Daewoo Doosan 440 Plus 460 Series 470 Plus Skid Steer Operation & Maintenance Manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan 440 Plus 460 Series 470 Plus Skid Steer Operation & Maintenance Manual – PDF DOWNLOAD
Operation & Maintenance Manual
SKID STEER LOADER
440 Plus
460 Series
470 Plus
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.
Safety Message for Owners and Operators :
- Your DOOSAN equipment has been designed with the safety of the persons who will operate and service it in mind. However, our care in designing this equipment does not guarantee that it will be used in a safe manner.
- Safe operating practice is where your responsibility and the responsible actions of the persons who operate this equipment take over.
Owner/Employer Responsibility:
- Both the Occupational Safety and Health Act (OSHA) and the American National Standards Institute (ANSI) make you, the employer, responsible for providing formal training and a safe workplace environment for the use of this equipment.
- Your responsibility also includes establishing daily inspections and scheduled maintenance practices to ensure the equipment’s ongoing safe operating condition. The manual you are reading now is intended to help you meet your responsibilities.
- It identifies warning labels on the equipment and explains what they mean. It describes some of the general and specific hazards to be aware of when operating the equipment.It also offers some suggestions for establishing workplace rules and operator training programs.
- As the owner/employer, you also have the responsibility to be certain that the equipment you have placed into service is capable of doing its intended job. – 1 –
TABLE OF CONTENTS:
Daewoo Doosan 440 Plus 460 Series 470 Plus Skid Steer Operation & Maintenance Manual – PDF DOWNLOAD
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 ………………………………………………………………………………………………….11
2.3. Safety Warning Label Locations and Descriptions ……………………………………………………………………12
2.3.1. Label Locations …………………………………………………………………………………………………………12
2.3.2. Label Descriptions……………………………………………………………………………………………………..13
2.4. General Safety and Hazard Information ………………………………………………………………………………….18
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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
2.6.3. Maintaining and Inspecting Hydraulic Equipment …………………………………………………………..32
2.6.4. Precautions for High Pressure Oil………………………………………………………………………………..33
2.6.5. Preventing Battery Hazards ……………………………………………………………………………………….34
2.6.6. Waste Material Precautions ……………………………………………………………………………………….35
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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 …………………………………………………………………………………………………………..37
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 ………………………………………………………………………………………………….45
5.2.2. Pedals ……………………………………………………………………………………………………………………46
5.2.3. Boom Pedal …………………………………………………………………………………………………………….46
5.2.4. Bucket Pedal …………………………………………………………………………………………………………..47
5.2.5. Auxiliary Hydraulics Thumb Control …………………………………………………………………………….47
5.2.6. Engine Control …………………………………………………………………………………………………………48
5.2.7. Seat Bar ………………………………………………………………………………………………………………….49
5.3. Controls (Joystick : Option) ………………………………………………………………………………………………….50
5.3.1. Drive Control Lever ………………………………………………………………………………………………….51
5.3.2. Boom & Bucket Handle ………………………………………………………………………………………………52
5.3.3. Auxiliary Hydraulic Thumb Control ………………………………………………………………………………53
5.3.4. Engine Control Joystick………………………………………………………………………………………………55
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6.0. OPERATING INSTRUCTIONS
6.1. Inspection Before Boarding ………………………………………………………………………………………………….56
6.2. Boarding the Loader …………………………………………………………………………………………………………….56
6.3. Starting………………………………………………………………………………………………………………………………..57
6.4. Traveling and Steering …………………………………………………………………………………………………………59
6.5. Traveling and Steering (Joystick : Option)………………………………………………………………………………..61
6.6. Operation …………………………………………………………………………………………………………………………..62
6.7. Traveling on a Slope, Parking ………………………………………………………………………………………………64
6.8. Towing Procedures ………………………………………………………………………………………………………………66
6.9. Lifting ………………………………………………………………………………………………………………………………..67
6.10. Transportation ……………………………………………………………………………………………………………………..68
6.11. Bucket and Attachments ……………………………………………………………………………………………………….69
6.12. Boom Lock Operation………………………………………………………………………………………………………….. 72
7.0. PERIODIC MAINTENANCE
7.1. Safety Warnings……………………………………………………………………………………………………………………74
7.2. Access to Items Requiring Service …………………………………………………………………………………………75
7.2.1. Rear Door and Engine Hood ……………………………………………………………………………………..75
7.2.2. Canopy Tilting …………………………………………………………………………………………………………..76
7.3. Daily Pre/Post Start Checks ………………………………………………………………………………………………….77
7.3.1. Pre-Start Checks ……………………………………………………………………………………………………….77
7.3.2. After Starting-Before Operation……………………………………………………………………………………78
7.4. Service Schedule ………………………………………………………………………………………………………………..79
7.5. Lubrication Points ………………………………………………………………………………………………………………..81
7.6. Operator Restraint Lubrication and Maintenance ……………………………………………………………………..86
7.6.1. Lubrication ………………………………………………………………………………………………………………87
7.6.2. Function ………………………………………………………………………………………………………………….87
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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
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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
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
R.D