Daewoo Doosan 440 Plus Skid Steer Loader Service Manual – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan 440 Plus Skid Steer Loader Service Manual – PDF DOWNLOAD
Parts Book
SKID STEER LOADER
440Plus
EM0AK-00001-UP
- This parts book lists all serviceable parts for DOOSAN Skid steer Loader model 440Plus and includes chassis, mast, attachment and optional accessories.
2.SKIDSTEER LOADER IDENTIFICATION:
- Skid steer Loaders are identified with model names and serial numbers which are shown on the identification plate mounted on a prominent position (cowl or top cover) of the truck. If the identification plate has been removed, or if the model name or serial number stamped on the identification plate is illegible, then please refer to the decal on the top cover for the model name and to the serial number stamped on the frame. DOOSAN dealers or parts depot need this information to determine which components were included on the machine when it was assembled at the factory.
3.HOW TO ORDER PARTS:
- When ordering parts, your order should specify the model name, the serial number of the machine, the quantity, part number and part name of the parts which are needed. If in doubt about the part number, please provide your dealer with a complete description of the needed item.
4.HOW TO USE THE PARTS BOOK:
- DOOSAN parts books include illustrations of the groups or assemblies which make up the machine. These illustrations show the standard components and attachments for each machine. The caption under each illustration identifies the part number and name of the group or assembly shown.
- Captions provide an additional information if any. Within each illustration is a parts list identifying each serviceable part in the illustration. When a part name is indented in this list, it means that serviceable item is a part of the serviceable item under which it is indented.
5.UNNOTICED REVISION OF TRUCK :
- Continuing improvement and advancement of product design may cause changes to your machine which may not be included in this parts book.
6.ABBREVIATIONS :
- O.D. Outside diameter G Order by inch I.D. Inside diameter See hose fabrication guide A Not part of this group K See mast arrangement B Use as required M Metric part C Indicates change R Remg part may be available D Order by meter X Major component exchange E Order by centimeter y Separate Illustration F Not shown z Not serviced separately
TABLE OF CONTENTS:
Daewoo Doosan 440 Plus Skid Steer Loader Service Manual – PDF DOWNLOAD
• BASIC ENGINE
Fig.1.01 A298067 CRANKSHAFT PULLEY ·························2
1.02 A293241 AGENCY APPROVAL ····························3
1.03 A293244 CYLINDER BLOCK········· … ········ …………. 5
1.04 A293266 CRANKCASE BREATHER·····················6
1.05 A293278 CAMSHAFT ············································7
1.06 A293287 FRONT GEAR TRAIN ACCESSORY ·····8
1.08 D461454 FAN DRIVE BELT·································10
1.08 D461455 PULLY ··················································10
1.09 A293326 FLYWHEEL HOUSING·························11
1.10 D461395 FLYWHEEL··········································12
1.11 A293370 FRONT GEAR COVER·························13
1.12 A293388 CYLINDER HEAD·································15
1.13 A293413 INJECTOR············································16
1.14 A293422 LIFTING ARRANGEMENT···················17
1.15 A298046 OIL LEVEL GAUGE······························18
1.16 A293454 OIL FILLER ARRANGEMENT ··············19
1.17 A293458 OIL PAN················································21
1.18 A293472 ENGINE PISTON··································22
1.19 A293487 ROCKER LEVER··································23
1.20 A298008 TURBOCHARGER PLUMBING············24
1.21 A298012 VALVE COVER·····································25
1.22 D461450 CRANKSHAFT··································25.1
1.23 A298160 GASKET KIT······································25.2
• LUBRICATION SYSTEM
