grease in the area before removing.
2) Remove the control cable clevis pin and yoke from the 1) Clean and dry all parts with a suitable solvent.
spool. 2) Lubricate the new o-rings and rod wiper with clean oil.
3) Remove the flange (31). Insert the o-rings and rod wiper into the groove in the
4) Remove the end cap (25). front and in the back of the valve. Be careful not to nick
5) While holding the spool, remove the screw (23). or cut the o-ring during assembly.
6) Carefully remove the spool from the valve body and 3) Insert the detent spool (13 or 22) through the bush (9 and
inspect. If the spool shows any signs of wear or scoring, 12), insert the spring (11) and the bush (9). If necessary,
the entire valve must be replaced. insert the ring (10). Assemble the detent to the spool and
7) Remove the rod wiper (5) and the o-rings (2) from the tighten to 10 N•m (7 ft.-lbs.).
valve body. Be careful not to scratch the bore or conta- 4) After assembly, check for operation of the spring by
minate it with foreign material. pushing down on the detent. This should compress the
spring. It should return when released. Apply grease to
Tilt Spool Assembly (without Detent): Assembly and the springs and bushings.
Installation 5) Place the cap (14) over the assembly and install the
mounting screws (15). Tighten them to 7.5 N•m (5.5 ft.-
1) Clean and dry all parts with a suitable solvent. lbs.). Reassemble the bushing (17) with detent balls
2) Lubricate the new o-rings and rod wiper with clean oil. (16), the ring (18), and the spring (19).
Insert the o-rings and rod wiper into the groove in the 6) Place the new lubricated o-ring (21) with clean oil onto
front and in the back of the valve. Be careful not to nick the end cap (20). Place the end cap over the assembly
or cut the o-ring during assembly. and tighten to 20 N•m (15ft.-lbs.).
3) Install the screw (23) onto the end of the spool and 7) Assemble the yoke and clevis pin to the spool.
screw it down. Tighten to 30 N•m (22 ft.-lbs.).
4) After assembly, check for operation of the spring by
pushing down on the screw. This should compress the 2-2.3 Install the control valve.
spring. It should return when released. Apply grease to
the springs and bushings. For installation, refer to the photos and illustrations with the
5) Place the end cap (25) over the assembly and install removal steps, above.
the mounting screws (15). Tighten them to 7.5 N•m (5.5
ft.-lbs.). 1) Mount the control valve onto the frame with 3 mounting
6) Place the seal (30) into the flange (31) and install the bolts.
mounting screws (24). 2) Connect the hose assemblies and tube assemblies.
IMPORTANT
Install the fittings carefully to avoid damaging the o-rings.
Hand tighten, then tighten with a wrench to 65 N•m (100 ft.-
lbs.).
223
3) Install the valve spool control linkages.

4) Connect the centering device on the control valve side
of the HST pump.
2-2.4 Check and set maximum system pressure.
1) Insert an appropriate-sized pressure gauge into

the female auxiliary line coupling.
2) Start the diesel engine and allow about 30 seconds
for the gauge to settle.
3) Run the engine to HIGH IDLE - 2975 + 50 RPM.
4) Engage the center hydraulic control pedal (auxiliary
pedal) fully.
5) Check the reading on the pressure gauge. Maximum
system pressure at HIGH IDLE should be 2480 + 35
PSI.
04-6
1) Place the cylinder in a vice and remove the rod cover.

2) Remove the rod assembly from the boom cylinder
assembly.
3) Remove the nylon lock nut, piston, and rod cover
from the rod.
4) Disassemble the piston: wear rings, dust ring, o-ring.
5) Disassemble the rod cover: o-ring, back-up rings, dust
wiper, bushing, U-packing.
04-5b 6) Remove the bushing from the knuckle and head
cover.
2-3.2 Assemble the boom cylinder.

CAUTION
Return the auxiliary pedal to its neutral position while For assembly, refer to the illustration with the disassem-
making adjustments to prevent overtemperature dam- bly steps, above.
age.
6) If adjustment is necessary, do the following: Loosen the
seal (jam) nut (43) with a 13mm wrench.
CAUTION
7) Insert a 5mm allen wrench into the screw (42). Only trained personnel should perform this proce-
8) To increase system pressure, turn the allen wrench slowly dure.
in a clockwise direction. To decrease system pressure, Select a clean area to do this work.
turn the allen wrench slowly in a counter-clockwise Wash the cylinder clean and drain the oil.
direction. The most you will be able to rotate the screw Handle all parts carefully.
in either direction is ⁄ turn.
9) When the pressure reading is within 2480 + 35 1) Install the bushings in the knuckle and head cover.
PSI, remove the allen wrench and tighten the seal nut. 2) Install the seals in the rod cover.
10) Recheck the system pressure again after tightening the 3) Assemble the piston: wear rings, dust ring, o-ring.
seal nut. 4) Assemble the rod cover: o-ring, back-up rings, dust
2-3 Boom and bucket cylinders wiper, bushing, U-packing.
5) Install the rod cover and piston in the rod and tighten
2-3.1 Disassemble the boom cylinder. the nylon lock nut. Torque: 258 N•m (190 ft. lb.)
6) Install the rod assembly in the tube assembly.
CAUTION
Only trained personnel should perform this procedure.
Select a clean area to do this work.
Wash the cylinder clean and drain the oil.
Handle all parts carefully.
224
3) Assemble the rod cover: o-rings, back-up rings,

2-3.3 Disassemble the bucket cylinder. dust wiper, bushing, U-packing, washer, dust ring.
4) Install the rod cover and piston in the rod and tighten
the nylon lock nut. Torque: 258 Nm (190 ft. lb.)
5) Install the rod assembly in the tube assembly.
04-6a
CAUTION
1) Place the cylinder in a vice and remove the rod cover.

2) Remove the rod assembly from the boom cylinder
assembly.
3) Remove the nylon lock nut, piston, and rod cover from
the rod.
4) Disassemble the piston: cushion ring, wear ring, slyde
ring, backup ring, o-ring.
5) Disassemble the rod cover: o-rings, back-up rings, dust
wiper, bushing, U-packing, washer, dust ring.
6) Remove the bushing and dust seals from the knuckle
and head cover.
2-3.4 Assemble the bucket cylinder.
For assembly, refer to the illustration with the disassembly

steps, above.
CAUTION
1) Install the bushing and dust seals in the knuckle and

head cover.
2) Assemble the piston: cushion ring, wear ring, slyde
ring, backup ring, o-ring.
225
2-4 Hydraulic lines
The hydraulic lines (hoses) are routed among hydraulic

components as listed below. Hex-head hose fittings contain
o-ring seals. When removing hydraulic hoses, be sure to
note placement of any coiled hose protectors. These must
be located in the same place on the hoses at installation.
Hoses include:
• Hydraulic oil tank to hydraulic pump

• Hydraulic pump to control valve
• Control valve
• Hydraulic oil cooler
• Hydraulic oil cooler to hydraulic oil filter
• Hydraulic oil filter to HST pump
For reference, see the Hydraulic Lines section of the

1340XL(DSL 602) Parts Manual. Refer to the Fitting
Installation information in section 10 General
Information /Miscellaneous for standard torque specifica-
tions.
226
2-5 Boom and bucket cylinder lines
2-5.1 Remove and install the boom cylinder lines.
The boom lines attach to the right and left boom cylinders at
the back of the cylinders. From the attachment points (on
each side), flexible hoses run to tubing connections. The
tubing mounts to the frame by plates and brackets. They ter-
minate by fittings at the hydraulic control valve.
Removal consists of: (1) disconnecting the lines and hoses

at their cylinder and control valve connection points and (2)
removing the bracket/plate bolts and washers that mount
the lines to the frame. Hex-head fittings on tubing lines, con-
nectors, tees, and elbows contain o-ring seals. When
removing HST hoses, be sure to note placement of any
coiled hose protectors. These must be located in the same
place on the hoses at installation.
The installation procedure is the reverse of removal.
For reference, see the Boom and Bucket Lines section of

the 1340XL(DSL 602) Parts Manual. Refer to the Fitting
Installation information in section 10 General Information/
Miscellaneous for standard torque specifications.
2-5.2 Remove and install the bucket cylinder lines.
The bucket lines attach to the right and left bucket cylinders
at the back of the cylinders. From the attachment points (on
each side), flexible hoses run to tubing connections on the
boom. The tubing mounts to the boom by clamps. At the
back of the boom they terminate by fittings to hoses that run
to tubing connections. The tubing mounts to the frame by
plates and brackets. The tubing lines terminate by fittings at
the hydraulic control valve.

removing the clamp/bracket/plate bolts and washers that
mount the lines to the boom and frame. Hex-head fittings on
tubing lines, connectors, tees, and elbows contain o-ring
seals. When removing HST hoses, be sure to note place-
ment of any coiled hose protectors. These must be located
in the same place on the hoses at installation.
The installation procedure is the reverse of removal. For ref-

erence, see the Attachment Lines section of the 1340XL
(DSL 602) Parts Manual. Refer to the Fitting Installation
information in section 10 General Information
/Miscellaneous for standard torque specifications.
227
2-6 Attachment lines
The attachment tubing lines attach to the front of the left

boom arm, with quick-coupler fittings at the ends. The tub-
ing mounts to the boom by clamps. At the back of the boom
they terminate by fittings to hoses that run to tubing con-
nections. The tubing mounts to the frame by plates and
brackets. The tubing lines terminate by fittings at the
hydraulic control valve.

removing the clamp/bracket/plate bolts and washers that
mount the lines to the boom and frame. Hex-head fittings on
tubing lines, connectors, tees, and elbows contain o-ring
seals. When removing HST hoses, be sure to note place-
ment of any coiled hose protectors. These must be located
in the same place on the hoses at installation.
The installation procedure is the reverse of removal. For ref-

erence, see the Attachment Lines section of the
Information/Miscellaneous for standard torque specifica-
tions.
228
04 Hydraulic System 04.3 Troubleshooting
04.3 Troubleshooting
3-1 Test Equipment
The following items should be sufficient to allow you to per-

form most troubleshooting operations on the 1340XL(DSL
602) hydraulic system.
• Pressure gauges:
10,000 PSI (600 BAR)
1000 PSI (60 BAR)
• Fittings:
1-1/16-12 o-ring
9/16-18 o-ring
7/16-20 o-ring
• 1340XL(DSL 602) Hydraulic Schematic
229
04 Hydraulic System 04.3 Troubleshooting
3-2 Troubleshooting Guide
The following troubleshooting guide presents possible causes and actions in a logical order from simplest/most likely to more
complex/less likely (more drastic). For any symptom, if a given action does not identify the problem, proceed to the next action.
Symptom Possible Cause Action
No hydraulic cylinder action Hydraulic oil level is low or empty Check level in tank. Add oil if
necessary. Check for leaks.
Pedals are disconnected Check linkage. Repair as needed.
Contaminated/Damaged relief Clean/Replace the relief valve.

valve
Damaged hydraulic pump Check pump. Replace if
necessary.
Hydraulic oil is too thick Let machine warm up before
operating.
Rough hydraulic cylinder action Hydraulic oil level is low Check level in tank. Add oil if
Slow hydraulic cylinder action Pedal is hitting floor, or there is dirt Check adjustment. Remove dirt.
under pedal
Internal cylinder leakage Check condition of cylinders and
repair as needed.
Damaged hydraulic pump Check pump. Replace if needed.
Damaged control valve Check valve. Replace if needed.
Hydraulic oil is too thick Let machine warm up before

operating.
Hydraulic cylinders leak oil Damaged cylinder rods or seals Repair cylinders.
230
05 Hydrostatic System Contents
05 Hydrostatic System
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 ADJUSTMENT PROCEDURES ................234

05.2.1 HYDROSTATIC (HST) PUMP ASSEMBLY.........................................234
05.2.1.1 Remove and install the HST pump.......................................234
05.2.1.2 Test ports, gauges, and fittings............................................234
05.2.1.3 HST functional test: System Pressure..................................234
05.2.1.4 HST functional test: Charge Pressure ..................................234
05.2.2 HST MOTOR.......................................................................................236
05.2.2.1 Remove the drive motor .......................................................236
05.2.2.2 Install the drive motor ...........................................................236
05.2.2.3 Drive Motor Functional Test: Check Flushing Valve .............236
05.2.3 HYDRAULIC FILTER MOUNTING .....................................................237
05.2.3.1 Remove the hydraulic filter mounting ...................................237
05.2.3.2 Assemble and install the hydraulic filter mounting................237
05.2.4 DRAIN RELIEF VALVE .......................................................................238
05.2.4.1 Remove and disassemble the drain relief valve...................238
05.2.4.2 Assemble and install the drain relief valve ...........................238
05.2.5 HYDROSTATIC (HST) LINES.............................................................239
05.3 DISASSEMBLY AND REASSEMBLY ..............................................................240

