PDF Operator Manual Daewoo Doosan 400 Series Skid Steer Loaders - 636 KB
This is the Operation and Maintenance Manual for the Daewoo Doosan 440 Plus, 460 Series, and 470 Plus skid steer loaders.
It's the primary guide for operators to learn the machine's controls, safety features, and correct operating techniques.
The manual also outlines all the required daily, weekly, and periodic maintenance tasks to ensure the loader's longevity and reliability.
It is a must-have for anyone operating or maintaining these powerful machines.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
SB2334E04
Operation &
Maintenance Manual
SKID STEER LOADER
440 Plus
460 Series
470 Plus
0510
--- Page 3 ---
7.7. Engine Lubrication ..............................................................................................................................88
7.7.1. General ....................................................................................................................................88
7.7.2. Draining Engine Oil ..................................................................................................................89
7.7.3. Remove/Replace Engine Oil Filter ..........................................................................................91
7.8. Engine Cooling System ........................................................................................................................91
7.9. Fan Belt ................................................................................................................................................92
7.9.1. Belt Tension ..............................................................................................................................92
7.9.2. Adjustment................................................................................................................................92
7.10. Two Stage Air Filter ..............................................................................................................................93
7.10.1. Removal-Primary Element ......................................................................................................93
7.10.2. Removal-Secondary Element ..................................................................................................94
7.10.3. Installation ................................................................................................................................94
7.11. Spark Arrestor ......................................................................................................................................94
7.11.1 General ....................................................................................................................................94
7.11.2 Maintenance ............................................................................................................................95
7.12. Battery ..................................................................................................................................................95
7.12.1. Remove and Install ..................................................................................................................95
7.12.2 Jump Starting the Loader ........................................................................................................96
7.13. Fuel System/Filters ..............................................................................................................................97
7.13.1. Removal/Installation-Fuel Filter,Water Separater ....................................................................98
7.13.2. Fuel Tank Drain ........................................................................................................................99
7.14. Priming the Fuel System ....................................................................................................................101
7.14.1. Bleeding the Fuel System ......................................................................................................101
7.14.2. Draining the Water ................................................................................................................103
7.14.3. Cleaning Fuel Strainer............................................................................................................104
7.15. Hydraulic System Maintenance ..........................................................................................................106
7.15.1. Oil Level Indicator ..................................................................................................................106
S-9
7.15.2. Filter Replacement ................................................................................................................107
7.15.3. Hydraulic Fluid Replacement ................................................................................................108
7.16. Chain Case Drain and Refill ..............................................................................................................109
7.17. Parking Brake Adjustment ..................................................................................................................110
7.18. Tire Maintenance ................................................................................................................................111
7.18.1. General Information ................................................................................................................111
7.18.2. Inflation Pressures ..................................................................................................................111
7.18.3. Installation and Removal ........................................................................................................111
8.0. DIMENSIONAL & PERFORMANCE SPECIFICATION
8.1. Dimensional Specifications ................................................................................................................112
8.2. Operational Specification (Per SAE J732 Feb 80) ............................................................................116
8.2.1. Performance ..........................................................................................................................116
8.2.2. Power Unit ..............................................................................................................................117
8.2.3. Final Drive Components ........................................................................................................118
8.2.4. Hydrostatic Transmission Pump ............................................................................................119
8.2.5. Hydraulic System ..................................................................................................................120
8.2.6. Electrical Components ..........................................................................................................123
8.2.7. Instrument Features ..............................................................................................................124
8.2.8. Seat ........................................................................................................................................124
8.2.9. Noise ......................................................................................................................................124
8.2.10. Fluid Capacities & Specifications ...................................................................................125
• ENVIRONMENT PROTECTION SECTION ............................................................................................126
• WORLDWIDE NETWORK
S-10
--- Page 4 ---
2. SAFETY INFORMATION
The following section of this manual discusses rules or take obvious precautions. Often you can
some of the general and specific safety issues avoid an accident by recognizing situations that
for your equipment. It gives you basic safety pre- might be hazardous. Furthermore, anyone who
cautions. It also shows you where to find warn- operates, maintains, or repairs this equipment
ing labels used on this equipment. The warnings should have the necessary training, skills, and
themselves are reproduced here for you to read. tools.
