Doosan 430, 430 Plus (1340XL), 440 Plus (DSL702), 450, 450 Plus (1760XL), 460, 460 Plus (2060XL), 470 Plus (DSL902) Skid Steer Loader Service Training Manual 2005

Doosan 430, 440 Plus, 450, 460, 470 Plus Series Service & Repair Manual - 2005

This professional-grade service manual provides the essential technical foundation required to maintain factory-spec performance and maximize the operational lifespan of your Doosan equipment. By utilizing precise diagnostic procedures and factory tolerances, owners and fleet managers reduce unscheduled downtime and ensure high-precision hydraulic and engine repairs.

Comprehensive Model Coverage & Engine Powerplants

This manual covers the following Doosan Skid Steer Loader models, including their respective US market designations and specific engine hardware:

• Doosan 430 / 430 Plus (1340XL) – Yanmar / Cummins A2000
• Doosan 440 Plus (DSL702) – Cummins A2300
• Doosan 450 / 450 Plus (1760XL) – KIA / Cummins B3.3NA
• Doosan 460 / 460 Plus (2060XL) – Cummins B3.3NA
• Doosan 470 Plus (DSL902) – Cummins B3.3T (Turbocharged)

Essential Service Advantages

• Precision Calibration: Execute exact valve adjustments and fuel injection timing to maintain engine efficiency and emission standards.
• System Integrity: Utilize factory-defined relief valve settings and hydraulic flow rates to prevent component cavitation and premature failure.
• Safety Compliance: Detailed testing protocols for the seat bar safety sensors and parking brake interlock systems ensure a secure operating environment.
• Cost Management: Perform in-house diagnostics using the comprehensive troubleshooting flowcharts to avoid expensive third-party service calls.

Documentation Scope & Official Formats

This digital release encompasses the complete Service Training Manual (Ref: DS SLT 0605 Rev-01) issued by the Doosan Infracore Overseas Service Team. It includes seven primary technical modules ranging from general machine overviews to complex maintenance data tables, providing a professional reference for the 2005 model year production.

Technical Reference & System Specifications

Technical Identification & Factory Standards

• Serial Number Locations: The Machine ID plate is located on the main chassis frame, typically visible near the entry point or lifting points. Individual engine ID plates are located on the engine block for Cummins A and B series identification.
• Factory Specifications (Proof of Quality):
  • Main Relief Valve Pressure: 195 bar (2828 PSI) for control valve circuits.
  • HST Charge Pressure Switch: Setting at 5.97 kg/cm² for system protection.
  • Engine Oil Pressure Warning: Activates when pressure drops below 0.5 kg/cm².
  • Valve Clearance (A2000/A2300): 0.3mm for both Intake and Exhaust.
  • Valve Clearance (B3.3 Series): 0.35mm (Intake) / 0.50mm (Exhaust).

Visual Diagnostics & System Schematics

• Hydraulic & Harness Routing: Includes complete hydraulic circuit schematics for Standard, Option (High Flow), and Joystick control models.
• Exploded Views: Detailed visual breakdowns of the HST pump (Sauer Danfoss & Rexroth AA20VG), HST orbital motors, and the control valve spool assemblies.
• Electrical Logic: Provides full-page wiring diagrams including color-coded charts (RD, BK, WH, etc.) and power supply logic for Key OFF, IGN, and Start positions.
• Diagnostic Tools: Includes specialized anti-stall control valve flow diagrams and HST pressure warning light logic tables.

Detailed Table of Contents

• I. General: Machine nomenclature, exterior views, and boom type comparisons (Conventional vs. Vertical).
• II. Operation: Safety protocols, instrument panel guides, and control types (Manual bar vs. Pilot joystick).
• III. Engine: Deep dive into Cummins A2000 and B3.3 series, including lubrication, cooling, and fuel systems.
• IV. Chassis: Main frame construction, pump coupling, and power train components.
• V. Hydraulic System: Hydrostatic Static Transmission (HST) system, pump/motor internals, and control valve logic.
• VI. Electric System: Wiring colors, preheat controllers, and sensor resistance values (Thermal/Fuel senders).
• VII. Maintenance Data: Machine speeds, fluid capacities (UTTO/DEXRON III), and service interval tables.

Professional Value & Wear Standards

This documentation provides specific "Service Standards" including detailed timing adjusting screw instructions for the HST system and resistance ohm values for solenoids (e.g., Fuel shut-off: 7.4 Ω). It defines factory wear limits and fluid specifications to ensure all components—from the chain case to the radiator—operate within their engineered tolerances.