05.3.1 HYDROSTATIC (HST) PUMP ............................................................240
05.3.2 HST MOTOR ......................................................................................243
05.4.1 TEST EQUIPMENT ............................................................................248
231
05 Hydrostatic System 05.1 General
05.1 General
1-1 Hydrostatic (HST) system components to the hydraulic tank, to remove hot fluid from the system.
A drain valve maintains 70 PSI at the motors for lubricati-
The 1340XL(DSL 602) skid steer loader uses a Sauer- ion purposes.
Sunstrand Series 40 - M35 variable displacement, tandem
hydrostatic (HST) pump as its drive transmission. It is the The hydraulic charge pump, which is bolted to the HST
central component in the HST system, which also includes pump and directly driven by it, supplies cool fluid to the
two HST drive motors, a drain relief valve, and hydraulic system and keeps the closed loop charged to prevent
lines and hoses. cavitation. (The charge pump draws fluid from the
hydraulic tank.) Charge pressure in the pump is main-
1-2 Overview of operation tained by two charge check valves and high pressure
relief valves. The charge pressure relief valve is factory
The HST PUMP sends oil to the left and right side HST set for 130 - 150 PSI (8.9 - 10.3 BAR) above case pres-
MOTORS. The HST PUMP drives the HST MOTORS for- sure. In order to function properly, charge pressure at the
ward or reverse according to the position of the drive con- pump must be no less than this.
trol levers.
1-5 Check/High pressure relief valves
From the HST MOTORS, oil is returned to the HYDRAULIC
TANK through the DRAIN RELIEF VALVE, which controls
the drain flow.
Various HYDROSTATIC LINES, both metal tubing and

hose, carry hydraulic oil between the HST PUMP and the
HST MOTORS.
1-3 HST pump
The Sauer-Sunstrand Series 40 - M35 variable displace-

ment, tandem pump controls and transfers power through
the hydraulic motors. It can provide an infinitely variable
speed range between zero and maximum in both forward
and reverse directions. The M35 pump uses a paralletaxial 05-1
piston/slipper design with a tiltable swashplate to vary the
pump's displacement. Reversing the swashplate direction These valves (two per pump or four total) protect the HST
of tilt reverses oil flow direction from the pump and motor from system overpressure. They serve a dual purpose as
output rotation. bypass valves for machine towing.
Pump displacement control is provided by a control shaft 1-6 Pump charge relief valve
directly connected to the swashplate. This direct displace-
ment control, or DDC, makes pump displacement and out-
put flow proportional to shaft movement. The signal actual-
ly starts with movement of the drive control levers, which
causes linkage rods to operate the pintle levers mounted on
the pump.
1-4 Basic closed circuit
The main ports of the HST pump are connected by

hydraulic lines to the main ports of the hydraulic motors.
Fluid flows in either direction from the pump to the motors
then back to the pump in a closed circuit. Fuild flow direc-
tion and speed depends on the tilt angle of the pump swash-
plate. System pressure is determined by machine load. 05-3
The pump and motors require case drain lines, connected These valves direct any unused charge flow back to the
hydraulic tank. They are factory set at 130 - 150 PSI (8.9
- 10.3 BAR).
232
05 Hydrostatic System 05.1 General
1-7 Bypass valve
In order to tow the loader (short distances only at low

speed), it is necessary to allow fluid to bypass the HST
pump. The high pressure relief valves also serve this pur-
pose. For the proper procedure and illustration, see topic 6.
Towing Procedure in section 10 General Information
/Miscellaneous.
1-8 Repairs
Minor repairs and troubleshooting inspections can be made

to the HST system components. However, cleanliness is
absolutely required. Particle contamination, no matter how
tiny, is the chief cause of component malfunction and per-
manent failure. Work only in a clean area. Before discon-
necting lines, clean off port areas. Protect all exposed seal-
ing surfaces and open cavities. Remove any nicks or burrs
present on part edges before reassembly. Never set
removed parts on any surfaces that are not absolutely free
of foreign material. It is recommended that all gaskets and
o-rings be replaced whenever repairs are performed.
Lightly lubricate them with clean petroleum jelly before
assembly. Clean all gasket sealing surfaces before
installing new gaskets. Clean parts with a clean solvent
wash and air dry them before reassembly.2-1 Hydostatic
(HST) pump assembly
233
05 Hydrostatic System 05.2 Removal And Installation Procedures
05.2 Removal and Installation Procedures

2-1 Hydostatic (HST) pump assembly 2-1.3 HST functional test: system pressure
2-1.1 Remove and install the HST pump.
For detailed procedures, see 8-1 Engine/Hydrostatic Pump

Removal and 8-2 Engine/Hydrostatic Pump Installation in
section 00 Engine.
2-1.2 Test ports, gauges, and fittings
05-4b
1) Jack loader and place it on blocks so that all wheels are

off the ground.
2) Raise and lock canopy in position.
05-4
3) To improve port access on the control valve side of the
Gauge Connections - HST, disconnect the centering control at the pintle
Tandem Pump (Top View) lever arm, as shown above, and move the control
aside.
4) Front pump, ports "A" and "B": remove plugs and insert a
10,000 PSI (600 BAR) gauge into each port.
5) Start the diesel engine and run it at full throttle stroke
lever.
6) Check gauge readings. System pressure should be
3335 PSI. If readings are not equal or are above or
below the specification on either side, the high pres-
sure relief valves may be stuck with contaminants,
worn, or scored. Remove the valves, clean them,
replace and recheck.
05-4 7) Repeat the procedure for the rear pump.
Gauge Connections - 2-1.4 HST functional test: charge pressure

Tandem Pump (Side View)
Gauge Information
System 10,000 PSI or 600 BAR Gauge
A Pressure
Port “A” 9/16-18 O-Ring Fitting
System 10,000 PSI or 600 BAR Gauge
B Pressure
Port “B” 9/16-18 O-Ring Fitting
500 PSI or 35 BAR Gauge
Charge
C Tee into Charge Pressure Filter
Pressure
Outlet Line
05-5
Case 500 PSI or 35 BAR Gauge
D
Pressure 1-1/16-12 O-Ring Fitting
1) Jack loader and place on jack stands so that all wheels
NOTE: Tandem pumps have 2 additional syatem pressure are off the ground.
gauge ports (for system ports “C” and “D” ) in the 2) Raise and lock canopy in position.
rear section.
234
3) Remove hydraulic pressure sender from the elbow on

the hydraulic filter and insert a 500 PSI (35 BAR) gauge
into the orifice. See above photo.
4) Start the diesel engine and run it at full throttle.
5) Check gauge reading. Charge pressure should be 130 -
150 PSI (8.9 - 10.3 BAR). If reading is low, the charge
relief valve may be stuck with contaminants, worn, or
scored.
6) Stop the engine. Leave the gauge installed. Take loader
off blocks. Lower and secure canopy and drive loader.
Check gauge readings during operation.
7) If charge pressure is below 130 PSI, suspect internal
damage to HST.
8) To confirm operation, remove the drive hoses to the
motors. Cap the lines so that the fluid is dead-headed.
Start the loader and run it at 1/2 throttle, stroke control
lever slowly, and monitor system pressure. The pressure
should build to no more than 3500 + 200 PSI before the
relief valves open. If the pump develops less than 3000
PSI during this check, replace the HST.
9) Make mechanical adjustments to the drive control link
ages if necessary.
235
2-2 HST drive motor 3) Check parts for evidence of sticking. If dirty, clean
with a suitable solvent, allow to air dry, coat with clean
hydraulic fluid and replace. If damaged, replace all
2-2.1 Remove the drive motor. parts, coating the new parts with clean hydraulic fluid
before installing.
05-8
1) Drain the hydraulic system at the hydraulic tank below

the level of the motors.
2) Disconnect the hydraulic hoses at the HST pump. (Mark
them for reassembly.)
3) Disconnect the hoses to the drain relief valve (at the
motor).
4) Remove the 4 bolts that mount the motor flange to the
frame. Remove the motor.
5) Remove the hoses from the motor.
2-2.2 Install the drive motor.
1) Connect the HST pump hoses to the motor.

2) Mount the motor flange to the frame with 4 bolts.
3) Connect the hydraulic hoses to the drain relief valve.
4) Connect the hoses to the HST pump.
5) Fill the hydraulic tank to the proper level.
2-2.3 Drive motor functional test : check flushing valve
If one drive seems stronger than another, or if one side of

the loader shows hesitation, "sticking," or drift to one side
under full travel, the flushing valve on the hesitating side
may be sticking. If the symptoms appear sudden, the prob-
lem is most likely hydraulic and not mechanical in origin.
Remove, inspect, clean and/or replace the flushing valve as

follows:
1) Remove the plugs and washers.

2) Remove the springs and poppets.
236
2-3 Hydraulic filter mounting
2-3.1 Remove the hydraulic filter mounting.
05-9
1) Remove the spin-on filter element from the filter head.

Turn the element counter-clockwise using a filter wrench.
2) Disconnect the hydraulic inlet and outlet hoses.
3) Remove the bolts and hard washers that hold the filter
head assembly to the bracket.
2-3.2 Assemble and install the hydraulic filter mounting.

General Information/Miscellaneous for standard torque
specifications.
1) Install the bolts and hard washers that hold the filter
head assembly to the bracket.
2) Connect the hydraulic inlet and outlet hoses.
3) Install the spin-on filter element to the filter head. See
the Periodic Maintenance section of this manual for filter
installation and tightening procedure.
237
2-4 Drain relief valve 2-4.2 Assemble and install the drain relief valve.
2-4.1 Remove and disassemble the drain relief valve. Refer to the Fitting Installation information in section 10
General Information/Miscellaneous for standard
torque specifications.
1) Insert the poppet, spring, and spring seat into the

valve body and install the retaining ring.
2) Fit the connectors (tee and straight) to the apppropriate
ends of the valve.
Note the direction-of-flow arrow on the valve body. It
should point toward the HST motors.
3) Fit the mounting bracket over the valve and attach it
to the frame with the bracket, bolts, and hard washers.
4) Connect the hoses to the HST motors.
5) Connect the hoses to the hydraulic oil tank.
05-10
1) Locate the drain relief valve. It mounts to the lower left

side of the frame.
2) Loosen the clamp for the hose to the hydraulic oil tank
and disconnect the hose.
3) Disconnect the hoses that run to the HST motors.
4) Remove the two bolts and hard washers that hold the
mounting bracket to the frame.
5) Remove the tee and straight connectors from the ends of
the valve.
05-11
6) Disassemble the drain relief valve: remove the retaining

ring, spring seat and spring, and poppet.
238
2-5 Hydrostatic (HST) lines
The HST tubing lines and hoses are routed among compo-
nents as listed below. Hoses attach by worm-drive clamps.
Hex-head fittings on tubing lines, connectors, tees, and
elbows contain o-ring seals. When removing HST hoses, be
sure to note placement of any coiled hose protectors. These
must be located in the same place on the hoses at installa-
tion.
Hoses and tubing lines include:
• Hose from drain relief valve tee to hydraulic oil tank

• Hoses from drain relief valve to HST motors
• 2 hoses from HST pump to HST motor (L.H.)
• 2 hoses from HST pump to HST motor (R.H.)
For reference, see the Hydrostatic Lines section of the

Information/Misc-ellaneous for standard torque specifi-
cations.
05-12
239
05 Hydrostatic System 05.3 Disassembly and Assembly
05.3. Disassembly and Assembly

3-1 HST Pump
NOTE : Only trained personnel should disassemble.

When making repairs on hydrostatic systems, clean the
work area before disassembly and keep all parts clean.
Mark the match points on housing.
5
IGAT090P
3. Remove four check and relief valves (5). The valve may
be removed from the special plug by pulling straight out.
6
2 3
IGAT088P
1. Remove the screws (1) and hydraulic pump (2) from

the HST pump (3).
16
IGAT091P
4. Remove the charge relief valve (6) from end cap (16).
1
7 8 9 10
11
IGAT089P
2. Remove the coupling (4) from the hydraulic pump.
IGAT092P
5. Remove plug (7), O-ring (8), shim (9), spring (10) and
valve poppet (11) from the charge relief valve.
NOTE : Protect all exposed sealing surfaces and open

cavities from damage and foreign material.
It is recommended that all gaskets and O-rings be
replaced.
240
17
12
IGAT093P IGAT096P
6. Remove screws (12) from the pump. 9. Remove the valve plate (17) from the end cap (16).
Separate the front and rear sections of pump.
(Front pump is engine side and rear pump is hydraulic
19
pump side).
Followings are disassembly procedure of front pump.
14
13 18
IGAT097P
10. Remove the cylinder block (18) from the housing (19).
IGAT094P
24
22
7. Remove coupling (13) and O-ring (14) from the front
pump.
21 23
IGAT098P 20
15
11. Remove the slipper retainer and piston assembly (20)

16 from the cylinder block (21). Remove the slipper
retainer guide (24), pins (22) and slipper hold down
retainer (23) from the cylinder block.
IGAT095P
8. Remove screws (15) and the end cap (16) with the
valve plate from the front pump.
241
26
19
25
31
30
IGAT099P IGAT102P
12. Remove the retaining ring (25) from the housing (19) 16. Remove the screws (30) and the trunnion covers (31)
using plier. (mark the position of cover for re-assembly).
13. Remove support washer (26) and lip seal.
27
28
32
IGAT103P
IGAT100P
17. Remove both bearings (32).
14. Remove retaining ring (27) and front shaft (28) with
bearing from the housing.
28 33
34
29
IGAT104P
18. Remove thrust plate (33).

IGAT101P
19. Do step 14 through 18 to disassemble rear pump.

15. Remove the retaining ring (29) and press the shaft
(28) out of the bearing (34). NOTE : There is no lip seal in the rear pump. Remove the
retaining ring first. Then the shaft and bearing may be
removed.
242
20. Assemble HST pump in the reverse order of disas- 3-2. HST Motor
sembly. Refer to following torques when installing.
CAUTION : Cleanliness is extremely important when
End cap onto the housing ..............................47~61 N•m repairing a hydraulic motor. Work in a clean area. Before
(35~45 lb•ft) disconnecting the lines, clean the port area of the motor
thoroughly. Before starting the disassembly procedures,
Assembly of front and rear pump ...................47~61 N•m drain the oil from inside the motor.
(35~45 lb•ft)
Charge relief valve ......................................54~125 N•m 1

(40~100 lb•ft)
Check and relief valve ....................................41~68 N•m

(31~50 lb•ft)
IGAT105P
1. Place the motor in a vise with the output shaft down.

Clamp across the mounting flange of the motor not the
housing. Excessive clamping pressure will cause dis-
tortion.
2. Remove four bolts (1) from motor with socket spanner.
IGAT106P
3. Lift the valve housing (2) straight up.
243
3
4 7
IGAT107P IGAT110P
4. Remove O-ring (3) and channel plate (4) from the 7. Remove valve drive (7).
valve housing (2).
IGAT111P
IGAT108P
8. Remove gear wheel set (8) from bearing housing (9).

5. Remove disc valve (5) from the valve housing (2).
10
6
IGAT112P
IGAT109P
9. Remove O-ring (10) from gear wheel set (8).

6. Remove balance plate (6) from the valve housing.
Apply some clean oil for removal, if needed.
244
11
16
IGAT113P IGAT116P
10. Remove cardan shaft (11) from bearing housing (9). 14. Remove shaft and bearing assembly (16) from bear-
ing housing.
11. Separate bearing housing from the vise.
Followings are procedures for assembly of HST
motor.
12
16
13
IGAT114P
12. Remove six screws (12) and front cover (13) from IGAT116P
bearing housing.
15. Install shaft and bearing assembly (16) to bearing
housing (9).
14
15 14
15
13
IGAT115P
13
IGAT115P
13. Remove shaft seal (14) and O-ring (15) from front
cover (13).
16. Install shaft seal (14) and O-ring (15) to front cover
(13).
245
12
8
13
9 9
IGAT119P IGAT111P
17. Install front cover (13) to bearing housing (9) and 20. Install gear wheel set (8) to bearing housing (9).
tighten six screws (12) with torque of 24 L 2 N•m
(210 L 17 lb•in).
7
8
10
IGAT110P
IGAT112P
21. Install valve drive (7) to gear wheel set (8).
18. Install O-ring (10) to gear wheel set (8).

