Dl420a (950106-00816ae) Om en (#10001 - 2014)
Dl420a (950106-00816ae) Om en (#10001 - 2014)
Dl420a (950106-00816ae) Om en (#10001 - 2014)
Safety ..........................................................................................1-1
Safety Decals..................................................................................... 1-2
Visibility Information ......................................................................... 1-12
Unauthorized Modifications.............................................................. 1-14
General Hazard Information............................................................. 1-14
Before Starting Engine..................................................................... 1-22
Machine Operation........................................................................... 1-25
Maintenance .................................................................................... 1-33
Battery.............................................................................................. 1-43
Towing ............................................................................................. 1-45
Shipping and Transportation............................................................ 1-46
Operation....................................................................................3-1
Instrument Panel Control Functions................................................... 3-1
New Machine Break-in Procedures ................................................... 3-1
Engine Start and Stop........................................................................ 3-2
Machine Travel ................................................................................ 3-10
Machine Shut Down......................................................................... 3-13
F/R (Forward/Reverse) Travel Control System (Optional)............... 3-15
Additional Braking ............................................................................ 3-16
Boom Raise Kick-out ....................................................................... 3-17
Bucket Angle Indicator ..................................................................... 3-17
Boom Lower Kick-out (Optional) ...................................................... 3-18
Adjustment of Bucket Position Switch.............................................. 3-18
Towing Machine............................................................................... 3-19
If Engine Stalls While Traveling ....................................................... 3-20
Allowable Water Depth .................................................................... 3-20
Operation Under Abnormal Conditions ............................................ 3-21
Transportation ...........................................................................5-1
Transporting Machine ........................................................................ 5-1
Lifting Machine................................................................................... 5-5
Troubleshooting ........................................................................6-1
Braking............................................................................................... 6-1
Electrical System ............................................................................... 6-2
Engine................................................................................................ 6-2
Hydraulic System ............................................................................... 6-5
Steering.............................................................................................. 6-7
Travel System .................................................................................... 6-8
Specification ..............................................................................7-1
General Specifications ....................................................................... 7-1
Working Range and Dimensions ....................................................... 7-2
Working Capacities ............................................................................ 7-4
Approximate Weight of Workload Materials....................................... 7-5
Index ...........................................................................................8-1
Intended Use
The machine is intended to be used under normal conditions for
applications described in this manual. If it is used for other
purposes, or in potentially hazardous environments, special
precautions must be followed and the machine must be
equipped for such use. Examples include, but are not limited
falling object guards, work lights, etc. Do not engage in
prohibited uses as described in this manual. Contact your
DOOSAN distributor for further information.
The machine is designed for a maximum machine weight
(includes equipment and attachments) of 21,955 kg (48,402 lb)
for DL420A. If the maximum weight is exceeded, no warranties
on the part of the manufacturer will apply. However, always pay
attention to national regulations for traveling on public roads.
Engine
DL420A has a DOOSAN DE12TIS 11.05 liter engine. This
engine is turbo charged and direct injection type. The number of
cylinder is 6.
DL420A Foreword
1
Power Transmission
The transmission is electrohydraulically controlled, where all
gears are in constant mesh. The gear ranges are achieved by
applying different combinations of clutches. Between the engine
and transmission gears there is a hydraulic torque converter,
which controls the output torque. The front and rear axles have
planetary gears in the wheel hubs and this reduces the strain on
the respective driveshafts. The axles' differntials use a LSD
(Limited Slip Differential) design or DHL (Differential Hydraulic
Lock) design(optional).
Brake System
The machine is provided with a dual circuit, all hydraulic, brake
system with one circuit for each axle. Each circuit meets the
requirements for secondary brake capability.
Parking Brake
The parking brake is a dry disk brake built into the transmission
output shaft. The brake is applied by spring force and is
released hydraulically.
Steering System
The machine uses a load sensing, hydraulic power steering
system. It has a steering arc of 40°.
Cabin
The cabin has a heating and ventilation system with defrosting
for front and rear windows. Air-conditioning is standard. The
cabin has two emergency exits, the door and right side window.
Foreword DL420A
2
Equipment
The machine can be provided with different types of optional
equipment, depending on the requirements of different markets.
Examples of such equipment are lever steering, Boom
Suspension System (LIS), secondary steering, separate
attachment locking, automatic greasing.
COMMUNICATION EQUIPMENT
INSTALLATION
IMPORTANT
All installation of optional communication equipment must
be done by trained professionals and according to the
DOOSAN CE instructions applicable to the machine.
