Daewoo Doosan 430 450 Series Skid Steer Loader Operation & Maintenance Manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan 430 450 Series Skid Steer Loader Operation & Maintenance Manual – PDF DOWNLOAD
Operation & Maintenance Manual
SKID STEER LOADER
430 Series
450 Series
430 Series
450 Series
FOREWORD:
• This manual explains the safety rules, lubrication, testing and controls to operate and maintain the DOOSAN Skid Steer Loader for safe and optimal performance.
• The operator should be familiar with all of the contents of this manual before starting the vehicle to insure maximum performance, safety and economy.
• Descriptions explain the testing, starting, operation, and stop procedures in detail.
• To maintain the vehicle in top condition, the operator should periodically check the vehicle in accordance with the service schedule.
• The periodic maintenance intervals in this manual are based on the service hour meter.
TABLE OF CONTENTS:
Daewoo Doosan 430 450 Series Skid Steer Loader Operation & Maintenance Manual – PDF DOWNLOAD
CONTENTS
1.0. OWNER/OPERATOR SAFETY OVERVIEW
1.1. Safety Message for Owners and Operators ………………………………………………………………………………1
1.1.1. Owner/Employer Responsibility ……………………………………………………………………………………1
1.1.2. Operator Responsibility ………………………………………………………………………………………………..2
1.2. Maintaining a Safe Workplace………………………………………………………………………………………………….3
1.3. Matching the Machine to the Job …………………………………………………………………………………………….4
1.3.1. Warning Signal Options………………………………………………………………………………………………..4
1.3.2. Modifications ………………………………………………………………………………………………………………4
1.4. Maintenance Practices …………………………………………………………………………………………………………..5
1.5. Operator Safety Training …………………………………………………………………………………………………………5
1.5.1. Formal Training …………………………………………………………………………………………………………..5
1.5.2. Inspection Training ……………………………………………………………………………………………………..6
1.5.3. Training Program Development ……………………………………………………………………………………6
1.5.4. Practical Training…………………………………………………………………………………………………………7
1.5.5. Recognition ………………………………………………………………………………………………………………..7
1.6. Information Resources for Operation, Maintenance, and Safety ………………………………………………….7
2.0. SAFETY INFORMATION
2.1. Safe Operating Practices…………………………………………………………………………………………………………9
2.2. Rated Operating Load Plate ………………………………………………………………………………………………….12
2.3. Safety Warning Label Locations and Descriptions ……………………………………………………………………13
2.3.1. Label Locations …………………………………………………………………………………………………………13
2.3.2. Label Descriptions……………………………………………………………………………………………………..14
2.4. General Safety and Hazard Information ………………………………………………………………………………….18
1.0. OWNER/OPERATOR SAFETY OVERVIEW
1.1. Safety Message for Owners and Operators ………………………………………………………………………………1
1.1.1. Owner/Employer Responsibility ……………………………………………………………………………………1
1.1.2. Operator Responsibility ………………………………………………………………………………………………..2
1.2. Maintaining a Safe Workplace………………………………………………………………………………………………….3
1.3. Matching the Machine to the Job …………………………………………………………………………………………….4
1.3.1. Warning Signal Options………………………………………………………………………………………………..4
1.3.2. Modifications ………………………………………………………………………………………………………………4
1.4. Maintenance Practices …………………………………………………………………………………………………………..5
1.5. Operator Safety Training …………………………………………………………………………………………………………5
1.5.1. Formal Training …………………………………………………………………………………………………………..5
1.5.2. Inspection Training ……………………………………………………………………………………………………..6
1.5.3. Training Program Development ……………………………………………………………………………………6
1.5.4. Practical Training…………………………………………………………………………………………………………7
1.5.5. Recognition ………………………………………………………………………………………………………………..7
1.6. Information Resources for Operation, Maintenance, and Safety ………………………………………………….7
2.0. SAFETY INFORMATION
2.1. Safe Operating Practices…………………………………………………………………………………………………………9
2.2. Rated Operating Load Plate ………………………………………………………………………………………………….12
2.3. Safety Warning Label Locations and Descriptions ……………………………………………………………………13
2.3.1. Label Locations …………………………………………………………………………………………………………13
2.3.2. Label Descriptions……………………………………………………………………………………………………..14
2.4. General Safety and Hazard Information ………………………………………………………………………………….18
cont. 2.0 SAFETY INFORMATION
2.4.1. Unauthorized Modification…………………………………………………………………………………………..18