4
11
IGAT124P
IGAT113P
22. Install channel plate (4) with O-ring to gear wheel set.
19. Install cardan shaft (11) to bearing housing (9).
246
5
1
4
IGAT125P IGAT105P
23. Install disc valve (5) to channel plate (4). 26. Tighten four bolts with the torque of 140 L 5 N•m
(100 L 4 lb•ft).
16
IGAT109P
24. Install balance plate (6) to valve housing (2).
IGAT106P
25. Install valve housing (2) including balance plate to

motor.
247
05 Hydrostatic System 05.4 Troubleshooting
05.4. Troubleshooting
4-1 Test Equipment

form most troubleshooting operations on the DSL 601 HST
system.
• Pressure gauges:
10,000 PSI (600 BAR)
1000 PSI (60 BAR)
• Fittings:
1-1/16-12 o-ring
9/16-18 o-ring
7/16-20 o-ring
• Servo bypass loop hose - see section 05 Hydrostatic
System, 2-1.5 HST functional test: Swashplate
Neutral Adjustment for parts list
• 1340XL(DSL 602) Hydraulic Schematic
248
4-2 Troubleshooting Guide
HST does not operate Damaged linkage Repair linkage and replace.
Hydraulic oil level is low Check level in tank. Add oil if

Check the charge pressure.
Charged suction line or filter is Check the charge, suction, and
plugged return pressure. Replace the filter
and clean the suction line.
Plugged control valve sleeve orifice Remove sleeve and check for
plugged orifice.
Damaged HST pump or motor Check drive shaft, replace
shaft damaged parts.
Damaged charge relief valve Check charge pressure.

Replace relief valve if necessary.
Damaged hydraulic pump shaft Replace hydraulic pump.
Pump or motor inside leakage Check for wear. If severe, replace

damaged parts or entire unit. If
either pump or motor is worn from
fluid contaminants, both units will
be affected and both will need to
be repaired or replaced.
Clean out tank and lines and
replace filter.
Drive chain is broken or damaged Check, repair/replace chain.
Higher than normal noise Flushing valve in HST motor is Check valve spool. Clean or
stuck or defective. replace as necessary.
Air leak in line Check suction line clamp.
Check for oil line, o-ring, and
packing damage.
Incorrect piping to HST or Check bolts. Check clamps
improper mounting for interference.
Check and repair defective parts.

Pump or motor wear caused by
Clean piping, tank, and replace
excessive speed.
filter. Check engine RPM.
249
HST output is low or operation is Charge pressure too low Check charge pressure. If too low,
sluggish check charge pump. If pump is
okay, check for plugged filter or
lines. Check for contaminants.
Internal wear of HST pump or Clean and repair pump or motor.

motor Replace filter.
Check or relief valve not operating Replace valve. If dirt is the problem,
properly clean the piping and replace the
filter. Check motor for
contamination.
Pump or motor inside leakge. Check, repair and replace the

damaged parts.
HST Temperature is high Relief pressure setting is low Adjust the pressure to specification.
(case temperature higher than
82oC/148oF) Air intake in line Check and repair piping.
Oil cooler is clogged Clean or replace oil cooler.
Drain relief valve does not operate Repair or replace drain relief valve.
properly
Hydraulic oil level is low Check oil level, add as needed.
Abnormal machine driving. Check relief pressure setting and

Pressure is higher than setting replace the valve as needed.
pressure.
Suction line or filter is plugged Check the charge, suction, and

return pressure. Replace the filter
and clean the suction line.
Clean or repair the pump or

Internal wear of pump or motor
motor. Replace the filter.
250
Motor runs rough Relief pressure setting is low Adjust the pressure.
Air leak in line Check the piping and

replace/tghten as necessary.
Relief valve not operating properly Replace the relief valve.
Machine pulls to one side Wrong tire pressure Check all tires for correct pressure.
(Also see “One side of machine is
not driving or drives improperly,”
below.) Unbalanced steering linkage Check linkage and adjust as
necessary.
Pump or motor not operating Replace the pump or motor.

properly
Machine moves when drive Possible mechanical problem in Check the neutral control levers
control levers are in neutral. the drive linkage and centering control devices.
Check the adjustment of the drive
control levers. Readjust as
necessary.
251
One side of machine is not driving Possible HST problem Swap the right side/left side lines
or drives properly between the HST and the motors.
a. If the problem shifts to the side

that previously worked, the
problem is in the HST.
Check the charge/relief valves,
first by interchanging the valves. if
the problem changes side, clean
or replace the bad charge/relief
valve.
b. If the problem remains on the

same side after swapping lines,
the problem is in the motor. Check
the motor.
Possible motor problem Check for stuck flushing valve.

Clean/replace. Check for other
contamination or wear in the
motor. If contamination is found,
the entire system will need to be
checked and cleaned.
Machine “tracks” (pulls to one Possible mechanical problem in Check the neutral control levers
side) the drive linkage and centering control devices.
Check the adjustment of the drive
control levers. Readjust as
necessary.
252
06 Electrical System Contents
06 Electrical System
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
06.2.2.1 Components .........................................................................258
06.2.2.2 Operation ..............................................................................258
06.2.3 CHARGING SYSTEM.........................................................................259
06.2.3.1 Components .........................................................................259
06.2.3.2 Operation ..............................................................................259
06.2.4 LIGHTING AND AUXILIARY SYSTEM ...............................................260
06.2.4.1 Components .........................................................................260
06.2.4.2 Operation ..............................................................................260
06.2.5 INSTRUMENT PANEL ........................................................................261
06.2.5.1 Instrument Panel Components .............................................261
Key Switch Connections. ...........................................................261
06.2.5.2 Instrument Panel Layout.......................................................262
Front ...........................................................................................262
Rear - Right-hand side ...............................................................263
06.2.5.3 Item descriptions and functions ............................................264
06.3.1 TEST EQUIPMENT .............................................................................267
253
06 Electrical System Electrical Wiring Diagram
Electrical Wiring Diagram
254
WIRING SCHEMATIC-ELECTRIC
MODEL : 1340XL / DSL602
254.1
06 Electrical System 06.1 General
06.1 General
The DSL 602 skid steer loader has a 12 volt, negative
ground electrical system. It includes the following features.
See section 2 Components, Systems and Operation for
details.
• 12-volt, 100 ampere-hour battery with 625 cold-cranking

amps
• 35-amp alternator with built-in voltage regulator
• Dual-element intake air pre-heater
• Circuit breaker for protecting starting circuit components
• Neutral safety switches on each drive lever centering
control to prevent starting with transmission engaged
• Dual front and single rear area floodlights
• System monitoring with switches with associated indi-
cator lights and audible warning buzzer:
• Parking brake
• Preheat
• Engine oil pressure
• Engine water temperature
• Charge alternator
• HST charge pressure
• HST oil temperature
• Hydraulic oil filter
• Fuel gauge
• Hour meter
• Fuses for lighting, instrument panel, horn and start (key
switch) circuits
• Available Options:
• Strobe Light
• Cab Heater
• Back up Alarm
• Horn
• Cigar Lighter
255
06 Electrical System 06.2 Components, Systems And Operation
06.2 Components, Systems And Operation

2-1 Component locations
2
1
06-1
Figure 06-1. Right Side View, Electrical Components
1) Pre-heat timer
2) Safety relay (for post engine start hold-in)
3) Control unit
4) Circuit breaker (for starting circuit)
5) Intake air pre-heater
6) Cab wiring connector
256
2-1 Component locations, continued
1
3
6
4 8
9
10
16
12 13
8
06-2
Figure 06-2. Top View, Electrical Components
1) Parking brake switch connector

2) Neutral switches
3) Cab wiring connector
4) HST pressure switch
5) HST oil temperature switch
6) Hydraulic filter switch
7) Alternator
8) Water temperature switch
9) Engine oil pressure switch
10) Intake air pre-heater
11) Fuel sender
12) Safety relay (for post engine start hold-in)
13) Timer
14) Starter motor (on engine, not shown)
15) Starter solenoid (on starter, not shown)
16) Engine Stop Solenoid/Diode
257
2-2 Starting system
2-2.1 Components
See Figures 06-1, 06-2 and the DSL 602 Wiring Diagram for
the following components.
Pre-heat circuit:
• Intake air heater

• Pre-heat indicator light on the instrument panel
• Pre-heat timer (for pre-heat indicator light)
• Pre-heat circuitry in key switch
Starting circuit :
• Key switch
• Battery
• Starter solenoid and motor
• Alternator/regulator
• Neutral switches (2)
• Engine stop (fuel) solenoid
• Safety relay
• Circuit breaker
• Fuse in instrument panel
2-2.2 Operation
The starting circuit includes an air pre-heater for use when

the ambient cold-starting temperature is below -5° C (23°
F). The key switch includes a pre-heat position, and a pre-
heat indicator light on the instrument panel glows for about
30 seconds while the intake air is heating. A count-down
timer controls the instrument light on-time.
Two roller-head type limit switches (normally closed) are

connected in series between the key switch and the starter.
The roller fits into the detent of the centering control rods.
(See Figure 06-2.) If either lever is out of its neutral posi-
tion, the switch is opened and the loader will not start.
A safety relay holds in the circuit after the engine starts.
The battery is 12V-100AH, with 625 cold-cranking amps

output. The starter motor is rated 2.5 kW.
The starting circuit is protected by its own circuit breaker.

A start fuse in the instrument panel protects the start key
switch.
The fuel solenoid and associated circuitry is protected by a

suppressive diode.
258
2-3 Charging system
2-3.1 Components
See Figures 06-1, 06-2 and the Wiring Diagram for the fol-
lowing components.
• Keyswitch
• Battery
• Alternator
• Charge indicator light on the instrument panel
2-3.2 Operation
The machine uses a 35-amp alternator with built-in voltage

regulator. When the key switch is in the IGN position, the
instrument panel Charge warning light turns on. It turns off
once the engine starts. If it remains on, this indicates a
problem in the charging system.
259
2-4 Lighting and auxiliary system
2-4.1 Components
lowing components.
• Light switch on the instrument panel

• 15-amp fuse
• Battery
• Front light (2)
• Rear light (1)
2-4.2 Operation
The machine has one rear and two front area lamps. They
are controlled by a three-position light switch mounted
above the key switch on the left-hand instrument panel.
The front lights turn on when the switch is in the "1" position.
The rear light turns on when the switch is moved to the "2"
position. (The front lights remain on when the rear light is
on.)
260
2-5 Instrument panel
2-5.1 Instrument panel components
lowing components.
• Panel - left- and right-hand sides

• Fuse in left-hand side panel
• Control unit
• Switches:
Switch Status
Type
* Engine oil pressure switch NC
HST charge pressure switch NC
HST oil temperature switch NO
Water temperature switch NO
Hydraulic oil filter switch NO

Parking brake switch NO
*The engine oil pressure switch and its associated warning light do not operate through the control unit. All other switches and
their respective indicator lights do operate through the control unit.
Key switch connections
Terminal
Key B BR R1 R2 C ACC
Position
Off O
R1 O O O O
Acc O O O
Start O O O O O
06-3
261
2-5.2 Instrument panel layout
Front
9 10 8 11 14 13 12 15
E F
2 3 4 5 6 7 1 16 17 18 19 06-4
1) Key Switch
4) Charge warning light
5) HST oil temperature warning light
6) HST pressure warning light
7) Oil filter warning light
8) Warning light
9) Stop light
10) Buzzer
11) Light switch
12) Pre-heat light
14) Fuel gage
15) Hour meter
16) Fuse-lamp
17) Fuse-instrument panel
18) Fuse-start
19) Fuse-horn
NOTE: The left-hand instrument panel is a sealed unit.

Warning lamps cannot be replaced individually. In the right-
hand unit, the pre-heat light (12) and parking brake light (13)
can be replaced from the back.
262
Rear Ð right hand side
06-5
263
2-5.3 Item descriptions and functions
1) Key Switch 4) Charge warning light
06-6 06-9
• W h e n t h e k e y i s t u r n e d t o t h e “ P R E H E AT ” • The light turns on when trouble occurs in the charg-

position, the light turns on and preheat of air heater ing system.
begins. The light goes off automatically after 30 seconds.
• When the key is turned to the “IGN” position, all the 5) HST oil temperature warning light
warning lights on the instrument panel come on.
• When the key is turned to the “ST”
position, the engine is started.
When the key is released, it will return to the “IGN” posi-
tion automatically.
06-10
• The light turns on when the temperaturre of the

hydraulic oil to drive HST goes up to 100oC (212oF).
06-7
• The light turns on when the temperature of the engine

cooling water exceeds 110o C (230oF).
06-8
• The light turns on when the engine oil pressure is below

0.5kg/cm2 (15 psi)
264
2-5.3 Item descriptions and functions, continued
6) HST pressure warning light 9) Stop light
06-11 06-14
• The light turns on when the pressure of the HST pump • The light turns on simultaneously with water tempera-
oil falls below 3.51 kg/cm2 (50 psi). ture and engine oil pressure warning lights.
7) Oil filter warning light 10) Buzzer
06-12 06-15
• If the oil filter becomes clogged, the light turns on. • The buzzer is activated simultaneously with water
temperature and engine oil pressurre warning
8) Warning light lights.
10) Light switch
06-13
06-16
• The light turns on simultaneously with Charge HST oil
temperature, HST pressure and oil filter warning lights.
• Step 1: Two front lights turn on.
• Step 2: Two front lights and one rear light turn on
simul-taneously.
265
2-5.3 Item descriptions and functions, continued
12) Pre-heat light 14) Fuel gage
E F
06-17 06-19
• When the key is turned to the “PREHEAT” position, the • Fuel gage shows the amount of fuel in the fuel
light is turns on and preheating of air begins. tank.
Light turns off automatically after 30 seconds.
15) Hour meter
06-20
06-18
• Hour meter indicates the total hours of vehicle

• Raising the hand lever, the parking brake is engaged operating.
and the light turns on.
266
06 Electrical System 06.3 Troubleshooting
06.3 Troubleshooting
3-1 Test equipment

form most electrical troubleshooting operations on the DSL
601 electrical system.
• Volt/ohmmeter (Multimeter)
• Jumper wires (variety of lengths) with alligator clip ends
• Needle tips
• External 12-volt source
• DSL 601 Wiring Diagram
267
3-2 Troubleshooting guide
NOTE: The lighting, instrument panel, and start (key switch) fuses (and horn fuse - optional, if equipped) located in the right-
side instrument panel are all 15-amp tube-type fuses.
Discharged battery Loose/damaged alternator belt. Tighten/replace belt.