Before you operate or perform any maintenance Improper operation, maintenance, or repair of
on this equipment, read this Safety Information this equipment can be dangerous and could
section carefully. Also carefully read the opera- result in injury or death.
tion and other sections of this manual and heed
all of the safety information they contain. Also Do not operate or perform any lubrication, main-
locate, read, and understand the warning decals tenance, or repair on this equipment until you
on the equipment itself. have read and understood the operation, main-
tenance, and repair information in this manual.
2.1. Safe Operating Practices
You will find safety precautions and warnings
Always use common sense and be alert for pos- both in this manual and on the equipment itself.
sible hazards. Most accidents happen because If you ignore these warnings, bodily injury or
someone failed to follow basic safety death could occur to you or to others.
-9-
Hazards are identified by the exclamation point every possible circumstance that might involve a
(!) “Safety Alert Symbol” followed by words such hazard. You must ensure that your operating
as “DANGER,” “WARNING,” or “CAUTION.” techniques, tools, and work procedures are safe
for you and others. You should also make sure
that the equipment will not be damaged or made
unsafe by your chosen operation, maintenance,
DANGER or repair procedures.
WARNING The information in this manual was current at
the time the manual was written. However, spec-
CAUTION ifications, torques, pressures, measurements,
IA0OA01I adjustments, and illustrations can change at any
Pay attention to safety alert symbols. They time. These changes can affect
mean your safety and/or the safety of others equipment service. Before starting any job,
is involved. obtain the most current and complete informa-
tion. Consult your DOOSAN dealer for the most
Hazard messages appear with the safety alert current information.
symbol. They explain the hazard, either in words
or by internationally recognized pictures. The safety rules and regulations in this section
represent some, but not all rules and regulations
The dangers, warnings, and cautions in this of the Occupational Safety and Health Act
manual and on the equipment cannot cover (OSHA).
- 10 -
--- Page 5 ---
2.4.3. Mounting and Dismounting
CAUTION MOUNTING AND DISMOUNTING
• NEVER jump on or off the machine. NEVER get on or off a moving machine.
• When mounting or dismounting, always face the machine and use the handrails.
• Do not grasp or come in contact with any control levers when getting on or off the machine.
• Ensure safety by always maintaining at least three-point contact of hands and feet with the
handrails and steps.
• Always remove any oil or mud from the handrails, steps and shoes.
• NEVER mount or dismount the machine with engine running.
HA0OA03I
- 19 -
2.4.4. Fire Prevention and Hazardous Fluids and Vapors
DANGER FIRE PREVENTION AND HAZARDOUS FLUIDS AND VAPORS
Fuel, oil, antifreeze, and other flammable fluids and combustibles can be ignited by a flame or hot sur-
faces. Vapors can be particularly FLAMMABLE and can be HAZARDOUS.
• Keep open flame and hot surfaces away from flammable fluids and combustibles.
• Stop the engine and do not smoke when refueling.
• Tighten all fuel and oil caps securely.
• Refueling and oiling should be done in well ventilated areas.
• Keep oil and fuel in a designated area and do not allow unauthorized persons to enter.
• Thoroughly remove wood chips, leaves, paper and other flammable items accumulated in the engine
compartment .
• Check fuel and hydraulic systems for leaks prior to starting or using vehicle.
Have any leaks repaired before operating the machine.
Wipe up any excess oil, fuel or other flammable fluids.
• Be sure a fire extinguisher is present and working and that personnel are properly trained in extin-
guisher operation.
• Never use ether or other starting aids on any engine with glow plugs or other engine preheating devices.
• See OSHA Class 1910.178.
• Avoid skin contact, injestion and excessive breathing of vapors from fuel, oil, antifreeze, and other fluids.
• See California Proposition 65 in the front of this book.
HA0OA04I
- 20 -
--- Page 6 ---
2.5.16. Precautions for Stopping the engine.
CAUTION
When the engine stops and the seat bar (pedal locking device/parking) is secured in place (lowered).
if the pedal is depressed, then the boom or the bucket descends.
CAUTION
When the pedal is kept depressing, then even though the seat bar (pedal locking device/parking) is
raised, the boom or the bucket keeps moving regardless of engine’s running or not.
- 29 -
2.6. Maintenance Safety
2.6.1. Periodic Maintenance
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 warn-
ings in the operators manual and all machine decals.
3. Do not attempt to service machine unless you have the necessary skill, information, safety gear,
and tools and equipment to perform the procedure correctly.
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 the engine, 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 operation of all controls, correct torque on all fasteners
and 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 service procedures can lead to machine malfunction
or damage, injury to operator or bystanders, or death.