2.4.2. Clothing and Personal Protective Items ……………………………………………………………………….18
2.4.3. Mounting and Dismounting …………………………………………………………………………………………19
2.4.4. Fire Prevention and Hazardous Fluids and Vapors ……………………………………………………….20
2.5. Operating Safety ………………………………………………………………………………………………………………….21
2.5.1. Work Site Safety ……………………………………………………………………………………………………….21
2.5.2. Operator’s Cab …………………………………………………………………………………………………………22
2.5.3. Safe Operating Practices …………………………………………………………………………………………..22
2.5.4. Ventilation for Enclosed Areas ……………………………………………………………………………………23
2.5.5. Flammable and Explosive Atmospheres ……………………………………………………………………….23
2.5.6. Precautions for Mirrors, Windows, and Lights ………………………………………………………………24
2.5.7. Ensuring Visibility ……………………………………………………………………………………………………..24
2.5.8. Traveling in Reverse, Safe Working Zone ……………………………………………………………………25
2.5.9. Avoiding High-Voltage Cables……………………………………………………………………………………..25
2.5.10. Operating on Snow ……………………………………………………………………………………………………26
2.5.11. Working on Loose Ground …………………………………………………………………………………………26
2.5.12. Preventing Crushing or Cutting ……………………………………………………………………………………27
2.5.13. Parking ……………………………………………………………………………………………………………………27
2.5.14. Precautions for Attachments ……………………………………………………………………………………….28
2.5.15. Precautions for Loading and Emptying the Bucket…………………………………………………………28
2.5.16. Precautions for Stopping the Engine…………………………………………………………………………….29
2.6. Maintenance Safety ………………………………………………………………………………………………………………30
2.6.1. Periodic Maintenance ………………………………………………………………………………………………..30
2.6.2. Precautions for High Temperature Operations ………………………………………………………………31
cont. 2.0 SAFETY INFORMATION
2.6.3. Maintaining and Inspecting Hydraulic Equipment …………………………………………………………..32
2.6.4. Precautions for High Pressure Oil………………………………………………………………………………..33
2.6.5. Precautions Battery Hazard ……………………………………………………………………………………….34
2.6.6. Waste Material Precautions ……………………………………………………………………………………….35
2.6.7. Rotating Fans and Belts …………………………………………………………………………………………….35
2.6.8. Tire Maintenance……………………………………………………………………………………………………….36
3.0. SERIAL NUMBER LOCATIONS
3.1. Vehicle Serial Number …………………………………………………………………………………………………………..37
3.2. Engine Serial Number …………………………………………………………………………………………………………..38
4.0. MACHINE COMPONENTS
4.1. Identification of Machine Parts ………………………………………………………………………………………………39
5.0. CONTROLS AND INSTRUMENTS
5.1. Instrument Panel ………………………………………………………………………………………………………………….41
5.2. Controls …………………………………………………………………………………………………………………………….45
5.2.1. Drive Control Lever ………………………………………………………………………………………………….46
5.2.2. Boom Pedal …………………………………………………………………………………………………………….47
5.2.3. Bucket Pedal …………………………………………………………………………………………………………..47
5.2.4. Attachment Pedal ……………………………………………………………………………………………………..48
5.2.5. Auxiliary Hydraulic Thumb Control ………………………………………………………………………………49
5.2.6. Engine Control…………………………………………………………………………………………………………..50
5.2.7. Seat Bar ………………………………………………………………………………………………………………….51
5.3. Controls (Joystick : Option) ………………………………………………………………………………………………….52
5.3.1. Drive Control Lever ………………………………………………………………………………………………….53
5.3.2. Boom & Bucket Handle ………………………………………………………………………………………………54
5.3.3. Attachment Pedal ……………………………………………………………………………………………………..55
5.3.4. Auxiliary Hydraulic Thumb Control ………………………………………………………………………………56
5.3.5. Engine Control Joystick………………………………………………………………………………………………57
6.0. OPERATING INSTRUCTIONS
6.1. Inspection Before Boarding ………………………………………………………………………………………………….58
6.2. Boarding the Loader …………………………………………………………………………………………………………….58
6.3. Starting………………………………………………………………………………………………………………………………..59
6.4. Traveling and Steering …………………………………………………………………………………………………………61
6.5. Traveling and Steering (Joystick : Option)………………………………………………………………………………..63
6.6. Operation …………………………………………………………………………………………………………………………..64
6.7. Traveling on a Slope, Parking ………………………………………………………………………………………………67
6.8. Towing Procedures ………………………………………………………………………………………………………………68
6.9. Lifting ………………………………………………………………………………………………………………………………..69
6.10. Transportation ……………………………………………………………………………………………………………………..70
6.11. Bucket and Attachments ……………………………………………………………………………………………………….71