Loose/dirty connections. Adjust/clean clamps, posts.
Battery faulty. Replace battery.
Alternator faulty. Check or replace alternator.
Engine does not crank Battery may be discharged. Check battery condition.
Start fuse may be blown. Check fuse in instrument panel.
Circuit breaker may be tripped. Reset circuit breaker. If it trips
again, look for short in start wiring.
Circuit breaker may be faulty. Jumper around circuit breaker.
If engine starts, replace circuit
breaker.
Problem in neutral safety Wiggle drive levers while trying to
mechanisms. start. If engine starts, adjust
neutral switches and/or centering
control(s).
Neutral switch(es) may be faulty. Jumper neutral switch(es) one at
a time. If engine starts, replace
neutral switch(es).
Safety relay may be faulty. Jumper safety relay. If engine
starts, replace safety relay.
Engine cranks but does not start Loader is out of fuel. Check fuel tank.
Diode may be faulty. Remove diode. If engine starts,
replace diode.
Engine has starting problem not Check engine. See section
related to electrical system. 00 Engine in this manual.
Alternator may be faulty. Check alternator.
Intake pre-heater does not work Wiring problem. Check pre-heater wiring.
Pre-heat relay may be faulty. Check wiring to relay. If OK,
replace timer. Jumper relay. If pre-
heater works, replace relay.
Pre-heater element may be faulty. Check element. If problems
found, replace pre-heater.
Pre-heater light stays on after 30 Timer may be faulty. Check wiring to timer. If OK,
seconds replace timer.
268
Instrument panel indicator lights Fuse may be blown. Check/replace fuse in instrument
do not come on or give faulty panel.
indications.
Control unit may be faulty. Replace control unit.
Individual panel lights do not Bulbs may be faulty. Check/replace bulbs.

come on.
Wiring to light may be faulty. Check individual wiring.
Repair faulty connections or
replace wires.
Fuel gage does not work or Sender wiring may be faulty. Check wiring between meter and
gives faulty indication (other instrument panel. Check sender
instrument panel functions are OK). ground.
Gage may be faulty. Replace gage.
Hour meter does not register Meter wiring may be faulty. Check meter wiring.
hours (other instrument panel
functions are OK). Meter may be faulty. Replace meter.
Rear or front flood lights do not Fuse may be blown in instrument Check/replace fuse in instrument
turn on. panel. panel.
Bulb(s) may be burned out. Check/replace bulbs.
Wiring may be faulty. Check connections and wires.

Check connections in cab wiring
connector.
269
270
07 Structures and Chassises Contents
07 Structures and Chassis
07.1 GENERAL.........................................................................................................273
07.2 REMOVAL AND INSTALLATION, AND ADJUSTMENT

PROCEDURES .................................................................................................274
07.2.1 BUCKET .............................................................................................274
07.2.1.1 Remove the bucket...............................................................274
07.2.1.2 Install the bucket...................................................................274
07.2.2 QUICK-TACH ......................................................................................275
07.2.2.1 Remove the Quick-Tach .......................................................275
07.2.2.2 Disassemble the lever assembly ..........................................276
07.2.2.3 Reassemble and install the Quick-Tach...............................277
07.2.2.4 Adjust the Quick-Tach lever spring washers ........................277
07.2.3 BUCKET CYLINDERS, BOOM CYLINDERS, BOOM LOCK,
AND BOOM ........................................................................................278
07.2.3.1 Remove the bucket cylinders ...........................................................278
07.2.3.2 Remove the boom cylinders.............................................................279
07.2.3.3 Remove the boom lock ....................................................................279
07.2.3.4 Remove the boom ............................................................................279
07.2.3.5 Install the boom, boom lock, boom and bucket
cylinders ...........................................................................................280
07.2.4 SEAT BAR AND SEAT........................................................................281
07.2.4.1 Remove, install, and adjust the seat bar system..................281
07.2.4.2 Remove the seat...................................................................281
07.2.4.3 Install the seat.......................................................................281
07.2.5 CANOPY .............................................................................................282
07.2.5.1 Remove the canopy ..............................................................282
07.2.5.2 Install the canopy..................................................................283
07.2.5.3 Adjust the canopy stops........................................................283
07.2.6 REAR DOOR AND ENGINE HOOD ...................................................283
07.2.6.1 Remove the rear door...........................................................283
07.2.6.2 Remove the door latch and lever assembly .........................284
07.2.6.3 Remove the engine hood .....................................................284
07.2.6.4 Install the rear door and engine hood ..................................284
07.2.7 UPPER PLATE AND FLOOR PLATE .................................................285
07.2.7.1 Remove the upper plate .......................................................285
07.2.7.2 Remove the floor plate .........................................................285
271
07 Structures and Chassises Contents
07.2.7.3 Install the floor plate .............................................................285

07.2.7.4 Install the upper plate ...........................................................285
07.2.8 BOTTOM PLATE AND ENGINE OIL PAN COVER ............................286
07.2.8.1 Remove the bottom plate and engine oil pan cover.............286
07.2.8.2 Install the bottom plate and engine oil pan cover.................286
07.2.9 TANKS ................................................................................................287
07.2.9.1 Remove the fuel level sender assembly...............................287
07.2.9.2 Install the fuel level sender assembly...................................287
272
07 Structures and Chassises 07.1 General
07.1 General
The frame, boom, and bucket are grouped together in part
because they are the "large" components of the DSL 602
skid steer loader. However, the category includes a number
of important, related sub-components.
• Quick-Tach
• Bucket and boom cylindrers and related hydraulic lines
and valves
• Seat and seat bar
• Canopy
• Upper plate and floor plate
• Bottom plate and engine oil pan cover
• Fuel and hydraulic oil tanks and their respective senders,
filters, and other assemblies
Above all, safety must be your chief concern when working

with frame, boom, and bucket components. Their size and
weight require a proper hoist and support straps - never rely
upon the hydraulic cylinders to hold the boom or bucket in a
position for service. Use the boom lock whenever the boom
is in the raised position. Use the safety lock when raising
the canopy, and a hoist and straps for removal and installa-
tion. Provide support for plates and covers when removing
them.
Operational problems related to the frame, boom, and buck-

et are usually fairly easy to diagnose. Cylinders that do not
hold show evidence of leaking seals or hoses. Chatter or
jerky movements often mean uneven cylinder rod length
adjustment, or bent cylinder rods. (Some symptoms, how-
ever, can point to hydraulic or hydrostatic system problems
- see the troubleshooting procedures of sections 04 and 05.)
Where adjustments are necessary, pay close attention to
specifications to avoid premature and DANGEROUS com-
ponent failure.
273
07 Structures and Chassises 07.2 Removal, Installation And Adjustment Procedures
07.2 Removal, Installation And Adjustment Procedures

2-1 Bucket
CAUTION
WARNING Do not damage the Quick-Tach handles by driving
them against the bucket.
When removing the bucket, the operator must get a 4) When you are sure the top edge of the Quick-Tach is
second person to assist. inserted, tilt the Quick-Tach backward until the back of
the bucket is perpendicular to the ground.
2-1.1 Remove the bucket. 5) Lock the bucket to the Quick-Tach by pushing down
both handles on the Quick-Tach.
1) Start the engine. Lower the boom to the ground.
2) Tilt the Quick-Tach forward until the bucket cutting edge WARNING
touches the ground.
Make sure that the Quick-Tach wedges are fully
extended into the holes. Failure to secure the wedges
can cause injury or death.
07-2x
3) Pull out both handles on the top of the Quick-Tach and 07-2x
disengage the lock.
4) Remove the bucket by driving backward and at the

same time tilting the Quick-Tach slightly downward.
2-1.2 Install the bucket.
1) Start the engine.
2) Tilt the Quick-Tach forward.
3) Drive forward toward the bucket until the top edge of
the Quick-Tach is completely inserted into the flange of
the bucket.
274
2-2 Quick-Tach
2-2.1 Remove the Quick-Tach.
WARNING
Read the OperatorÕs Manual and decals on the machine
before operating or servicing the machine. Follow all
warnings and instructions when making repairs, adjust-
ments, or servicing. Check for correct function after
repairs, adjustments, or servicing. Failure to follow
instructions can cause injury or death.
WARNING
Position the Quick-Tach so that unexpected movement
does not occur.
07-4
1) Tilt the Quick-Tach forward in order to access the bucket

hinge pin mounting bolts and boom pin mounting bolts.
2) Remove the boom pin mounting bolts and pins from
the Quick-Tach.
3) Rotate the Quick-Tach forward until the top of the Quick-
Tach reaches the ground. Remove the bucket cylinder pin
mounting bolts and hinge pins from the boom. The Quick-
Tach can now be removed.
275
2-2.2 Disassemble the lever assembly.
4
12,13
19
6,17
5
7
8,14,15 3 20
1
18
9,10,11
21
16
07-5A
1 WELDMENT 1) Remove the cotter pin, washer, and clevis pin at the
2 ROD AS lever assembly end.
3 WASHER 2) Remove the cotter pin, washer, and clevis pin from the
4 WASHER rod end.
5 NUT ; LOCK 3) Remove the spring pin and separate the wedge, spring,
6 PIN ; COTTER and rod.
7 WASHER
8 PIN
9 PIN ; GUIDE
10 PIN ; SPLIT
11 WASHER ; HARD
12 HANDLE-L.H.
13 HANDLE-R.H.
14 WASHER ; PLAIN
15 PIN ; SPLIT
16 WEDGE
17 NUT
18 SPRING
19 BUSHING
20 WASHER ; HARD
21 NIPPLE ; GREASE
276
2-2.3 Reassemble and install the Quick-Tach.
1) Install the upper and lower pads on the weldment

assembly.
2) Assemble the lever assembly: wedge, spring, and rod
held in place by the spring pin; clevis pin, washer, and
cotter pin at both the rod end and lever assembly end.
3) Assemble and install the handle assemblies: washers
and bushings, castle nut and cotter pin. Mount the plates
with 4 bolts, each side. Install the bucket cylinder hinge
pins and pin mounting bolts. Install the boom pins and pin
mounting bolts.
2-2.4 Adjust the Quick-Tach lever spring washers.
07-5B
1) Remove the cotter pin.

2) Adjust the castle nut in or out against the spring washers
as necessary to obtain proper tension. Torque specifica-
tion: 2 - 2.7 N•m. You should be able to move the handle
with reasonable force, but it should be tight enough to
prevent loosening under operation.
3) Reinstall the cotter pin.
277
2-3 Bucket cylinders, boom cylinders, boom

lock, and boom
2-3.1 Remove the bucket cylinders.
1) Remove the bucket and Quick-Tach (see steps above).
WARNING
When suspending the boom, hoist it slowly and as hor-
izontal as possible.
4) Remove the bolts and cover.
2) Hoist the boom so that bucket cylinder hidden end can be

easily accessed from behind of the boom.
5) Remove bolts and washers, pin assembly.

3) Hoist the bucket cylinder or hold the bucket cylinder by
another person for the bucket cylinder not to be dropped
freely.
278
2-3.3 Remove the boom lock.
Knob
Boom 07-10
Lok
6) Dissemble the hose and remove the bucket cylinder. 1) With the boom in the lowered position, remove the
knob at the rear of the boom lock.
2-3.2 Remove the boom cylinders. 2) Remove the pin mounting bolt, washer, spacer and
large pin at the front. The boom lock can now be
1) Lower the boom completely. removed.
2-3.4 Remove the boom.
2) Disconnect the hydraulic hoses connected to the

boom cylinders.
1) Suspend the boom with slings around each crossmember.
2) Raise the boom to a suitable height for removal. Be
sure the slings will hold the boom securely.
3) Remove the boom cylinder pin mounting bolts

and pins at the front and rear of each cylinder. The boom
cylinders can now be removed.
07-12
3) Disconnect the hoses for the bucket and attachment

lines.
279
2) Pull down the boom fully.
DANGER : When working on a machine with the boom

up, always engage the boom lock.
3) Check the gap between the plate - stopper (1) and

contacting surface of frame
4) Raise the boom.
5) Put spacer (2) as required on the side of occuring the

07-13 gap in order to have even contacting surface of frame
in both sides (L.H., R.H.) when boom is down fully.
4) Remove the boom pin mounting bolts and pins where 2-3.5 Install the boom, boom lock, boom and buck-
the boom attaches to the frame. The boom can now be et cylinders.
removed.
Boom:
1) Suspend the boom with slings around each crossmember.

2) Raise the boom to a suitable height for installation. Be
sure the slings will hold the boom securely.
3) Install the boom pins and pin mounting bolts where the
boom attaches to the frame.
4) Connect the hoses for the bucket and auxiliary lines.
Boom lock:
1) With the boom in the lowered position, install the large

pin, washer, spacer and pin mounting bolt at the front.
2) Install the knob at the rear of the boom lock.
Boom cylinders:
Note : If needed, add or remove shims, to adjust boom 1) Lower the boom completely.
seating balance as following procedure. 2) Install the boom cylinder pins and pin mounting bolts at
the front and rear of each cylinder.
Adjustment of boom stopper 3) Connect the hydraulic hoses for the boom cylinders.
Bucket cylinders:
Spacer (2.3t) 1) Suspend the boom with slings around each crossmember.
2) Raise the boom to a suitable height to install the bucket
cylinders. Be sure the slings will hold the boom secure-
Plate-stopper (6t) ly at this height.
3) Install the pins and pin mounting bolts where they
connect to the boom crossmember.
Boom
Rubber 4) Connect the hydraulic hoses for the bucket cylinders.
Contacting surface of Frame
1) Put each 1 plate-stopper (1) with rubber (3) on both

sides when boom is raised.
280
2-4 Seat bar and seat
2-4.1 Remove, install, and adjust the seat bar system.
07-15
5) Remove the seat belt guide assembly with seat

belt, and seat belt (buckle part) from the seat plate
07-13A by removing the bolts, nuts and washers.
2-4.3 Install the seat.

1) Refer to section 02 Control System, "Seat Bar System
Installation" and "Seat Bar System Installation and
1) Install the seat belt guide assembly with seat belts into
Adjustment" for the detailed procedures for remov-
the seat plate by installing the bolts, nuts and washers.
ing, installing, and adjusting these components
2) Set the seat into the canopy.
3) Raise the canopy.
2-4.2 Remove the seat.
4) Install the 4 nuts and washers that mount the seat to the
bottom of the canopy seat plate.
1) Raise the canopy.
5) Lower the canopy.
07-13B
2) Remove the 4 nuts and washers that mount the seat

to the bottom of the canopy seat plate.
3) Lower the canopy.
4) Lift the seat out of the canopy.
281
2-5 Canopy
2-5.1 Remove the canopy.
WARNING
The parking brake MUST be engaged any time the
loader is being serviced. If the parking brake is NOT set,
the loader may roll. Failure to set the parking brake
could result in death or serious injury.
07-19
4) Disconnect the wiring connector at the rear canopy (RH).