- 30 -
--- Page 7 ---
4. MACHINE COMPONENTS
4.1. Identification of Machine Parts
IC0O004P
- 39 -
IC0O005P
- 40 -
--- Page 9 ---
5.2.7. Seat Bar
• The seat bar is installed to help protect the op-
erator.
IA0OA17P IA0OA18P
Raised Position Lowered Position
NOTE: The pedals are locked if the seat bar is NOTE: 440Plus, 460 Plus/460/470Plus are
in the raised position. Lower the seat bar to equipped with a seat bar safety interlock that
operate the pedals. sets the park brake with the seat bar raised.
The seat bar must be lowered for travel.
- 49 -
5.3. Controls (Joystick : Option)
1 3
7
4 2
6 5
8
IA4O5001
1 Drive Control Handle 5 Parking Brake
2Boom & Bucket Handle 6 Throtlle Lever
3 Auxiliary Hydraulic 7 Horn Button
Thumb Control 8 Pressure Relief
4 Seat Bar
- 50 -
--- Page 10 ---
DANGER Cold Temperature Starting and Operation
Before any Doosan skid steer loader is operated in cold ambient temperatures (below 45° F), the
hydrostatic system needs to be properly warmed up to assure precise drive operation. This is espe-
cially crucial due to the fact it has a servo controlled hydrostatic drive system.
To properly warm up the hydraulic system you should: 1. Disconnect any attachment lines from the
auxiliary hydraulic couplings. 2. Following all proper procedures as outlined in this manual, start the
engine and run at high idle (full throttle position). 3. Set the auxiliary hydraulic pedal in the full oper-
ational position. 4. Depending on ambient temperature proper warm up time will vary from 3 to 15
minutes. This procedure should be continued until both A) The outside of the hydraulic tank is warm
to the touch and B) Using short slow movements the drive controls react normally to inputs. Caution
should be taken during the initial control movements as warm oil may be delayed in reaching the
control servos.
- 58 -
6.4. Traveling and Steering
(1) Push the throttle lever forward to raise the (1) Steering procedure is illustrated as follows:
engine speed. • Gradual Turning
(2) Operate the boom and bucket pedals to raise the Push one lever farther forward than the other.
bucket to 15-20 cm (6-8 in) above the ground.
(3) Push left and right drive control levers simulta-
neously forward (or pull them backward) to make
the vehicle travel forward (or backward).
(4) To stop the vehicle, make the left and right drive
control levers return to the neutral position slow-
ly. DOOSAN skid steer loader is designed with
drive control levers which return to neutral posi-
tions automatically, when the levers are released.
Left Turn Right Turn
IA0OA46I
CAUTION
When traveling or steering, always lower the
boom to the carry position.
Forward Backward
IA0OA45I
- 59 -
--- Page 11 ---
1. Use proper rated cables and slings for lifting. 6.10. Transportation
(min. durable force of cable/sling = 2,500Kgf)
2. Lifting cables should have sufficient length to
prevent contact with the machine.
3. Use the 4 holes for lifting i.e. 2 holes in front side
frame and 2 holes in inside mast with U-clamp or
strap. 15 or less
U - Clamp or Strap
IA0OA55I
BOOM BOOM
U - Clamp
or Strap
Outside
Mast • Use secure, stable, sufficient strength ramps to
Inside
Mast load (or unload) the machine onto (or from) a
transport vehicle and keep the steel ramps
IC0O051I inclined 15° or less.
• Follow instructions of the traveling on slopes,
440 Plus 460 Plus/460 while moving on the ramp.
470 Plus • Lower the bucket to the floor and stop the engine
after loading the machine onto a transport vehi-
cle.
• Engage the parking brake.
- 68 -
• Fix the skid loader tightly to the transport truck 6.11. Bucket and Attachments
bed with an approved securing device. The ma-
The loader is equipped with a Universal
chine has 3 fixing points, i.e. 1 holes in front up-
Attachment System (Quick-Tach) in front of the
per frame and 2 holes in lower rear frame.
vehicle for rapid replacement of bucket or var-
• Use wheel blocks to prevent vehicle from moving
ious attachments.
during transportation.
Wire Rope
(1) Installation
Wire Rope
IC0O046I
440 Plus
Wire Rope
IA0OA57P
Wire Rope
<Figure 1>
(1) Pull up both handles.