6.12. Boom Lock Operation………………………………………………………………………………………………………….. 74
7.0. PERIODIC MAINTENANCE
7.1. Safety Warnings……………………………………………………………………………………………………………………76
7.2. Access to Items Requiring Service …………………………………………………………………………………………77
7.2.1. Rear Door and Engine Hood ……………………………………………………………………………………..77
7.2.2. Canopy Tilting …………………………………………………………………………………………………………..78
7.3. Daily Pre/Post Start Checks ………………………………………………………………………………………………….80
7.3.1. Pre-Start Checks ……………………………………………………………………………………………………….80
7.3.2. After Starting-Before Operation……………………………………………………………………………………80
7.4. Service Schedule ………………………………………………………………………………………………………………..82
7.5. Lubrication Points ………………………………………………………………………………………………………………..84
7.6. Operator Restraint Lubrication and Maintenance ……………………………………………………………………..87
7.6.1. Lubrication ………………………………………………………………………………………………………………87
7.6.2. Function ………………………………………………………………………………………………………………….88
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 ………………………………………………………………………………90
7.8. Engine Cooling System …………………………………………………………………………………………………………92
7.9. Fan Belt ………………………………………………………………………………………………………………………………93
7.9.1. Belt Tension………………………………………………………………………………………………………………93
7.9.2. Adjustment………………………………………………………………………………………………………………..94
7.10. Two Stage Air Cleaner…………………………………………………………………………………………………………..95
7.10.1. Removal-Primary Element …………………………………………………………………………………………97
7.10.2. Removal-Secondary Element ……………………………………………………………………………………..97
7.10.3. Installation ………………………………………………………………………………………………………………..97
7.11. Spark Arrestor ……………………………………………………………………………………………………………………..98
7.11.1. General ……………………………………………………………………………………………………………………98
7.11.2. Maintenance …………………………………………………………………………………………………………….98
7.12. Battery ………………………………………………………………………………………………………………………………..99
7.12.1. Remove and Install ……………………………………………………………………………………………………99
7.12.2. Jump Starting the Loader …………………………………………………………………………………………..99
7.13. Fuel System/Filters …………………………………………………………………………………………………………….100
7.13.1. Removed/Installation – Fuel Filter ………………………………………………………………………………101
7.13.2. Fuel Tank Drain ……………………………………………………………………………………………………….101
7.14. Priming the Fuel System ……………………………………………………………………………………………………..102
7.14.1. Bleeding the Fuel System …………………………………………………………………………………………102
7.14.2. Draining the Water ………………………………………………………………………………………………….104
7.14.3. Cleaning Fuel Strainer………………………………………………………………………………………………105
7.15. Hydraulic System Maintenance …………………………………………………………………………………………….106
7.15.1. Oil Level Indicator ……………………………………………………………………………………………………106
7.15.2. Filter Replacement ………………………………………………………………………………………………….108
7.15.3. Hydraulic Fluid Replacement ……………………………………………………………………………………108
7.16. Chain Case Oil Drain and Refill…………………………………………………………………………………………….109
7.16.1. Chain Case Oil Drain ………………………………………………………………………………………………109
7.16.2. Chain Case Oil Refill ………………………………………………………………………………………………..110
7.17. Parking Brake Adjustment ……………………………………………………………………………………………………111
7.18. Tire Maintenance ………………………………………………………………………………………………………………..112
7.18.1. General Information ………………………………………………………………………………………………….112
7.18.2. Inflation Pressures……………………………………………………………………………………………………112
7.18.3. Installation and Removal …………………………………………………………………………………………..112
8.0. DIMENSIONAL & PERFORMANCE SPECIFICATIONS
8.1. Dimensional Specifications ………………………………………………………………………………………………….113
8.2. Operational Specification (Per SAE J732 Feb 80) ………………………………………………………………….117
8.2.1. Performance …………………………………………………………………………………………………………..117
8.2.2. Power Unit ………………………………………………………………………………………………………………118
8.2.3. Final Drive Components …………………………………………………………………………………………..119
8.2.4. Hydrostatic Transmission Pump ………………………………………………………………………………..120
8.2.5. Hydraulic System ……………………………………………………………………………………………………121
8.2.6. Electrical Components …………………………………………………………………………………………….123
8.2.7. Instrument Features ………………………………………………………………………………………………..123
8.2.8. Seat ……………………………………………………………………………………………………………………….124
8.2.9. Noise ……………………………………………………………………………………………………………………..124
8.2.10. Fluid Capacities & Specifications ………………………………………………………………………………125
2.4.1. Unauthorized Modification…………………………………………………………………………………………..18