5) Lift the canopy slightly with the hoist in preparation
for removal.
07-16
1) Remove the front set bolts and washers on each side.
6) Remove ving-retaining (2) and link (3), nuts (4), then dis-
connect parking cable assembly (5).
7) Remove the pedal lock cable (refer to 2-13-1 remove the
pedal lock system)
07-17
2) Remove the canopy hinge stoppers on the rear side of

the canopy
07-20
8) Remove the cotter pin, washers, spacer and clevis

pin from the gas spring where it attaches to the frame.
3) Raise the canopy and suspend it from a hoist with a sling.

282
07-21 07-20b
9) Remove the bolt and nut from the rear hinges. The 1) Loosen the jam nut.
canopy can now be removed with the hoist. 2) Turn the stop in or out until the it measures 62-64mm
from the surface of the cross member.
2-5.2 Install the canopy. 3) Tighten the jam nut.
4) Check the canopy lock. It should hold the canopy with
1) Suspend the canopy from a hoist with a sling. out excessive play.
2) Install the bolt and nut for the rear hinges.
3) Install the cotter pin, washers, spacer and clevis pin for 2-6 Rear door and engine hood
the gas spring where it attaches to the frame.
4) Connect the wiring connector at the rear canopy. 2-6.1 Remove the rear door.
5) Install the front set bolts and washers on each
side(torque : 54~68N.m)
6) Install the canopy hinge stopper on the rear side of the
canopy.
WARNING
The parking brake MUST be engaged any time the
2-5.3 Adjust the canopy stops.
loader is being serviced. If the parking brake is NOT set,
the loader may roll. Failure to set the parking brake
could result in death or serious injury.
07-20a
The canopy tilt should be adjusted at the stops so that the 07-22
maximum lifting angle is approximately 65°. This can be
measured with a protractor held along the bottom surface of
1) Suspend the rear door from a hoist with a sling.
the canopy when it is tilted back against the adjusted stops.
2) Remove the top and bottom hinge bolts.
Adjust the stop on each side as follows:
3) Raise and remove the rear door with the hoist.
283
2-6.2 Remove the door latch and lever assembly.
Lock nut
Lever assembly
Latch
Spring
07-22A
1) Disconnect the door spring. 2-6.4 Install the rear door and engine hood.
2) Remove the lock nut and pin.
Installation of these components is a straightforward
reversal of the disassembly procedures above, using the
2-6.3 Remove the engine hood. bolts and washers described. To install the rear door, sus-
pend it with a hoist and sling.
07-23
1) Open the engine hood.

2) Remove the 4 hood hinge bolts and spring washers.
284
2-7 Upper plate and floor plate
2-7.1 Remove the upper plate.
In order to remove the upper plate and the floor plate, you
need to remove the hydraulic control rods, control pedal
shaft assembly, and drive control levers. Refer to section 02
Control System for these procedures. After these compo-
nents are removed, do the following to remove the upper
plate and the floor plate.
Floor plate
Upper plate
07-24
1) Remove the 6 bolts and washers from the upper plate

and remove the plate.
2-7.2 Remove the floor plate
1) Remove the 4 bolts and washers from the floor plate

and remove the plate.
2-7.3 Install the floor plate
1) Install the 4 bolts and washers to attach the floor plate.
2-7.4 Install the upper plate.
1) Install the 6 bolts and washers to attach the upper plate.

2) Attach the control system components. See section 02
Control System.
285
2-8 Bottom plate and engine oil pan cover
2-8.1 Remove the bottom plate and engine oil pan cover.
BOTTOM
PLATE
E/G OIL
DRAIN
COVER
07-25A
1) Remove the bolts and washers that hold the bottom

plate to the frame.
2) Remove the bolts and washers that hold the engine oil
pan cover to the frame.
2-8.2 Install the bottom plate and engine oil pan cover.
Installation of these components is a straightforward rever-

sal of the disassembly procedures above, using the bolts
and washers described.
286
2-9 Tanks 2-9.1 Remove the fuel level sender assembly.
The fuel tank and the hydraulic oil tank are part of the loader 1) Drain all fuel from the tank and store in an appropriate
frame and cannot be removed. The following tank compo- container.
nents can be removed/installed.
DANGER
Fuel, oil, antifreeze. and other flammable fluids and
combustibles can be ignited by a flame or hot surfaces.
Vapors can be particularly FLAMMABLE and can be
HAZARDOUS.
¥ Keep open flame and hot surfaces away from flam-
mable fluids and combustibles.
¥ Do not smoke near hazardous fluids and vapors. 07-26
¥ Tighten all fuel and oil caps securely.
¥ Refueling and oiling should be done in well venti-
lated areas. 2) Disconnect the fuel supply and return lines.
¥ Keep oil and fuel in a designated area and do not
allow unauthorized persons to enter. 3) Remove the 6 screws and fiber washers that hold the
¥ Check fuel and hydraulic systems for leaks prior to sender to the top of the tank. Support the sender as you
starting or using vehicle. Have any leaks repaired remove the screws so that the unit does not fall.
before operating the machine. Wipe up any excess 4) Remove the sender through the access at the top of the
oil, fuel or other flammable fluids. tank.
¥ Be sure a fire extinguisher is present and working
and that personnel are properly trained in extin-
guisher operation. 2-9.2 Install the fuel level sender assembly.
¥ See OSHA Class 1910.178
¥ Avoid skin contact, injestion and excessive breathing 1) Insert the sender through the access at the top ofthe
of vapors from fuel, oil, antifreeze, and other fluids. tank.
2) Install the 6 screws and fiber washers that hold the
sender to the top of the tank. Support the sender as you
insert the screws so that the unit does not fall.
3) Connect the fuel supply and return lines.
4) After refilling the fuel tank, it will be necessary to bleed
the fuel system before starting the diesel engine. For the
proper procedures, refer to Periodic Maintenance in sec-
tion 10 General Information/Miscellaneous.
07-25B
287
288
10 General Information/Miscellaneous Contents
10 General
Information/Miscellaneous
10.1 PERIODIC MAINTENANCE .............................................................................291

10.1.1 SAFETY WARNINGS .........................................................................291
10.1.2 ACCESS TO ITEMS REQUIRING SERVICE .....................................292
10.1.2.1 Rear door and engine hood..................................................292
10.1.2.2 Canopy tilting ........................................................................292
10.1.3 BOOM LOCK OPERATION ................................................................294
10.1.4 DAILY PRE/POST START CHECKS ..................................................295
10.1.4.1 Pre-Start Checks ..................................................................295
10.1.4.2 After Starting - Before Operation ..........................................295
10.1.5 SERVICE SCHEDULE........................................................................296
10.1.6 LUBRICATION POINTS......................................................................298
10.1.7 OPERATOR RESTRAINT LUBRICATION AND MAINTENANCE ......300
10.1.7.1 Lubrication ............................................................................300
10.1.7.2 Function ................................................................................300
10.1.8 ENGINE LUBRICATION .....................................................................301
10.1.8.1 General .................................................................................301
10.1.8.2 Draining Engine Oil...............................................................301
10.1.8.3 Remove/Replace Engine Oil Filter .......................................301
10.1.9 ENGINE COOLING SYSTEM.............................................................302
10.1.10 FAN BELT ...........................................................................................303
10.1.10.1 Belt Tension ..........................................................................303
10.1.10.2 Adjustment ............................................................................303
10.1.11 TWO STAGE AIR FILTER ...................................................................304
10.1.11.1 Removal - Primary Element ..................................................304
10.1.11.2 Removal - Secondary Element .............................................304
10.1.11.3 Installation .............................................................................304
10.1.12 SPARK ARRESTOR............................................................................305
10.1.12.1 General .................................................................................305
10.1.12.2 Maintenance .........................................................................305
10.1.13 BATTERY ............................................................................................306
10.1.13.1 Remove and Install ...............................................................306
10.1.13.2 Jump Starting the Loader .....................................................306
10.1.14 FUEL SYSTEM/FILTERS....................................................................306
10.1.14.1 Removal/Installation - Fuel Filter ..........................................306
10.1.14.2 Fuel Tank Drain.....................................................................306
10.1.15 INJECTION PUMP PRIMING .............................................................307
289
10 General Information/Miscellaneous Contents
10.1.16 HYDRAULIC SYSTEM MAINTENANCE ............................................307

10.1.16.1 Hydraulic Oil Indicator/Filler Neck.........................................307
10.1.16.2 Filter Replacement ................................................................307
10.1.16.3 Hydraulic Filter Indicator Light ..............................................307
10.1.16.4 Hydraulic Tank Drain Plug ....................................................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
10.1.20.1 General Information ..............................................................311
10.1.20.2 Inflation Pressures ................................................................311
10.1.20.3 Installation and Removal.......................................................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
10.6.3.1 Torques for Hose Clamps .....................................................330
10.6.3.2 Hydraulic Line Installation.....................................................330
10.6.3.3 Assembling Fittings with Straight Threads and
O-Ring Seals.........................................................................330
10.6.3.4 Torques for O-Ring Face Seal Fittings .................................331
10.6.3.5 37° Flared and Straight Thread O-Ring Fittings ...................332
10.6.3.6 45° Flared and 45° Inverted Flared O-Ring Fittings .............333
10.6.3.7 Other Fittings ........................................................................334
290
10 General Information/Miscellaneous 10.1 Periodic Maintenance
10.1 Periodic Maintenance

1-1 Safety Warnings
WARNING
1. Never attempt to service a machine unless you
are authorized and qualified to do so.
2. Before attempting any service on this machine,
familiarize yourself with all instructions and warnings
in the operators manual and all machine decals.
3. Do not attempt to service machine unleess you have
the necessary skill, information, safety gear, and
tools and equiment to perform the procedure cor-
rectly.
4. While service is being performed ensure a warning
tag is installed on or near the ignition key switch and
clearly visible to prevent inadvertent starting of the
machine during service.
5. If a service procedure necessitates running
theengine, the control levers must remain in the neu-
tral position and the emergency brake must be fully
engaged. Failure to do so can result in injury or
death.
6. After completing service check for : proper opera-
tion of all controls, correct torque on all fasteners
any fittings, any fluid leaks (prior to and after starting
engine), all tools and equipment must be removed
from the machine.
7. Ensure all hoisting and supporting equipment is in
good repair and of adequate capacity to support
loader.
8. Failure to follow safety precautions and proper ser-
vice procedures can lead to machine malfunction or
damage, injury to operator or bystanders, or death.
291
1-2 Access to items Requiring Service 1-2.2 Canopy tilting
IMPORTANT Daily Maintenance checks can be carried out

by opening the rear door and engine hood of DAEWOO skid
steer loader.
1-2.1 Rear Door and Engine Hood
Pull the door handle backward to open the rear door.
• Stop the loader on level ground and lower the boom

all the way.
• Turn off skid loader.
• Set park brake.
• Loosen both mounting bolts at the front corners of the
canopy.
10-1
Push the door handle forward to close the rear door.
NOTE: the rear door can be locked by placing a pad lock on

the hasp provided.
CAUTION
Always keep rear door closed except for service.
Confirm that the rear door is closed and the door latch
is firmly engaged before operating the loader.
• Remove attaching hardware.
10-2
More service space can be obtained if operator opens up

the engine hood after opening the rear door.
• Hold the grip handles on canopy and then lift slowly

all the way up.
292
(Left Hand Canopy Lock)
• Hook the rectangular canopy lock(s) to the hook(s)

attached on rear sides of the canopy.
• To lower, reverse the above procedure.
CAUTION
Never operate without canopy lowered and properly
secured.
293
1-3 Boom Lock Operation
DANGER
When working on a machine with the boom up, always
engage the boom lock.
1. To engage boom lock
10-8
Figure 1
Make sure the release lever is secured in the lock posi-

tion with knob when the boom lock is in use.
• With boom fully lowered, hold lock arm and remove

knob.
• Lower lock arm onto cylinder.
• Ensure release lever is in lock position and secured
with knob.
• Raise boom until lock arm rests on the cylinder rod.
• Lower boom slowly until the lock arm contacts top of
cylinder. (Figure 1)
2. To disengage boom lock
10-9 10-10
Figure 2 Figure 3
The release lever should be in the release position only

when releaseing the boom lock.
• Rotate lever clockwise to release position. (Figure 2)
• Raise boom until lever reaches position as shown in
Illustration. (Figure 3)
• Lower boom slowly to lowest position.
• Lift boom lock arm, rotate lever counterclockwise.
• Mount lock arm in original position using knob.
IMPORTANT Do not attempt to lower boom once lock is

engaged or cylinder damage will result.
294
1-4 Daily Pre/Post Start Checks
WARNING
If any of the following pre/post start checks indicate
that service may be required, have such service per-
formed before using the machine.
1-4.1 Pre-Start Checks
1. Check engine oil level. Refill if necessary.

2. Check hydraulic oil level. Refill if necessary.
3. Check coolant level. Refill if necessary.
4. Check the engine fan/alternator belt.
5. Check the battery and battery cables.
6. Check the fuel system for leaks.
7. Check the hydraulic system.
8. Grease all fittings.
9. Inspect for any loose or missing nuts and bolts.
10. Inspect structural members and welds for crack or
deformation.
11. Check the loader tires for proper inflation and unusual
wear.
12. Check the fuel level.
13. Check the condition and security of the operator seat
belt and seat bar.
1-4.2 After starting - Before Operation
1. Start the engine and observe the initial exhaust color at

start and at normal operating temperatures.
Excessively black, blue, or white exhaust is an indica-
tion of a problem. Listen for any abnormal sounds.
2. Check the operation of all exterior lights, instrument
panel indicator lights and installed optional equipment.
3. Check the operation of all switches.
4. Check the operation of all controls.
a. Check loader for movement with controls in neutral.
Should movement occur refer to service manual fpr
proper adjustment procedure.
b. Check for proper operation of boom, bucket, and
accessories (if attached).
c. Insure that the boom and bucket pedals are locked
with the seat bar raised.
295
1-5 Service Schedule
This maintenance schedule was designed for you to receive

optimum performance and reliability from your SKID STEER
LOADER under typical working conditions. Failure to follow
a scheduled maintenance program can lead to premature
wear and component failure. Adverse conditions (e.g.,
excessive dust or corrosive vapors, etc.) may require more
frequent service.
SERVICE SCHEDULE HOURS

every every every every every every
ITEM SERVICE REQUIRED
day 50 100 250 500 1000
Check the oil level and fill oil as needed. m m
Replace the oil. m m

Engine Oil (First time)
Replace the oil filter. m m

(First time)
Fuel System Clean and replace fuel filter element. m m m

(First time) (Clean) (Replace)
Check cooling level and add as needed.