Fig. 2.01 A298041 LUBE OIL FILTER ································26
2.02 A293448 LUBE OIL PUMP ··································27
• COOLING SYSTEM
Fig. 3.01 A298039 ENGINE OIL COOLER ·························28
3.02 A293295 THERMOSTAT ·····································29
3.02 A298017 WATER OUTLET CONNECTION·········29
3.02 A298021 WATER PUMP······································29
3.03 D424620 MOUNTING GP – RADIATOR & OIL COOLER···31
• AIR INLET & EXHAUST SYSTEM
Fig.4.01 A293418 AIR INTAKE MANIFOLD ······················34
4.02 A298030 EXHAUST MANIFOLD ·························35
4.03 D424617 AIR CLEANER GP································36
4.04 D424623 MUFFLER GP·······································37
• FUEL SYSTEM
Fig.5.01 A293316 FUEL FILTER ·······································38
5.02 A293334 FUEL INJECTION PUMP ·····················39
5.03 A293337 FUEL PUMP MOUNTING·····················40
5.04 A293349 FUEL PLUMBING ·································41
5.05 D424619 LINES GP – FUEL·································42
5.06 D424619-01 LINES GP – FUEL······························42.1
• ELECTRICAL SYSTEM
Fig.6.01 A293297 ALTERNATOR······································43
6.02 A298006 STARTING MOTOR ·····························44
6.03 A293238 AIR HEATER STARTING AID ·············-45
6.03 A298001 OIL PRESSURE SWITCH ····················45
Fig Name Page
Fig.6.03 A298062 PRE – HEAT CONTROLLER ················45
6.04 D424637 WIRING GP ··········································47
6.05 D423001 INSTRUMENT GP ································48
6.06 D424603 BATTERY GP ·······································49
• POWER TRAIN
D424609 MOUNTING GP – E/G & PUMP············50
D418078 COUPLING AS ·····································51
D422187 CHAIN DRIVE GP. ·······························52
D571037, D421259 WHEEL & TIRE GROUP······53
• BRAKE SYSTEM
D422986-01 BRAKE GP – PARKING PART 1 OF 2···55
D422986-01 BRAKE GP – PARKING PART 2 OF 2···57
D421874 BRAKE AS – RH, D421868 BRAKE AS – LH··58
• FRAME AND BODY
Fig.9.01 D422983 MTG GP – BOTTOM PLATE·················61
9.01 D422173 MTG. GP – CASE COVER····················61
9.01 D424662 MAIN FRAME ·······································61
9.01 D423021 MTG GP – E/G HOOD ··························61
9.02 D423190 BOOM AS·············································63
9.02 D423020 HINGE GP – BOOM & BUCKET ···········63
9.021 D424580 CHANGE OVER AR. –
HINGE GP – FOR DECKER ·················64
9.0211 D424827 CHANGE OVER AR. –
HINGE GP(FOR VOLVO OEM)·········64.1
9.022 D424582 PEDAL AS – FOR DECKER ·················65
9.023 D424831 PEDAL ASS’Y – FOR VOLVO ···········65.1
9.03 D415548 ROOF WINDOW MOUNTING GP········67
9.03 D423017 CANOPY GP ·············· .. ························67
9.03 D423022 REAR WINDOW GP·····························67
9.03 D423422 BACK MIRROR GP ······························67
9.04 D424630 FLOOR PLATE GP·······························68
9.05 D423016-01 REAR DOOR GP··································69
9.06 D425425 QUICK TACH GP ·································70
9.07 D416945 BOOM LOCK GROUP··························71
• OPERATOR STATION
Fig.10.01 D415588 SEAT GP – STD····································73
10.02 D571042 SEAT GP – SUSPENSION(OPTION) ···74
10.03 D421307 MTG. GP – SEAT BELT ························75
• CONTROL SYSTEM
Fig.11.01 D422331 SEAT BAR GP······································76
11.02 D416498 LOCKAS··············································77
11.03 D424597 CONTROLGP-DRIVE························79
11.04 D420210 CENTERING CONTROL ······················81
11.05 D422169 CONTROLGP-HYD.··························83
11.06 D424600 CONTROL GP -THROTTLE················85
• HYDRAULIC SYSTEM
Fig.12.01 D423007 FUEL CAP GP······································86
12.011 D423007-01 FUEL CAP GP ······································87
12.02 D423008 OIL LEVEL GP – HYDRAULIC··············88
– d.1 – S81050
(THIS PARTS BOOK IS FOR REFERENCE ONLY.