DL420A Foreword
3
PRODUCT PLATES
With the aid of the product plates, shown below, it is possible to
identify the machine and its components. The Product
Identification Number (PIN) indicates the model designation,
engine code and serial number of the machine. The Component
Identification Number, CIN, indicates the serial number of the
component. Make a note of the identification numbers.
When ordering spare parts, and in all telephone enquiries or
correspondence the PIN and CIN must always be quoted.
3 4
6 7
1,2
5 FG025207
Figure 1
Reference
Description
Number
The manufacturer's name and address, machine PIN.
1 Product Plate Operating weight, year of manufacture, year of delivery and position of CE
mark (EU/EEA countries only) (stamped into right side).
Operating weight, overall length, overall width, overall height, ground
2 Specification Plate clearance engine output, tire, turning radius, bucket capacity, dumping
reach, dumping clearance.
The manufacturer's name and address, serial number, machine model
3 Cabin designation, operating weight, cabin serial number, ROPS/FOPS number
and ROPS/FOPS certificate number.
4 Engine The engine type designation and number.
5 Front Axle The manufacturer's name and address and front drive axle CIN.
6 Transmission The manufacturer's name and address and transmission CIN.
7 Rear Axle The manufacturer's name and address and rear drive axle CIN.
Foreword DL420A
4
SAFETY MESSAGES
Safety messages and safety decals included in this manual and
on the machine provide instructions how to operate, service and
maintain the machine. Safety messages and safety decals
indicate potential hazards and describe safety precautions
required to avoid hazards. Operator and maintenance personnel
should read and understand these safety messages and decals
before beginning operation or maintenance.
Signal Words
The signal words "DANGER", "WARNING", "CAUTION" are
used throughout safety messages and safety decals in this
manual or on the machine. They indicate an existence of, and
the relative seriousness of, a hazard. All three indicate that a
safety risk is involved. Observe the precautions indicated
whenever a Safety Alert Symbol is present, no matter which
signal word appears next to it.
DANGER
DANGER - This signal word is used on safety messages and
safety labels and indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety messages and
safety labels and indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION - This signal word is used on safety messages
and safety labels and indicates a potentially hazardous
situation which, if not avoided, could result in minor or
moderate injury.
DL420A Foreword
5
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.
Foreword DL420A
6
2Safety
DL420A Safety
1-1
SAFETY DECALS
Safety decals are attached to the machine to alert the operator
or maintenance person about potential hazards, the
consequences of potential injury, and instructions and/or actions
required to avoid the hazard. The location of the safety decals
and the description of the decals are reviewed in the following
section. Please become familiarized with all safety decals and
their messages.
Make sure that all the safety decals are in their correct location
and legible. Clean or replace the safety decals if they are
damaged, missing, or the texts and pictorials are not legible.
When you clean the safety decals, use a soft cloth, water, and
soap. Do not use solvent, gasoline, or other harsh chemicals to
clean the safety decals because this could loosen the adhesive
that secures the decals to the machine. Remember, if a safety
decal is attached to a part that is replaced, install a new safety
decal on the replacement part.
This machine uses safety decals with and without text. The type
and number of safety decals can vary depending upon
geographical regions and machine models.
Safety DL420A
1-2
Safety Decals Without Text (No-Text)
Vertical Configuration
Safety decals without text consist of a safety sign and safety
information panel. The safety sign panel is located at the top or
left side and the safety information panel is located at the bottom
or right side of the decal depending on its configuration. The Hazard
safety sign panel uses a black triangular band and a pictorial to Panel
identify the hazard and the potential consequences of the failure
to follow instructions. The safety information panel uses
pictorials and/or prohibition signs to identify the actions
necessary to avoid the hazard.
Avoidance
Panel
Horizontal Configuration
Hazard Avoidance
Panel Panel
FG018723
Figure 1
DL420A Safety
1-3
Information and Location for Safety Decals
13
12
13 6
10
21
19 14 9 11(LIS)
12 5
15
21
4
6 17
10
3 1
9 14 8 18 19 20
11 11 11
(Steering) (Pilot) (Brake) 7
16
19
WL1400804
Figure 2
Safety DL420A
1-4
Safety Decal
1 2
3 4
950205-04644A
WL1400812
WARNING
AVOID DEATH OR SERIOUS INJURY
• Never use wheel loader without instructions.
• Read Operation & Maintenance Manual before
operation.
• Always fasten your seat belt.
• Explosion or electrocution can occur if machine
contacts utility lines or pipes. Check for overhead or
underground lines before operating.
• Keep bystanders out of travel path and always look in
the direction of travel.