Engine m
Cooling Check for leaks.
System
Check and adjust the tension of fan belt. m
Check the indicator.

(Clean or replace the outer element when the
m
red ring shows.)
Clean the dust cover.
Air
Cleaner
Replace the outer element.
(Replace the inner element every third time the m m
outer element is replaced). (Clean) (Replace)
296
SERVICE SCHEDULE HOURS

every every every every every every
ITEM SERVICE REQUIRED
day 50 100 250 500 1000
Tires Check air pressure and for damage to tires. m
Wheel Nuts Tighten to correct torque if loose. m
Seat Belt Check the condition od seat belt. m

Seat Bar Check the seat bar for correct operation. m
Safet Signs Check for damaged signs and replace if needed. m
Pivots Grease pivots as needed. m
Check the water level and battery cables for corrosion.

Battery Check whether battery cables are tightly clamped. m
Check covers.
Hydraulic Oil Check the oil level and add as needed. m
Hydraulic
Check for damage and leaks and replace as
Tubes and m
needed.
Hoses
Chain Case
Replace the oil. m
Oil
(First time)
Hydraulic
Replace the filter. m
Filter m
Hydraulic
Replace the hydraulic oil. m
Oil Tank
Spark Arrestor
Clean the spark chamber. m
for Muffler
297
1-6 Lubrication Points
10-11
1. Bucket cylinder pivot 2. Lower bucket/boom pivot 3. Upper bucket cylinder pivot
4. Front mast cylinder pivot 5. Rear mast cylinder pivot 6. Upper mast pivot
298
8 7 8
FASTEN SEAT BELT
10-19 10-21
7. Pedal assembly grease fittings 9. Drive control lever fitting (NOTE: Cab
must be opened to access.)
299
1-7 Operator Restraint Lubrication And Maintenance
10-23
1. Seat bar mounting points
1-7.1 Lubrication
All seat bar mounting points (right shown-left in mirror posi-

tion) should be checked for security, cleaned of any dirt and
debris, nad lubricated daily. Use either a spray lubricant or
a light machine oil at the points marked on the illustration.
Lubrication for the pedal lock linkage is covered in the pre-
vious section (1-6).
1-7.2 Function
Sit in seat and fasten seat belt. Check the seat belt for secu-
rity at mounting points. With the seat bar up, check for full
engagement of the pedal locks into the corresponding slots
on the pedal assembly. Lower the seat bar. Pedal lock
assemblies should fully disengage from pedals.
300
1-8 Engine Lubrication
10-26 10-27 10-28
1-8.1 General
Engine oil levels should be checked daily. Aftwer draining oil

and changing filter approximate refill amounts are 1.5 gal-
lons for the machine. Run loader briefly and check oil level
on dipstick before returning the loader to service. See sec-
tion 4 for fluid recommendations.
1-8.2 Draining Engine Oil
Remove the four bolts from the access plate on the left bot-
tom corner of the chassis. Remove the drain plug by either
reaching through the opening between the radiator and the
chassis or through the access plate. Drain oil into an
approved waste oil receptacle. Inspect drain plug gasket
and if serviceable, replace drain plug. If gasket is deformed
or torn, replace gasket and re-install drainplug. Discard oil in
accordance with local environmental rules and regulations.
1-8.3 Remove/Replace Engine Oil Filter
Raise and secure operators cab. Filter is located on left side

of engine block. Using a strap type or other style clean filter
wrench, remove the engine oil filter. Before installing new fil-
ter, coat the rubber gasket on the filter with clean oil. Install
filter BY HAND and tighten until gasket fully contacts the
mounting surface. Once this occurs tighten another 2/3 turn
to fully seat the gasket.
301
1-9 Engine Cooling System
NOTE: Check the cooling water level while the engine is

cold.
Accurate coolant level check is not guaranteed
when engine is hot, because a hot radiator can flow
coolant to sub-tank.
Check the coolant level on the sub-tank. Remove
the top cap of the sub-tank and fill to the “FULL”
mark if coolant level is below “LOW” mark on sub-
tank.
Fuel Tank FULL
LOW
10-29
NOTE: The radiator drain petcock is located on the right

radiator tank. Attach a section of 5/16” tubing to the nipple
on the petcock to allow fluid to drain outside of the chassis.
Collect the fluid and discard it in accordance with local/fed-
eral environmental rules and regulations.
10-30
CAUTION
1). Steam or hot liquid may spurt out if the radiator cap
is removed soon after the engine is stopped.
2). When removing the radiator cap, turn your face
away from the cap and cover the cap with a cloth.
Turn the cap slowly to release the pressure inside
the radiator.
302
1-10 Fan Belt
1-10.1 Belt Tension
Properly adjusted, the belt should have approximately 3/8”

to 9/16” (10-15 mm) of free play when checked by pressing
firmly on the belt between the fan and alternator pulleys.
10-31
1-10.2 Adjustment
Belt tension can be adjusted by loosening the upper and

lower pivot bolts on the alternator. Use a small pry bar to
move the alternator to achieve proper tension and retighten
pivot bolts.
10-32
303
1-11 Two Stage Air Filter
1-11.1 Removal-Primary Element
Every 50 operating hours or when the red ring shows on the

air cleaner indicator, the primary air cleaner element should
be removed and cleaned. Access to the air cleaner assem-
bly is gained through the rear service door. Loosen the can-
ister cover wing nut and remove the cover and gasket.
Remove the primary element wing nut and remove the pri-
mary element. This element can be cleaned up to six times
using compressed air and should be replaced every 250
operating hours.
1-11.2 Removal-Secondary Element
Unlike the primary element, the secondary element is

designed for replacement only and is not to be cleaned. The
secondary element is nested inside the primary element
and can be removed easily once the primary element is out
of the vehicle. The secondary element should be replaced
at least with every third change of the primary element.
1-11.3 Installation
Installation is simply the reverse of the above procedures.

Ensure that the element and gasket are not damaged dur-
ing replacement. the sir cleaner will not function properlu if
the gaskets do not seal completely.
IMPORTANT Extreme operating conditions may greatly

accelerate the need to clean or replace these elements.
304
1-12 Spark Arrestor
1-12.1 General
This vehicle is equipped with a U.S.D.A. Forestry Service

approved spark arrestor muffler. to keep it in working condi-
tion, the spark chamber must be emptied every 100 hours of
operation.
1-12.2 Maintenance
The engine must be completely cool before attempting to

clean the spark chamber. NEVER attempt to empty the
spark chamber on a hot engine. Raise and support the
loader and open and secure the operators cab. Remove the
clean out plug from the spark chamber. Ensure that the indi-
viduals performing this operation are wearing safety glass-
es with side shields. Start the engine and run for approxi-
mately 10 seconds while the second individual wearing pro-
tective gloves holds a piece of wood over the exhaust out-
let. Re-install plug and lower the secure cab.
305
1-13 Battery 1-14 Fuel System/Filters
10-37 10-38 10-39
1-13.1 Remove and Install

1-14.1 Removal/Installation-Fuel Filter
Removal: The battery is located in the right rear corner of
Open and secure the operators cab. Facing the loader,
the chassis. Access to battery is gained through the rear
the fuel filter is located above the right corner of the
service door.Disconnect the negative (–) battery cable first,
engine. Use a spanner wrench to remove the retaining
then disconnect the positive (+) cable. Remove the wing
ring from the filter head and remove the filter bowl. Follow
nuts from the battery hold down clamp, and remove the
the service schedule for replacement/cleaning intervals.
clamp assembly. Remove the battery from the loader.
Clean the filter using a light grade machine oil and com-
Installation: Installation procedure is the reverse of the
pressed air. NEVER use gasoline to clean filter. Align the
removal procedure. Before beginning installation, clean the
filter bowl and tighten the retaining ring by hand until
battery terminals and cable ends with a wire brush. Be sure
snug. Finish tightening using the spanner wrench. When
to connect the negative (–) cable last to minimize the poten-
complete, refer to section 1-15 for fuel system priming.
tial for sparking. Coat the terminals and cable ends with
grease to prevent corrosion.
WATER SEPARATOR: The water separator is located
inside the rear door on the left hand side for the DSL 601.
1-13.2 Jump Starting the Loader
Removal, cleaning and installation are identical to the
procedure for the DSL 601 fuel filter.
WARNING 1-14.2 Fuel Tank Drain
Never attempt to charge or jump start a frozen battery.
An explosion may occur.
Never attempt to start a jump loader by yourself. There

must be one person in the operators seat and one person
to connect and disconnect the jumper cables. Before begin-
ning to connect jumper cables, ensure that the ignition
switches in the off position, controls are in neutral and park-
ing brake is fully engaged. Connect from the positive (+) ter-
minal from the jumper battery to the positive (+) terminal on
10-40
the loader battery. Next, connect from the negative (–) ter-
minal on the jumper battery to the negative (–) terminal on
the loader frame. Once loader has started, remove the The fuel tank drain plug is located directly behind the left
ground cable from the frame first. rear tire on the chassis. Fuel drained should be disposed
NOTE: Ensure the jumper battery being used is a 12 volt of into an approved waste oil container. Discard the fuel
battery or electrical system damage will result. in accordance with local/federal environment rules and
regulations.
306
1-15 Injection Pump Priming Drain the hydraulic oil into an approved waste oil container.
While draining, check fluid and filter base for signs of parti-
cle contaminants.
Should you run the loader dry of fuel, it will be necessary to
prime the fuel system. This is accomplished by loosening INSTALLATION: Before installation you must coat the rub-
the vent joint (A) and pumping the priming lever (B) until air ber seal on the new filter with a light coat of hydraulic oil.
is bled from the system. Tighten vent joint (A) when com- Spin on filter by hand turning clockwise until the rubber filter
plete. seal makes complete contact with the filter head assembly.
At this point, turn the filter an additional 3/4 turn to fully tight-
en. When complete, run the loader and check the hydraulic
oil level indicator. Add fluid as needed. Discard the used fil-
ter in accordance with local/federal environmental rules and
regulations.
1-16.3 Hydraulic Filter Indicator Light
10-40a 10-40b
Injection Pump Fuel Pump
1-16 Hydraulic System Maintenance
10-44
Replace the filter when the filter light is illuminated. This indi-
cates a high pressure condition by a clogged filter.
1-16.4 Hydraulic Tank Drain Plug

10-41
1-16.1 Hydraulic Oil Level indicator/Filler Neck
The hydraulic oil level indicator and filler neck are located on
the right hand side of the loader inside the rear service door.
To properly check the fluid level, the loader should be on
level ground with the boom completely lowered and the
Quik-tach assembly tilted back. The fluid level as indicated
on the sight gauge should read between the two red lines. 10-45
Refer to specifications section 4 for complete information on
fluid capacities and requirements. The hydraulic tank drain plug is located directly behind the
rear tire on the chassis. Before draining, the loader should
1-16.2 Filter Replacement be on level ground with the boom completely lowered and
the Quik-tach tilted back. Once the loader is drained, oil
should be disposed of into an approved waste oil container,
in accordance with local/federal rules and regulations.
10-43
REMOVAL: Access to the DSL 601 filter is through the oper-

ator’s cab. Remove the filter by turning counterclockwise.
307
1-17 Chain Case Drain and Refill
1. Chain case drain plugs 2. Front chain case cover
TO DRAIN CHAIN CASE:
1. Remove drain plugs and drain case oil into an appro-

ved waste oil container.
TO REFILL CHAIN CASE:

1. Re-install and tighten drain plugs.
2. Remove front chain case covers.(RH, LH)
NOTE : Recommended fluid is APT CC or CD SAE 10W30
3. Refill is 10 liter(2.6 gal)/side
4. Re-install and tighten front chain case covers.(RH, LH)
1-18 Parking Brake Adjustment
10-49a
Should adjustment be required begin by opening the cab

and securing with safety latches.
1. Locate the park brake handle linkage and return spring.

2. Remove the spring (A) to release tension from the park-
ing brake linkage.
3. Loosen the jam nut (B), remove bolt (C), and rotate the
clevis on the linkage to adjust the cable tension until
parking brake engages fully and interlock functions prop-
erly.
4. Re-attach clevis, re-tighten jam nut and re-connect
spring when completed with the adjustment procedure.
308
1-19 Pedal Lock Adjustment
10-49b
309
The pedal lock is designed to prevent the three foot pedals

from being activated if the seat bar is up. Lowering the seat
bar pulls three spring loaded, notched levers away from the
bellcranks on the pedal shafts, making the pedals operable.
Raising the seat bar causes the springs to pull the notched
levers into a position that blocks the bellcranks, making the
pedals inoperable.
If adjustment is needed, do the following:

1) Check the positions of the levers when the seat bar is
raised and when it is lowered. Determine whether the
levers need adjustment toward or away from the bell-
crank ends.
2) Raise the seat bar to release tension from the linkage.
3) Loosen the jam nut (A), remove pin (B).
4) Rotate the clevis (C) to adjust cable length in or out, as
needed, until the pedal lock functions properly.
5) Re-attach the clevis and tighten the jam nut.
310
1-20 Tire Maintenance
1-20.1 General Maintenance
Tires should be checked regularly for wear, damage, and

proper inflation. When replacing tires, ensure that the size
matches those already on the vehicle. Mismatched tires can
change vehicle performance and cause premature wear
and damage to drive train components. If tires are replaced
in pairs, they should be mounted on the same side of the
vehicle to minimize stress on the drive train.
DANGER
Tires should only be mounted/dismounted from rims or
repaired by trained and autjorized personnel using the
proper equipment and procedures. Death or serious
injury could result. See OSHA 1910.177.
1-20.2 Inflation Pressures
45 psi (3.2 kg/cm2)
1-20.3 Installation and Removal
REMOVAL: Support the frame so that the tire(s) to be

removed are off ground. Insert a wedge under the tire to
prevent rotation while the lug nuts are being removed.
Remove tire and rim assembly.
10-50
INSTALLATION: Install the tire and rim assembly on the

axle. Tighten lug nuts to seat rim against axle assembly.
Insert a wedge under the tire to prevent rotation while
torquing lug nuts. Torque lug nuts to 146 L 20 N.m (108 L
15 ft.lbs) in the pattern illustrated above. Re-check torque
after 10 hours of operation.
311
10 General Information/Miscellaneous 10.2 Towing Procedures
10.2 Towing Procedures

WARNING
Towing loaders without following the procedures listed
below can result in damage to machine and injury to
personnel.
1. Open canopy and secure with safety latches.