(2) Tilt the Quick-Tach forward slightly and
IC0O046I drive forward to the bucket until the upper
460 Plus/460
470 Plus
- 69 -
--- Page 12 ---
7.3.2. After Starting-Before Operation
WARNING 1. Start the engine and observe the intial exhaust
If any of the following pre/post start checks color at start and at normal operating temper-
indicate that service may be required, have atures. Excessively black, blue, or white
such service performed before using the
exhaust is an indication of a problem. Listen
machine.
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.
Check loader for movement with controls in
neutral. Should movement occur refer to
service manual for proper adjustment
procedure.
a. Check for proper operation of boom, buck-
et, and accessories ( if attached ).
b. Insure that the boom and bucket pedals are
locked with the seat bar raised.
- 78 -
7.4. Service Schedule
This maintenance schedule was designed for scheduled maintenance program can lead to prema-
you to receive optimum performance and relia- ture wear and component failure. Adverse conditions
bility from your SKID STEER LOADER under (e.g., excessive dust or corrosive vapors, etc.) may
typical working conditions. Failure to follow a require more frequent service.
SERVICE SCHEDULE HOURS
ITEM every every every every every every
SERVICE REQUIRED day 50 100 250 500 1000
Check the oil level and fill oil as needed.
Engine Oil Replace the oil. (First time) (440Plus (460Plus)
Replace the oil filter. (First time) (440Plus) (460Plus)
Clean and replace fuel filter element. (Replace (Clean) (Replace)
Fuel System First time )
Priming the fuel system (First time)
Engine Check cooling level and add as needed.
Cooling Check for leaks
System Check and adjust the tension of fan belt
Check the indicator.
Air (Clean or replace the outer element when the red ring shows.)
Cleaner Clean the dust cover.
Replace the outer element.
(Replace the inner element every third time the outer (Clean) (Replace)
element is replaced).
- 79 -
--- Page 13 ---
7.7. Engine Lubrication
7.7.1. General
Engine oil level should be checked daily.
After draining oil and changing filter approximate refill amounts is 2.1gallon(8 liter) for the 440Plus,
460Plus/460/470Plus. Run loader briefly and check oil level on dipstick before returning the loader to service.
See section 8.2.10 for fluid recommendations.
IC0O032P IC0O032P
440Plus - Dipstick 460Plus/460/470Plus - Dipstick
- 88 -
.
7.7.2. Draining Engine Oil
Remove the four bolts from the access plate locat-
ed on the left bottom 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 drain plug. Discard oil in accordance with
440Plus
local environmental rules and regulations.
460Plus/460
470Plus
- 89 -
--- Page 14 ---
7.13.2. Fuel Tank Drain
The fuel tank drain plug is located directly behind the 440Plus ( right ), 460Plus/460, 470Plus ( left ) rear
tire on the chassis. Fuel drained should be disposed of into an approved waste oil container. Discard the
fuel in accordance with local/federal environmental rules and regulations.
IC0O038P IC0O039P
440Plus 460Plus/460
470Plus
- 99 -
FUEL FILLER
440Plus OIL CAP 460(Plus), 470Plus
OIL CAP
440Plus FUEL CAP 460(Plus), 470Plus
FUEL CAP
- 100 -
--- Page 15 ---
7.15.3. Hydraulic Fluid Replacement
TO REPLACE THE FLUID
The hydraulic tank drain plug is located direct-
ly behind the 440Plus ( left ), 460Plus/460,
470Plus ( right ) rear tire on the chassis.
Before draining, the loader should be on level
ground with the boom completely lowered
and the Quick-tach tilted back. Once the
loader is drained, oil should be disposed of
IC0O042P
into an approved waste oil container in accor-
440Plus
dance with local/federal rules and regulations.
INTERVAL OF REPLACEMENT
•Replace the fluid according to service sched-
ule(7.4)
•It may be nessary to change more frequently
then the normal interual if the fluid becomes
with foreigu material(dirt, water, grease, etc)
or if the fluid has beer subjected to tempera-
ture levels greater than the maximum
IC0O043P
recommeded.
460Plus/460
470Plus
- 108 -
7.16. Chain Case Drain and Refill
1. Chain case drain plugs
TO DRAIN CHAIN CASE:
1) Remove drain plugs and drain case oil into
an approved waste oil container.
TO REFILL CHAIN CASE:
1) Re-install and tighten case drain plugs.
2) Open cab and secure with safety latches.
3) Remove covers
IA0OB00P ( left side shown-right in mirror position )
4) Locate chain case filter necks.
2. Fill cover NOTE: Recommended fluid is DEXRON lll