PART NUMBERS AND SERAIL NUMBERS MAY BE
OUT DATED. ALWAYS USE THE ONLINE PARTS SYSTEM)
INDEX
Fig Name Page
Fig.12.03 D424607 LINES GP – HYDRAULIC ·····················89
12.031 D424607-01 LINES GP – HYDRAULIC ··················89.2
12.04 D422980 LINESGP-BOOM&BUCKETPART1 OF3····91
12.05 D422980 LINESGP-BOOM&BUCKETPART20F3····93
12.06 D422980 LINESGP-BOOM&BUCKETPART30F3····95
12.07 D422981-01 LINES GP -ATTACHMENT ·················97
12.08 D422998 MTG GP – CONTROL VN ····················99
12.09 D418205 CONTROL VALVE······························101
12.10 D424605 LINES GP – HST·································103
12.101 D424605-01 LINES GP- HST······························103.2
12.11 D515541 HSTMOTOR······································105
12.12 D514084 HST PUMP·········································107
12.121 D514107 HST PUMP(WITH ICP)····················107.2
12.13 D511659 BOOM CYLINDER······························108
12.13 D512132 BOOM CYLINDER(FOR DECKER)····108
12.131 D512166 BOOM CYLINDER(FOR VOLV0) ···108.1
12.14 D511803 BUCKETCYLINDER··························109
12.141 D512195 BUCKETCYLINDER·······················109.1
12.141 D512234 BUCKET CYLINDER (FOR DECKER) ··109.1
12.142 D512235 BUCKET CYLINDER(FOR VOLVO) ··109.2
12.15 D501500 MTGGP-OILFILTER·······················110
• IMPLEMENTS
Fig.13.01 D571185 ADAPTER – QUICK COUPLER··········111
13.02 D415549 MANUAL HOLDER·····························112
13.03 BUCKET············································· 113
13.04 D423734 TOOH BAR ASS’Y-·····························114
13.05 D423728 WEAR BLADE AS ······························115
• SERVICE EQUIPMENT AND SUPPLIES
Fig.14.01 D423003 PAINT & LUBRICANT GP ··················117
14.02 D424861 DECAL GP – FOR USA PART 1 OF 2···119
14.03 D424861 DECAL GP- FOR USA PART2 OF 2···121
14.04 D424862 DECAL GP – FOR CE PART 1 OF 2 ··123
14.05 D424862 DECAL GP – FOR CE PART 2 OF 2 ··125
14.06 D424965 DECAL GP- FOR DECKER PART 1 OF 2 ··127
14.06 D424965 DECAL GP· FOR DECKER PART 2 OF 2 ··129
• GENERAL OPTION SYSTEM
Fig.15.01 D423656 STROBE LIGHT ASS’Y ······················130
15.02 D423930 INSTALLATION GP· JUMPER CABLE ···131
15.03 D423790 CHANGEOVER AR· FOR HAND CONTROL ··133
15.04 D423454 CHANGEOVER AR – FOR SELF LEVEL VALVE ··135
15.041 D426046 CHANGE OVER AR. – SELF LEVEL
VALVE – FOR JOYSTICK················135.2
15.05 D424966 HIGH FLOW OPTION·························137
15.051 D426049 HIGH FLOW- FOR JOYSTICK·······137.2
15.06 D424870 CHANGEOVER AR – LIGHTING SYSTEM ·· 139
15.061 D426042 CHANGE OVER AR. – LIGHTING GP –
FOR JOYSTICK·······························139.2
15.07 D423966 CANOPY PANEL GP··························140
15.09 D424968 CABIN HEATER ·································142
15.09 D424969 CABIN HEATER – FOR DECKER ······142
15.10 D423984 MIRROR GP- FOR SIDE VIEW·•·······143
15.11 D423708 ALARM – BACKUP ASS’Y ··················144
15.111 D426026 BACKUP ALARM- FOR JOYSTICK···144.1
Fig Name Page
Fig.15.12 D571133 CHANGEOVER AR. – FLAT FACE FITTING ··145
15.13 D425667 HARD CABIN······································147
15.14 D424216 FRONT DOOR FRAME AS ················148