2. Locate bypass/relief valves on each side of HST pumps
(refer to illustrations)
NOTE: Mahine has 4 locations.
BYPASS VALVE/
CHECK VALVE
5/16Ó INTERNAL HEX
HST side view

10-50a
3. Loosen valves by turning counterclockwise 3-4 revo-

lutions.
WARNING
Opening of bypass valve will result in a loss of hydro-
static braking capacity. Take precautions to prevent
machine movement when opening the valves, and after
valves are opened.
4. Tow loader using the two draw eyes located at lower

rear portion of frame.
5. After towing, tighten valves to 9.5-14 N•m (7-10 ft/lbs.).
Damage to units may result from over-torquing
valves.
6. DAEWOO Skid Steer Loader can draw another machine
using the 2 drawing eyes on rear frame.
Specified draw bar forces are as follows:
2,110 Kg (w/load) 1,800 Kg (w/o load)
312
10 General Information/Miscellaneous 10.3 Dimensions
10.3 Dimensions
Item Unit specification
• Overall Height
A. Fully Raised in(mm) 142.4 (3617)
B. To Hinge Pin in(mm) 112.0 (2845)
C. To Canopy in(mm) 112.0 (2845)
• Overall Length
D. With Bucket in(mm) 115.1 (2924)
E. Less Bucket in(mm) 90.4 (2296)
• Overall Width
F. With Bucket in(mm) 61.5 (1562)
G. Less Bucket in(mm) 58.5 (1486)
• Others
H. Wheel Base in(mm) 37.9 (963)
I. Height To S.I.P. in(mm) 37.8 (959)
J. Ground Clearance in(mm) 7.5 (190)
T. Tread in(mm) 48.1 (1222)
U. Departure Angle deg 27o
Q
R A M
B
F S T G L C
I
N
J U
P H
E
D
313
• Dumping
K. Dump angle deg 55o
L. Dump Height in(mm) 86.3 (2192)
• Reach
M. Fully Raised in(mm) 20.4 (518)
• Rollback
N. Max. at Ground deg 25o
O. Max. Fully Raised deg 94o
• Digging
P. Digging Depth in(mm) 0.5 (13)
• Clearance (Circle)
Q. Front; Less Bucket in(mm) 46.6 (1183)
R. Front, With Bucket in(mm) 71.0 (1804)
S. Rear in(mm) 57.7 (1465)
Q
R A M
B
F S T G L C
I
N
J U
P H
E
D
314
DIMENSIONAL SPECIFICATIONS Bucket Width (F) - The maximum outside width in inches
(millimeters) of the bucket specified.
Definitions: Overall Width (G) - The maximum outside width in inches

(millimeters) of the machine specified exclusive of bucket.
Overall Operating Height (A) - Fully Raised - The vertical
distance in inches (millimeters) from the ground to the high- Wheelbase (H) - The vertical distance in inches (millime-
est point attainable. ters) from the center of the front wheel or idler to the center
of the rear wheel or sprocket.
Height to Hinge Pin (B) - Fully Raised - The vertical dis-
tance in inches (millimeters) from the ground to the center- Height to S.I.P. (I) - The vertical distance in inches (mil-
line of the bucket hinge pin. limeters) from the ground to the Seat Index Point.
Overall Height (C) - The vertical distance in inches (mil- Ground Clearance (J) - The minimum vertical distance in
limeters) from the ground to the highest point on the unit inches (millimeters) from the ground to the lowest point on
with the bucket on the ground. the machine between the tires or tracks with the lift arm
raised.
Overall Length (D) - The horizontal distance in inches (mil-
limeters) with the bucket on the ground and level, measured Dump Angle (K) - The maximum angle in degrees that the
from the foremost point of the bucket cutting edge to the longest flat section of the inside bottom of the bucket will
rear most point of the machine. rotate below horizontal with the bucket hinge pin at maxi-
mum height.
Overall Length (E) Without Bucket - The horizontal dis-
tance in inches (millimeters) from the furhtest rearwward to Dump Height (L) - the vertical distance in inches (millime-
the furthest point forward. ters) from the ground to the lowest point of the cutting edge
with the bucket hinge at maximum height and the bucket at
a 45o dump angle. the angle is less than 45o, specify angle.
Q
R A M
B
F S T G L C
I
N
J U
P H
E
D
315
10 General Information/Miscellaneous 10.4 Operational Specifications
10.4 Operational Specifications

4-1 Performance (Per SAE J732 Feb 80)
• Rated Capacity lb(kg) 1300 (590)

• Bucket Capacity (Dirt - 60”) ft3(m3) 10.7 (0.31)
• Operating Weight lb(kg) 5284 (2397)
• Tipping Load lb(kg) 2600 (1180)
• Hydraulic Lifting Capacity lb(kg) 3373 (1530)
• Bucket Break Out Force lb(kg) 3031 (1375)
• Boom Break Out Force lb(kg) 4056 (1840)
• Raising Time -W/O Load sec 4.2

• Lower Time -W/O Load sec 2.1
• Dump Time -W/O Load sec 2.4
• Rollback Time -W/O Load sec 1.7
• Drawbar Pull -W/O Load lb(kg) 4350 (1973)
-W/Load lb(kg) 4949 (2245)
• Travel Speed
mph(km.h) 7.6 (12.2)
• Forward
mph(km.h) 7.6 (12.2)
• Reverse
• Noise(w/option sound reduction

package) ´
LpA [dB(A)] 83
• Airborne Noise Results ´
LpW [dB(A)] 102
IAW ISO 6393, ISO 6394
and 86/662/EEC
316
4-2 Power Unit
• Make -
Yanmar
• Model -
4TNE84
• Type of Fuel -
Diesel
• Cooling Medium -
Water
• No. of Cylinders each
4
• Displacement in3(cc)
121.7 (1995)
• Bore Size in(mm)
3.31 (84)
• Stroke in(mm
3.54 (90)
• Horsepower Net hp(ps)/rpm
41.1 (41.7)/2800
• High Idle rpm
2975
• Torque ft.lb(kg.m)/rpm
>89.0 (12.3)
1500-1700
• Torque Rise %
>19.0
• Lubrication -
Full flow
317
4-3 Final Drive Components
• Chain - 2 Chain with

#80 & #80
• No. of Teeth
• Drive Sprocket (Motor) each 11
• Drive Sprocket (Axle) each 32
• Ratio 2.91
• Tire
• Type - Flotation-
Tubeless
• Size - 10-16.5, 6PR
• Pressure psi 45
(kg/cm2) (3.2)
• Wheel
• Size - 8.25 x 16.5
• Hole x Pitch Circle Diameter - 8 x 8”
318
4-4 Hydrostatic Transmission Pump
• Type - Piston, Variable

Displacement, manual
• Max. Displacement in3(cc)/rev 2.14 (35)
• Relief Setting Pressure psi 3270
• Charge Pump - None
• Rotation - Clockwise
• Swash Plate Operating Angle deg +16
• Mounting - SAE 2 Bolt B Mount
• Shaft - ANSI B92.1-1970
Class No. 5
30x15x16/32
• Standard Pump
Pressure and Flow
• Flow (Max.) LPM (GPM) 44.9 (11.9)
• Max. System Pressure psi- 2480+35
at charge pump bar 170+2.4
• High Flow Option Pump

Pressure and Flow
• Flow (Max.) LPM (GPM) 101 (26.7)
• Max. System Pressure psi- 2480+35
at charge pump bar 170+2.4
319
4-5 Hydraulic System
• Motor
• Type - Orbit, Fixed
Displacement
Bi-rotational
• Displacement in3(cc)/rev 410 (25)
• Mounting - SAE 4 Bolt B Mount
Spline Shaft
• Pump
• Type - Gear
• Capacity in3(cc)/rev 0.98 (16.0)
• Max. Pressure psi 3,000
• Max. Speed rpm 3,000
• Mounting - SAE 2 Bolt A Mount
• Shaft - SAE Spline Shaft
• Rotation - Clockwise
320
4-5 Hydraulic System, Continued
• Control Valve
• No. of Spools - 3
• Flow Capacity (Rate) 1(gal)/min 80 (21)
• Relief Setting Pressure psi 2392 (+70)
(set by valve supplier) kg/cm2 165 (+5)
• Circuit - • Series on Lift Float
Function with Detent
• Series on Tilt
• Series on Auxiliary
with Detent
• Boom Cylinder
• Type - Single Rod, Double Acting
• Number each 2
• Cylinder Bore in(mm) 1.97 (50)
• Cylinder Rod in(mm) 1.38 (35)
• Stroke in(mm) 39.7 (1009)
• Mounting - • Series Crest Crevice
• Plating on Rod - • Hard Chrome w/15-50
Micron Thickness
321
• Bucket Cylinder
- Single Rod, Double Acting
• Type
each 2
• Number
in(mm) 2.36 (60)
• Cylinder Bore
in(mm) 1.18 (30)
• Cylinder Rod
in(mm) 14.45 (367)
• Stoke
- • Single Crest Crevice
• Mounting
- • Hard Chrome w/15-50
• Plating on Rod
Micron Thickness
HRC 52-60 Hardness
• Hydraulic Filter
Full Flow Spin-On
• Type -
10 Micron Beta Rating
• Filter Rating -
of 1.5
132.5 (35)
• Rated Flow l(gal)/min
Closing PR13-17
• By-Pass Valve
(Normally Open Type)
322
• Hydraulic Lines and Fttings

O-Ring Face Seal
• Type -
Fitting (SAE J1453)
Unified Thread is
• Thread -
Standard
SAE 100R1 Hose
• Medium Pressure Line -
(SAE J517)
SAE 100R2 Hose
• Hydraulic High -
(SAE J517)
Pressure Line
SAE 100R12 Hose
• HST High -
(Parker 381-10)
Pressure Line
323
4-6 Electrical Components
• Alternator - 12V - 40A

• Battery - 12V-100AH, 625CCA
12.5 X 6.75 X 8.0”
• Starter - 12V - 2.5KW
• Lighting
each 2
• Head Lamps
each 1
• Rear Lamps
324
4-7 Instruments
• Instrument Panel (Left Side) - Standard

• Buzzer Alarm
• Stop (Red) Warning
(Yellow) Warning
• Engine Oil Pressure
• Engine Water Temperature
• Battery Voltage
• HST Charge Pressure
• HST Oil Temperature
• HST Filter
• Instrument Panel (Right Side) - Standard
• Fuel Meter
• Hour Meter
• Park Brake Monitor
• Pre-Heater Monitor
• Key Switch
• Light Switch
• Fuses
325
4-8 Seat
• Cover Material - Vinyl, Black

• Cushion Material - Urethane Foam
• Fore/Aft Adjustment in(mm) +3 (76)
326
10 General Information/Miscellaneous 10.5 Fluid Specification And Refill Capacities
10.5 Fluid Specification And Refill Capacities

Fluid Capacities & Specifications
Item Specifications Unit QÕty
• Engine Lubrication
-W/Filter API CC or CD SAE 10W30 for gal 1.5
Ambient Temp above 4 deg. F
-W/O Filter API CCor CD SAE 5W30 for gal 1.4
Ambient Temp below 4 deg. F
SAE 10W20CD; Texaco TDH; Mobil

• Hydraulic Tank gal 6.1
Fluid 423; Chevron Tractor Hydraulic
• Hydraulic System gal 7.8
Fluid; G Automatic Fluids meeting
Caterpillar TO-2 or Allison C3 standards
Total MP
• Chain Case API CC or CD SAE 10W30 gal 5.2/Total, 2.6 perside
• Fuel Tank #2 Diesel recommended for Ambient 13.8

Temp above 40 deg. F
gal
#1 Diesel recommended for Ambient
Temp below 40 deg. F
• Cooling Fluid Recommended mixture is 50/50 gal 1.6

ethylene glycol and water
• Grease Recommended is a mineral based

grease with a lithium thickener and
rust, corrosion and extreme pressure
additives. Viscosity conforms to
NOGI grade 2.
327
10 General Information/Miscellaneous 10.6 Tightening Specifications And Procedures
10.6 Tightening Specifications And Procedures

6-1. Tightening Torques For Major Components
No. Bolts or Nuts Tightening Torque (unit; N•m)

1 Front & Rear axle fastening nut 200+20 N•m (150+15 ft. lb.)
2 Tire hub nut 146+20 N•m (108+15 ft. lb.)
3 Drive motor bolt 125+15 N•m (92+11 ft. lb.)
4 Chain oil drain plug 125+15 N•m (92+11 ft. lb.)
5 Control valve mounting bolt 30+7 N•m (22+5 ft. lb.)
6 Hydtaulic pump, HST mounting bolt 125+15 N•m (92+11 ft. lb.)
7 Engine mounting bolt 200+20 N•m (147+15 ft. lb.)
8 Control valve banjo fittings 100+15 N•m (65+10 ft. lb.)
328
6-2. Standard Torques For Metric Fasteners
NOTE: Take care to avoid mixing metric and inch dimensional fasteners. Mis-matched or incorrect fasteners can
result in vehicle damage or malfunction, or possible injury. Exceptions to these torques are given in the Service
Manual where needed.
NOTE: Prior to installation of any hardware, be sure components are in near new condition. Bolt and nut threads
must not be worn or damaged. Hardware must be free of rust and corrosion. Clean hardware with a non-corrosive
cleaner and apply engine oil to threads and bearing face. If thread lock or other compounds are to applied, do not
apply engine oil.
Property, Class Property, Class Property, Class Grade Grade Grade

SIZE SIZE
5.8 8.8 10.9 21 52 83
AND AND
PITCH PITCH
N•m lbf ft. N•m lbf ft. N•m lbf ft. lbf ft. N•m lbf ft. N•m lbf ft. N•m
M3 x 0.5 0.62 0.5 0.99 0.7 1.34 1.0 20 UNC 4 6 6 9 9 12