• Ensure mirrors and rear view camera are clean and
working properly.
• Sound the horn to alert bystanders before operating
• Never operate machine from outside the operator's
position.
• TO LEAVE THE WHEEL LOADER:
1) Lower the attachment to the ground and make
sure all controls are in neutral.
2) Engage the parking brake.
3) Set pilot cutoff switch to OFF position.
4) Stop the engine and remove the key.
DL420A Safety
1-5
2. Emergency Exit (950205-04643)
IMPORTANT
If the primary exit is blocked, use right side window for
secondary exit.
950205-04643
WL1400805
WARNING
ROC
WARNING
AVOID DEATH OR SERIOUS INJURY
• Do not weld on or drill holes in the protective
structure.
• Replacing ROPS, if damaged or modified.
950205-04645
WL1400814
Safety DL420A
1-6
5. Warning Tag - "Do Not Operate" (950205-03802)
WARNING
AVOID DEATH OR SERIOUS INJURY
• Stop engine and remove the key.
• Attach "DO NOT OPERATE" warning tag to the
controls before servicing the machine.
• Do not operate when performing inspection or EX1301177
maintenance.
WARNING
ROTATING PARTS CAN CAUSE DEATH OR
SERIOUS INJURY
Keep away from belt and rotating parts. Stop engine
before servicing. EX1301181
WARNING
AVOID DEATH OR SERIOUS INJURY
• Read and follow instructions in Operation &
Maintenance Manual for battery maintenance.
• Keep arcs, sparks, flames, and lighted tobacco
away.
• Do not store metal tools or flammable materials
on or around batteries.
• Wear safety goggles and rubber gloves when EX1301183
working with batteries.
• If battery acid contact occurs:
1) Flush your skin with water immediately and
apply baking soda or lime to neutralize the
acid.
2) Flush your eyes with water for 10 ~ 15
minutes.
3) Get medical attention immediately.
DL420A Safety
1-7
8. Articulated Frame Lock (950205-01688B)
WARNING
AVOID DEATH OR SERIOUS INJURY
• Install articulated frame lock before servicing or
transporting.
950205-01688B
WL1400806
WARNING
CRUSHING HAZARD CAN CAUSE SERIOUS INJURY
OR DEATH
• Keep out of this area unless articulated frame 950205-01687A
WARNING
AVOID DEATH OR SERIOUS INJURY
• Moving a lift arm control or failure of a part can
cause lift arm to drop. 950205-01692A
WL1400808
• Never reach under or stand under raised lift arm
unless the lift arm is properly secured.
WARNING
AVOID DEATH OR SERIOUS INJURY
• Heat or impact can cause the accumulator to
explode.
• Keep away from flame. EX1301187
• Do not weld on or drill into accumulator.
Safety DL420A
1-8
12. Rotating Fan (950205-03788)
WARNING
CONTACT WITH ROTATING FAN CAN CAUSE
DEATH OR SERIOUS INJURY
Keep away from fan and rotating parts. Stop engine 950205-03788
before servicing.
EX1301182
WARNING
HOT PRESSURIZED FLUID CAN CAUSE
SERIOUS BURNS
• Do not loosen or open cap when hot.
EX1301180
• Before opening:
1) Turn engine off.
2) Allow machine to cool.
3) Tip cap and open slowly to relieve pressure.
WARNING
ROLL AWAY CAN CAUSE DEATH OR SERIOUS
INJURY
• Before disengaging park brake, block wheels to 950205-01691B
Additional Decal
IMPORTANT
Electrical welding on the frame can damage the
engine's electronic control unit (ECU).
950212-02440
EX1402396
DL420A Safety
1-9
16. Battery Disconnection (950205-03784)
IMPORTANT
AVOID ELECTRICAL COMPONENT DAMAGE
• Disconnecting the battery while the engine is
running can cause damage to electrical
components.
• Disconnect battery only when the engine is
turned OFF.
950205-01694B
WL1400809
IMPORTANT
• Check transmission oil level with parking brake
"ON".
1) Warm up the machine for 10 minutes or longer.
950205-01690B
2) Pace transmission lever in neutral position and
WL1400810
engage parking brake.
3) Check the transmission oil level using the
dipstick or gauge.
4) If necessary, add transmission oil
(Spec. SAE 15W40)
Correct oil level (Oil temp. 80°C (176°F)):
Hot zone (dipstick type)/Red line (gauge type)
Safety DL420A
1-10
19. Lift/Tie down (950205-03815)
Identifies lift point and tie down point location.
950205-03815
EX1301201
IMPORTANT
• Only use diesel fuel.