15.15 D424217 DOOR AS – FRONT····························149
15.16 D425610 LINESGP-ATTACHMENTRETURN ··149.2
15.17 D425970 PALLET AS – FORK ···························150
15.18 D424944 CHANGE OVER AR. – HIGH FLOW,
COMB LIGHT- FOR JOYSTICK······················150.1
• CE OPTION SYSTEM
Fig.16.01 D425567 ALTERNATE POWER SOURCE
(CIGAR LIGHTER) ·····························151
16.02 D423373 CHANGEOVER AR- FOR HORN(FOR CE)··153
16.021 D426019 CHANGE OVER AR. – HORN(JOYSTICK)
– FOR CE·········································153.2
16.03 D423349 CHANGEOVER AR – FOR REAR DOOR
LOCK(FOR CE & ITALY)····················154
16.04 D571169 LOCKABLE MANUAL GP
(FOR CE & ITALY) ·····························155
16.05 D423410-01 SIDE INSULATION GP –
CANOPY(FOR CE & ITALY) ··············156
16.06 D423376 CAP INSULATION GP –
NOISE REDUCTION(FOR CE & ITALY) ··157
16.07 D423176 INSULATION GP –
CHAIN CASE(FOR CE & ITALY) ·······159
16.08 D424784 MASTER DISCONNECT
SWITCH GP(FOR CE & ITALY) ·········160
16.09 D423181 CHANGEOVER AR- BOOT GP
(FOR CE & ITALY) ·····························161
16.10 D423805 SEALING GP(FOR CE & ITALY)········162
16.101 D426020 SEALING GP(JOYSTICK) – FOR CE ····162.1
16.11 D411628 MTG GP- REFLECTOR(FOR CE)·····163
16.12 D424460 CHANGEOVER AR –
MUFFLER(FOR CE & ITALY) ············164
16.13 D425853 CHANGE OVER AR. –
BOOM AS(FOR ITALY) ······················165
16.14 D423330 CHANGE OVER AR. –
WELDMENT AS-TACH(FOR ITALY) ··166
16.15 D423301 TACH LOCK GP(FOR ITALY) ············167
16.16 D424465 CHANGE OVER AR. –
INSTRUMENTGP(FOR ITALY)········169
16.17 D423292 CHANGE OVER AR. –
SEAT BAR GP(FOR ITALY)···············171
16.18 D424466 WIRING GP(FOR ITALY) PART 1 OF 2··173
16.18 D424466 WIRING GP(FOR ITALY) PART 2 OF 2··175
16.181 D426033 CHANGE OVER AR. –
WIRING(JOYSTICK) – FOR ITALY··175.2
16.19 D424467 CHANGER AR. –
LIGHTING SYSTEM(FOR ITALY) ······177
16.191 D426035 CHANGE OVER AR. – LIGHTING GP
(JOYSTICK)- FOR ITALY···············177.2
16.20 D424472 BUCKET GP(FOR ITALY) ··················178
• OPTION SYSTEM – FOR JOY STICK
Fig.17.01 D425962 CHANGE OVER AR. – SEAT BAR ·····179
17.02 D425840 CONTROL JOY STICK GP ················181
– d.2 – $B1050
(THIS PARTS BOOK IS FOR REFERENCE ONLY.
PART NUMBERS AND SERAIL NUMBERS MAY BE
OUT DATED. ALWAYS USE THE ONLINE PARTS SYSTEM)
Fig.17.03 D425915 STAND – JOY STICK ASS’Y – LH·······183
17.04 D425916 STAND – JOY STICK ASS’Y – RH ······185
17.05 D425964 CHANGE OVER AR. – FLOOR PLATE···187
17.06 D425965 CHANGE OVER AR.· THROTTLE & PARKING···189
17.07 D425966 LINES JOYSTICK GP PART 1 OF 2 ··191
17.07 D425966 LINES JOYSTICK GP PART 2 OF 2 ··193
17.08 D425967 CHANGE OVER AR. –
BOOM & BUCKET & ATTACH. ··········195
17.081 D517110 CONTROL VALVE······························197
17.09 D425976 CHANGE OVER. – WIRING GP ·········198
17.10 D425968 CHANGE OVER.- PUMP MOUNTING ··199
17.11 D517114 HST PUMP ·········································201
17.12 D517111 HST JOYSTIC VALVE························202
17.13 D517112 BOOM JOYSTIC VALVE····················203
17.14 D425969 CHANGE OVER. – DECAL GP···········204
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