M3.5 x 0.6 0.97 0.7 1.55 1.1 2.11 1.6 1/4 28 UNF 5 6 7 10 10 14
M4 x 0.7 1.44 1.1 2.30 2.1 3.13 2.3
M5 x 0.8 2.91 2.1 4.65 3.6 6.33 4.7 18 UNC 8 11 13 18 18 25
5/16 24 UNF
M6 x 1 4.94 3.6 7.90 6 10.8 8 9 13 14 20 20 28
M8 x 1.25 12.0 9 19.2 14 26.1 19 14 UNC 15 20 23 31 33 44
M8 x 1 12.8 9 20.5 15 27.9 21 7/16 20 UNF
17 23 26 36 37 50
M10 x 1.5 23.8 18 38.0 28 52 38
M10 x 1.25 25.1 19 40.1 30 55 41 13 UNC 37 50 57 77 80 110
1/2 20 UNF
M12 x 1.75 41.4 31 66 49 90 66 41 56 64 86 90 120
M12 x 1.25 45.3 33 72 53 98 72
12 UNC 53 72 82 110 115 155
M14 x 2 66 49 105 77 145 105 9/16 18 UNF
M14 x 1.5 72 53 115 85 155 115 59 80 91 125 130 175
M16 x 2 105 77 165 122 225 165 11 UNC 73 99 115 155 160 215
5/8 18 UNF
M16 x 1.5 110 81 175 130 240 175 83 110 130 175 180 245
M20 x 2.5 200 150 320 235 435 320
M20 x 1.5 225 165 355 260 485 355 10 UNC 130 175 200 270 280 380
3/4 16 UNF 145 195 225 300 315 425
M24 x 3 345 255 555 410 755 560
M24 x 2 375 275 605 445 820 605 9 UNC 125 170 320 435 455 615
M27 x 3 505 370 810 600 1100 810 7/8 14 UNF 140 185 355 480 500 680
M27 x 2 550 405 875 645 1190 880
8 UNC 185 255 485 655 680 925
M30 x 3.5 690 510 1100 810 1500 1100 1 14 UNF 210 285 540 735 765 1040
M30 x 3 715 530 1140 840 1550 1140
M30 x 2 765 656 1220 900 1660 1230 7 UNC 265 360 595 805 965 1310
M33 x 3.5 940 695 1500 1100 2040 1510 1-1/8 12 UNF
300 405 670 905 1080 1470
M33 x 2 1030 760 1640 1210 2240 1660
7 UNC 375 510 840 1140 1360 1850
M36 x 4 1200 885 1930 1430 2620 1940 1-1/4 12 UNF
M36 x 3 1280 945 2040 1510 2780 2050 415 565 930 1260 1500 2050
M39 x 4 1560 1150 2490 1840 3390 2500 6 UNC 490 665 1100 1490 1780 2420
M39 x 3 1640 1210 2630 1940 3570 2640 1-3/8 12 UNF
560 760 1250 1700 2040 2760
M42 x 4.5 1930 1430 3080 2280 4200 3100
M42 x 3 2070 1530 3320 2450 4510 3330 6 UNC 650 885 1450 1980 2370 3210
1-1/2 12 UNF
M45 x 4.5 2410 1780 3850 2840 5240 3870 735 995 1650 2230 2670 3620
M45 x 3 2580 1910 4120 3040 5610 4140
M48 x 5 2900 2140 4630 3420 6300 4650 * Unless otherwise specified
M48 x 3 3160 2330 5040 3720 6860 5060
1
Approximately equal to metric Property Class 5.8
2
3
329
6-3. Lines, Hoses, Fittings And Seals 6-3.3 Assembling Fittings with Straight Threads and
O-Ring Seals
6-3.1 Torques for hose clamps - Band Type
This type of fitting is used in many applications. The tube
end of the fitting will be different in deisgn so that it can
be used in many different applications. However, the
installation procedure of the fitting is the same.
10-5-1
CLAMP TORQUE ON RETIGHTENING

WIDTH NEW HOSE TORQUE
7.9 mm 0.9+0.2 N•m 0.7+0.2 N•m
(.312 in) 8+2 lb in 6+2 lb in
13.5 mm 4.5+0.5 N•m 3.0+0.5 N•m
(.531 in) 40+5 lb in 25+5 lb in
15.9 mm 7.5+0.5 N•m 4.5+0.5 N•m 10-5-2
(.625 in) 65+5 lb in 40+5 lb in
1. End of fitting body (connects to tube). 2. Fitting body.
3. Lock-nut. 4. Backup washer. 5. O-ring seal. 6. End of fit-
6-3.2 Hydraulic Line Installation ting that goes into other part.
1. For a metal tube to hose installation, install the tube and 1. Put locknut (3), backup washer (4) and O-ring seal
tighten all bolts finger tight. (5) as far back on fitting body (2) as possible. Hold
these components in this position. Turn the fitting into
2. Tighten the bolts at the rigid end. the part it is used on until backup washer (4) just
makes contact with the face of the part it is used on.
3. Install the hose and tighten all bolts finger tight.
2. To put the fitting assembly in its correct position, turn
4. Put the hose in a position so that it does not make the fitting body (2) out (counterclockwise) a maximum
contact with the machine or another hose. of 359o. Tighten locknut (3) to the torque shown in the
correct chart for the fitting used in this section.
5. Tighten the fittings or nut bolts on both connections.
NOTE: If the fitting is a connector (straight fitting), the hex
6. Start the engine. on the body takes the place of the locknut. To install this
type fitting, tighten the hex against the face of the part it
7. Move the implement control levers to all positions. goes into.
The torques shown in the charts that follow are to be
8. Look at the hose during movement of the implement. used on the nut part of 37o Flared, 45o Flared and
Make sure hose is not in contact with the machine or other Inverted Flared fittings (when used with steel tubing), O-
hoses. ring plugs, O-ring fittings and swivel nuts when used in
applications to 3000 psi (20 700 kPa).
9. Shut off the engine.
10. If necessary, put the hose in a new position where it will

not make contact when the implement is moved.
330
6-3.4 Torques for O-Ring Face Seal Fittings
IDENTIFYING FEATURE, O-RING GROOVE 10-5-3
O-RING FACE SEAL FITTING NUT

SAE THREAD STANDARD TORQUE
SIZE
DASH SIZE inch (N•m) (lb ft)
-4 9/16 - 18 16 + 3 12 + 2
-6 11/16 - 16 30 + 4 22 + 3
-8 13/16 - 16 50 + 7 37 + 5
-10 1 - 14 90 + 10 65 + 7
-12 1-3/16 - 12 120 + 15 90 + 10
-16 1-7/16 - 12 160 + 20 120 + 15
-20 1-11/16 - 12 190 + 20 140 + 15
-24 2 - 12 215 + 25 160 + 20
STRAIGHT THREAD O-RING PORT

FITTING END (FOR O-RING FACE
SEAL FITTINGS ONLY)
THREAD STANDARD TORQUE
SIZE
inch (N•m) (lb ft.)
5/16 - 24 5.0+1.5 45+15 lb in
3/8 - 24 12+2 110+20 lb in
7/16 - 20 20+4 15+3
1/2- 20 30+5 22+4
9/16 - 18 40+5 30+4
3/4 - 16 100+15 75+10
7/8 - 14 135+15 100+10
1-1/16 - 12 200+25 150+20
1-3/16 - 12 250+25 185+20
1-5/16 - 12 300+40 225+30
1-5/8 - 12 300+40 225+30
1-7/8 - 12 300+40 225+30

2-1/2 - 12 300+40 225+30
331
6-3.5 37o Flared and Straight Thread O-Ring Fittings
NOTE: The torques shown in the charts that follow are to

be used on the nut part of 37o Flared, 45o Flared and
Inverted Flared fittings (when used with steel tubing), O-ring
plugs, O-ring fittings and swivel nuts when used in applica-
tions to 3000 psi (20 700 kPa).
37o FLARED O-RING SWIVEL NUTS

FITTING - PLUG
10-5-4
37o FLARED AND STRAIGHT THREAD O-RING FITTINGS

(EXCEPT O-RING FACE SEAL FITTINGS)
NOMINAL TUBE O.D. THREAD STANDARD TORQUE

SIZE
inch
METRIC INCH (N•m) (lb ft)
3.18 .125 5/16 5.0+1.5 4+1
4.76 .188 3/8 11+1.5 8+1
6.35 .250 7/16 16+2 12+1
7.94 .312 1/2 20+5 15+4
9.52 .375 9/16 25+5 18+4
9.52 .375 5/8 35+5 26+4
12.70 .500 3/4 50+7 37+5
15.88 .625 7/8 65+7 48+5
19.05 .750 1-1/16 100+10 75+7
22.22 .875 1-3/16 120+10 90+7
25.40 1.000 1-5/16 135+15 100+11
31.75 1.250 1-5/8 180+15 135+11
38.10 1.500 1-7/8 225+15 165+11

50.80 2.000 2-1/2 320+30 240+22
332
6-3.6 45o Flared and 45o Inverted Flare Fittings
NOTE: The torques shown in the charts that follow are to

be used on the nut part of 37o Flared, 45o Flared and
Inverted Flared fittings (when used with steel tubing), O-ring
plugs, O-ring fittings and swivel nuts when used in applica-
tions to 3000 psi (20 700 kPa).
INVERTED 45o FLARED

45o FLARED
10-5-5
45o FLARED AND 45o INVERTED FLARE FITTINGS

NOMINAL TUBE O.D. THREAD STANDARD TORQUE
SIZE
METRIC INCH inch (N•m) (lb ft)
3.18 .125 5/16 5.0+1.5 4+1
4.76 .188 3/8 8.0+1.5 6+1
6.35 .250 7/16 11+2 8+1
7.94 .312 1/2 17+3 13+2
9.52 .375 5/8 30+3 22+2
11.11 .438 11/16 30+3 22+2
12.70 .500 3/4 38+4 28+3
15.88 .625 7/8 50+5 37+4
19.05 .750 1-1/16 90+8 65+6
22.22 .875 1-1/4 100+10 75+7
333
6-3.7 Other Fittings
Hi Duty (Shear Sleeve) Tube Fittings
After tube has been put through the nut and makes contact
against the tube shoulder in the fitting body, turn the nut with
a wrench until a small decrease in torque is felt. This is an
indication that the sleeve has been broken off the nut. Hold 10-5-6
the tube to prevent turning and tighten the nut 1-1/2 turns.
Hi Seal Fittings
Put nut and sleeve over the tubing with the short heavy end
of the sleeve facing the end of tubing. Put the tube end
against the counterbore in the body of the fitting and tighten
until nut is over the last thread on the body. The remainder
of space is used whenever the fitting is removed and 10-5-7
installed again.
Ermeto Tube Fittings
Put nut and sleeve over the tube with head or shoulder end
of sleeve next to nut. Push tube into counter-bore of fitting
body as far as possible. Turn nut clockwise until sleeve
holds tube and prevents movement. Tighten the nut 1-1/4
turns more to seat sleeve and give a locking action. When 10-5-8
necessary to assemble again, put sleeve over tube and
tighten nut until a sudden increase in torque is felt. Then
tighten 1/6 to 1/3 turn more to seat the sleeve.
Flex Fittings
Put nut and sleeve over the tubing and push tube into coun-
terbore of fitting body as far as possible. Tighten the nut until
it is against the hex part of the fitting body.
10-5-9
334

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Shop Manual

HOW TO USE THIS MANUAL.....................................................................................vii

00 ENGINE, 4TNE84 ................................................................................................................1

00.1 GENERAL ............................................................................................................3

00.3.5 FUEL FEED PUMP...............................................................................84

01 FUEL SYSTEM .................................................................................................................189

04 HYDRAULIC SYSTEM .....................................................................................................217

HYDRAULIC SCHEMATIC .........................................................................................218

06 ELECTRICAL SYSTEM ...................................................................................................253

ELECTRICAL WIRING DIAGRAM.............................................................................254

07 STRUCTURES AND CHASSIS........................................................................................271

10 GENERAL INFORMATION/MISCELLANEOUS ..............................................................289

10.1 PERIODIC MAINTENANCE .............................................................................291

10.1.6 LUBRICATION POINTS......................................................................298

The Table of Contents on the preceding pages is your best

The service groups in this manual - their order of presenta-

Sections 08 and 09 do not apply to service procedures and

Be certain to observe all Safety information included in

It is a requirement that only trained and knowledgeable

All Maintenance and Repairs must be performed to factory

This is the safety-alert symbol.

DANGER: Indicates an imminently hazardous situation

IMPORTANT: Indicates information an operator should

WARNING SAFETY INSTRUCTIONS

DANGER SAFETY RULES

jacks or hoist. Always use jack stands to support the

Because of the size of some of the machine components,

13. Repairs which require welding should be performed

14. Do not damage wiring during removal operations. Rei-

15. Be sure all protective devices, including guards and

16. Loose or damaged fuel, lubricant and hydraulic lines,

General Precautions For Disassembly Precautions For Disassembly

Preparations before disassembly 1) Removal of parts

6) Disassemby of bearings up to 10 minutes. Then, rinse it thoroughly with

• Cover washed parts in storage to keep them

• Keep the area where the machine is to be dis-

Procesures after disassembly

• Wash disassembled parts clean, neatly arrange

• When tightening bolts on certain designated

(7) Handling of bearings

Pay special attention to the following instructions

• Keep the working area, tools, worker’s hands,

Handling of Common Parts

(1) Handling of packings and O-rings

(2) Handling of O-rings

• Use only the O-rings prescribed in the Service Parts

(3) Handling of oil seals

• Be careful to see that the oil seal lips face the

00.1.1 SPECIFICATIONS ..................................................................................5

00.2 BASIC ENGINE.....................................................................................................9

00.2.1 CYLINDER BLOCK...............................................................................11

00.3 FUEL INJECTION EQUIPMENT ........................................................................45

00.3.1 FUEL SUPPLY SYSTEM ......................................................................47

00.4 LUBRICATING SYSTEM ....................................................................................97

00.4.1 LUBRICATION SYSTEM ......................................................................98

00.4.3 LUBE OIL FILTER & OIL PRESSURE CONTROL VALVE.................103

00.5 COOLING SYSTEM ..........................................................................................107

00.5.1 COOLING SYSTEM............................................................................108

00.6 AIR INDUCTION SYSTEM................................................................................115

00.6.1 AIR CLEANER ....................................................................................116

00.7 ELECTRICAL SYSTEM ....................................................................................119

00.7.1 ELECTRICAL SCHEMATIC ................................................................121

00.8 DISASSEMBLY AND REASSEMBLY...............................................................155

00.8.1 DISASSEMBLY AND REASSEMBLY PRECAUTIONS ......................156