2.4.2. Clothing and Personal Protective Items ……………………………………………………………………….18
2.4.3. Mounting and Dismounting …………………………………………………………………………………………19
2.4.4. Fire Prevention and Hazardous Fluids and Vapors ……………………………………………………….20
2.5. Operating Safety ………………………………………………………………………………………………………………….21
2.5.1. Work Site Safety ……………………………………………………………………………………………………….21
2.5.2. Operator’s Cab …………………………………………………………………………………………………………22
2.5.3. Safe Operating Practices …………………………………………………………………………………………..22
2.5.4. Ventilation for Enclosed Areas ……………………………………………………………………………………23
2.5.5. Flammable and Explosive Atmospheres ……………………………………………………………………….23
2.5.6. Precautions for Mirrors, Windows, and Lights ………………………………………………………………24
2.5.7. Ensuring Visibility ……………………………………………………………………………………………………..24
2.5.8. Traveling in Reverse, Safe Working Zone ……………………………………………………………………25
2.5.9. Avoiding High-Voltage Cables……………………………………………………………………………………..25
2.5.10. Operating on Snow ……………………………………………………………………………………………………26
2.5.11. Working on Loose Ground …………………………………………………………………………………………26
2.5.12. Preventing Crushing or Cutting ……………………………………………………………………………………27
2.5.13. Parking ……………………………………………………………………………………………………………………27
2.5.14. Precautions for Attachments ……………………………………………………………………………………….28
2.5.15. Precautions for Loading and Emptying the Bucket…………………………………………………………28
2.5.16. Precautions for Stopping the Engine…………………………………………………………………………….29
2.6. Maintenance Safety ………………………………………………………………………………………………………………30
2.6.1. Periodic Maintenance ………………………………………………………………………………………………..30
2.6.2. Precautions for High Temperature Operations ………………………………………………………………31
cont. 2.0 SAFETY INFORMATION
2.6.3. Maintaining and Inspecting Hydraulic Equipment …………………………………………………………..32
2.6.4. Precautions for High Pressure Oil………………………………………………………………………………..33
2.6.5. Precautions Battery Hazard ……………………………………………………………………………………….34
2.6.6. Waste Material Precautions ……………………………………………………………………………………….35
2.6.7. Rotating Fans and Belts …………………………………………………………………………………………….35
2.6.8. Tire Maintenance……………………………………………………………………………………………………….36
3.0. SERIAL NUMBER LOCATIONS
3.1. Vehicle Serial Number …………………………………………………………………………………………………………..37
3.2. Engine Serial Number …………………………………………………………………………………………………………..38
4.0. MACHINE COMPONENTS
4.1. Identification of Machine Parts ………………………………………………………………………………………………39
5.0. CONTROLS AND INSTRUMENTS
5.1. Instrument Panel ………………………………………………………………………………………………………………….41
5.2. Controls …………………………………………………………………………………………………………………………….45
5.2.1. Drive Control Lever ………………………………………………………………………………………………….46
5.2.2. Boom Pedal …………………………………………………………………………………………………………….47
5.2.3. Bucket Pedal …………………………………………………………………………………………………………..47
5.2.4. Attachment Pedal ……………………………………………………………………………………………………..48
5.2.5. Auxiliary Hydraulic Thumb Control ………………………………………………………………………………49
5.2.6. Engine Control…………………………………………………………………………………………………………..50
5.2.7. Seat Bar ………………………………………………………………………………………………………………….51
5.3. Controls (Joystick : Option) ………………………………………………………………………………………………….52
5.3.1. Drive Control Lever ………………………………………………………………………………………………….53
5.3.2. Boom & Bucket Handle ………………………………………………………………………………………………54
5.3.3. Attachment Pedal ……………………………………………………………………………………………………..55
5.3.4. Auxiliary Hydraulic Thumb Control ………………………………………………………………………………56
5.3.5. Engine Control Joystick………………………………………………………………………………………………57
6.0. OPERATING INSTRUCTIONS
6.1. Inspection Before Boarding ………………………………………………………………………………………………….58
6.2. Boarding the Loader …………………………………………………………………………………………………………….58
6.3. Starting………………………………………………………………………………………………………………………………..59
6.4. Traveling and Steering …………………………………………………………………………………………………………61
6.5. Traveling and Steering (Joystick : Option)………………………………………………………………………………..63
6.6. Operation …………………………………………………………………………………………………………………………..64
6.7. Traveling on a Slope, Parking ………………………………………………………………………………………………67
6.8. Towing Procedures ………………………………………………………………………………………………………………68
6.9. Lifting ………………………………………………………………………………………………………………………………..69
6.10. Transportation ……………………………………………………………………………………………………………………..70
6.11. Bucket and Attachments ……………………………………………………………………………………………………….71