K1016409
WL1400818
950205-01487
WL1400819
DL420A Safety
1-11
VISIBILITY INFORMATION
A rear view camera and mirrors ensure that visibility around the
machine, from the operator's seat, meets the latest ISO
standards for the region or marketplace that the machine is sold
into.
NOTE: These devices may vary from one region to another,
depending upon local and regional regulations. If a
machine is moved or sold into another region or
marketplace, it is the owner's responsibility to make
sure it complies with all regulations.
1. Mirror
FG025209
Figure 3
WARNING
AVOID DEATH OR SERIOUS INJURY
Failure to check for and clear people from the surrounding
area of a machine could result in serious injury or death.
The operator should make sure that visual aids (mirrors and
camera (s)) are in proper working condition. Look for any
possible blind spots.
Safety DL420A
1-12
While operating or traveling in places with poor visibility, and if it
is impossible to confirm the condition of the work site, or if an
obstacle is in the area around the machine, there can be a
danger that the machine may suffer damage or operator or
others may suffer serious personal injury.
Inspect equipment and immediately report if there are problems
with the visual aids. If machine cannot be fixed immediately, DO
NOT use the machine. Contact your local DOOSAN distributor
as soon as possible and ask for repairs.
Guidelines
• If the visibility cannot be sufficiently assured, use a
flagman. The operator should pay careful attention to the
signals and follow the instructions of the flagman.
• Signals should only be given by one flagman.
• When working in dark places, turn "ON" work lights and
front lights on the machine. Set up additional lighting in the
area.
• Stop operations if there is poor visibility, such as fog, snow,
rain, or sandstorms.
• Check mirrors and rear view camera (optional) lens on
machine before starting operations. Clean off any dirt and
adjust view to ensure good visibility.
When operating or traveling during poor visibility conditions, and
especially in a large machine, strictly adhere to the above
guidelines.
NOTE: Refer to ISO 5006 for additional guidelines and
information.
It may not be possible to adjust all visual aids to see all the way
around the machine. Therefore, additional precautions must be
taken to ensure the safe operation of the machine.
NOTE: Larger machines are more likely to have blind spots.
NOTE: Refer to ISO 5006 for weight class information.
DL420A Safety
1-13
UNAUTHORIZED
MODIFICATIONS
Any modification made without authorization or written approval
from DOOSAN can create a safety hazard, for which the
machine owner will be held responsible.
For safety's sake, replace all OEM parts with the correct
authorized or genuine DOOSAN part. For example, not taking
the time to replace fasteners, bolts or nuts with the correct
replacement parts could lead to a condition where the safety of
critical assemblies are dangerously compromised.
GENERAL HAZARD
INFORMATION
Safety Rules
Only trained and authorized personnel can operate and maintain
the machine.
Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
Do not operate the machine if you are not feeling well, if you are
taking medication that makes you feel sleepy, if you have been
drinking, or if you are suffering from emotional problems. These
problems will interfere with your sense of judgment in
emergencies and can cause accidents.
When working with another operator or with a person on work
site traffic duty, be sure that all personnel know the nature of the
work and understand all hand signals that are to be used.
Always observe strictly any other rules related to safety.
Safety Features
Be sure that all guards and covers are installed in their proper
position. Have guards and covers repaired immediately if
damaged.
Be sure that you understand the method of use of safety
features such as transmission lever neutral lock and the seat
belt, and use them properly.
Never remove any safety features. Always keep them in good
operating condition.
Failure to use safety features according to the instructions in the
Operation and Maintenance Manual could result in serious
bodily injury.
Safety DL420A
1-14
Inside Operator's Cabin
When entering the operator's cabin, always remove all mud and
oil from the soles of your shoes. If you operate the accelerator
and brake pedals with mud or oil stuck to your shoes, your foot
may slip and this can cause a serious accident.
Clean grease and dirt from pedals and controls. This contributes
to safe operation. Cleaning also provides an opportunity to
inspect equipment. Minor damage can be repaired or corrected
before major problems result.
Keep cabin floor and consoles free of tools and personal items.
Do not stick suction pads to the window glass. Suction pads act
as a lens and can cause fire.
Do not leave lighters laying around the operator's cabin. If the
temperature inside the operator's cabin becomes high, there is a
danger that lighter may explode.
Do not use cellular telephones inside the operator's cabin when
driving or operating the machine. There is a danger that this may
lead to an unexpected accident.
Never bring any dangerous objects such as flammable or
explosive items into the operator's cabin.
To ensure safety, do not use the radio or music headphones
when operating the machine. There is a danger that this may
lead to a serious accident.