6.12. Boom Lock Operation………………………………………………………………………………………………………….. 74
7.0. PERIODIC MAINTENANCE
7.1. Safety Warnings……………………………………………………………………………………………………………………76
7.2. Access to Items Requiring Service …………………………………………………………………………………………77
7.2.1. Rear Door and Engine Hood ……………………………………………………………………………………..77
7.2.2. Canopy Tilting …………………………………………………………………………………………………………..78
7.3. Daily Pre/Post Start Checks ………………………………………………………………………………………………….80
7.3.1. Pre-Start Checks ……………………………………………………………………………………………………….80
7.3.2. After Starting-Before Operation……………………………………………………………………………………80
7.4. Service Schedule ………………………………………………………………………………………………………………..82
7.5. Lubrication Points ………………………………………………………………………………………………………………..84
7.6. Operator Restraint Lubrication and Maintenance ……………………………………………………………………..87
7.6.1. Lubrication ………………………………………………………………………………………………………………87
7.6.2. Function ………………………………………………………………………………………………………………….88
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 ………………………………………………………………………………90
7.8. Engine Cooling System …………………………………………………………………………………………………………92
7.9. Fan Belt ………………………………………………………………………………………………………………………………93
7.9.1. Belt Tension………………………………………………………………………………………………………………93
7.9.2. Adjustment………………………………………………………………………………………………………………..94
7.10. Two Stage Air Cleaner…………………………………………………………………………………………………………..95
7.10.1. Removal-Primary Element …………………………………………………………………………………………97
7.10.2. Removal-Secondary Element ……………………………………………………………………………………..97
7.10.3. Installation ………………………………………………………………………………………………………………..97
7.11. Spark Arrestor ……………………………………………………………………………………………………………………..98
7.11.1. General ……………………………………………………………………………………………………………………98
7.11.2. Maintenance …………………………………………………………………………………………………………….98
7.12. Battery ………………………………………………………………………………………………………………………………..99
7.12.1. Remove and Install ……………………………………………………………………………………………………99
7.12.2. Jump Starting the Loader …………………………………………………………………………………………..99
7.13. Fuel System/Filters …………………………………………………………………………………………………………….100
7.13.1. Removed/Installation – Fuel Filter ………………………………………………………………………………101
7.13.2. Fuel Tank Drain ……………………………………………………………………………………………………….101
7.14. Priming the Fuel System ……………………………………………………………………………………………………..102
7.14.1. Bleeding the Fuel System …………………………………………………………………………………………102
7.14.2. Draining the Water ………………………………………………………………………………………………….104
7.14.3. Cleaning Fuel Strainer………………………………………………………………………………………………105
7.15. Hydraulic System Maintenance …………………………………………………………………………………………….106
7.15.1. Oil Level Indicator ……………………………………………………………………………………………………106
7.15.2. Filter Replacement ………………………………………………………………………………………………….108
7.15.3. Hydraulic Fluid Replacement ……………………………………………………………………………………108
7.16. Chain Case Oil Drain and Refill…………………………………………………………………………………………….109
7.16.1. Chain Case Oil Drain ………………………………………………………………………………………………109
7.16.2. Chain Case Oil Refill ………………………………………………………………………………………………..110
7.17. Parking Brake Adjustment ……………………………………………………………………………………………………111
7.18. Tire Maintenance ………………………………………………………………………………………………………………..112
7.18.1. General Information ………………………………………………………………………………………………….112
7.18.2. Inflation Pressures……………………………………………………………………………………………………112
7.18.3. Installation and Removal …………………………………………………………………………………………..112
8.0. DIMENSIONAL & PERFORMANCE SPECIFICATIONS
8.1. Dimensional Specifications ………………………………………………………………………………………………….113
8.2. Operational Specification (Per SAE J732 Feb 80) ………………………………………………………………….117
8.2.1. Performance …………………………………………………………………………………………………………..117
8.2.2. Power Unit ………………………………………………………………………………………………………………118
8.2.3. Final Drive Components …………………………………………………………………………………………..119
8.2.4. Hydrostatic Transmission Pump ………………………………………………………………………………..120
8.2.5. Hydraulic System ……………………………………………………………………………………………………121
8.2.6. Electrical Components …………………………………………………………………………………………….123
8.2.7. Instrument Features ………………………………………………………………………………………………..123
8.2.8. Seat ……………………………………………………………………………………………………………………….124
8.2.9. Noise ……………………………………………………………………………………………………………………..124
8.2.10. Fluid Capacities & Specifications ………………………………………………………………………………125
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