When operating the machine, do not put your hands or head out
of the window.
When standing up from the operator's seat, always place
transmission neutral lock lever in the "LOCK" position and set
pilot cutoff switch to "O" (OFF) position. If you accidentally touch
the work equipment levers when they are not locked, the
machine may suddenly move and cause serious injury or
damage.
When leaving the machine, completely lower the work
equipment to the ground, set transmission neutral lock lever in
the "LOCK" position, set pilot cutoff switch to "O" (OFF) position,
"APPLY" parking brake, and stop engine. Use the key to lock all
the equipment. Always remove key and take it with you.
DL420A Safety
1-15
Breathing Masks, Ear Protection May Be
Required
Do not forget that some risks to your health may not be
immediately apparent. Exhaust gases and noise pollution may
not be visible, but these hazards can cause disabling or
permanent injuries.
NOTE: The equivalent continuous A-weighted sound
pressure level at the workstation for this machine is
70 dB (A).
Measurement is obtained on a dynamic machine
following the procedures and cabin conditions as
described in ISO 6396.
NOTE: The guaranteed sound power level emitted by the
machinery for this machine is 105 dB (A).
Measurement is obtained on a dynamic machine with
the procedures as described in 2000/14/EC.
Safety DL420A
1-16
• When driving machine, avoid obstacles and
excessive rough terrain.
6. Keep the machine on terrain where working and traveling
conditions are good.
• Remove any large rocks or obstacles.
• Fill any ditches and holes.
• Provide machines for and schedule time to maintain
good terrain conditions.
7. Travel over longer distances (e.g. on public roads) at
adjusted (medium) speed.
• Always adjust the speed to prevent bouncing.
DL420A Safety
1-17
Fuel, Oil and Hydraulic Fluid Fire Hazards
Fuel, oil and antifreeze will catch fire if it is brought close to a
flame. Fuel is particularly flammable and can be hazardous.
Always strictly observe the following.
Add fuel, oil, antifreeze and hydraulic fluid to the machine only in
a well ventilated area. The machine must be parked with
controls, lights and switches turned "OFF". The engine must be
"OFF" and any flames, glowing embers, auxiliary heating units
or spark causing equipment must be extinguished, turned "OFF"
and/or kept well clear of the machine.
Static electricity can produce dangerous sparks at the fuel filling
nozzle. In very cold, dry weather or other conditions that could
produce a static discharge, keep the tip of the fuel nozzle in
constant contact with the neck of the fuel filling nozzle, to
ARO1050S
provide a ground.
Figure 7
Keep fuel and other fluid reservoir caps tight and do not start the
engine until caps have been secured.
To prevent hot coolant from spurting out, stop engine, wait for
the coolant to cool, then loosen the cap slowly to relieve the
pressure.
To prevent hot oil from spurting out, stop engine, wait for the oil
to cool, then loosen the cap slowly to relieve the pressure.
HAOA060L
Figure 9
Safety DL420A
1-18
Injury from Work Equipment
Do not enter or put your hand, arm or any other part of your body
between movable parts, such as between the work equipment
and cylinders, or between the machine and work equipment.
If the control levers are operated, the clearance between the
machine and the work equipment will change and this may lead
to serious damage or personal injury.
If going between movable parts is necessary, always position
and secure the work equipment so it cannot move.
HDO1010L
Figure 10
DL420A Safety
1-19
Protection from Falling or Flying Objects
On work sites where there is a danger that falling or flying
objects may hit the operator's cabin select a guard to match the
operating conditions to protect the operator.
Working in mines, tunnels, deep pits or on loose or wet surfaces
could produce danger of falling rock, roll over or hazardous
flying objects. Additional protection for operator's cabin could be
required in form of a FOPS/Falling Object Protective Structure
and/or ROPS/Roll Over Protective Structure reinforcement
system. HAOA110L
Figure 12
Safety DL420A
1-20
Attachment Precautions
Option kits are available through your dealer. Contact DOOSAN
for information on available 3 spool control valve and log fork
piping / valving / auxiliary control kits. Because DOOSAN cannot
anticipate, identify or test all the attachments that owners may
wish to install on their machines, please contact DOOSAN for
authorization and approval of attachments, and their
compatibility with optional kits.
Accumulator
The pilot control system is equipped with an accumulator. For a
brief period of time after the engine has been shut down, the
accumulator will store a pressure charge that may enable
hydraulic controls to be activated. Activation of any controls may
enable the selected function to operate under force of gravity.
When performing maintenance on the pilot control system, the
hydraulic pressure in the system must be released as described
in “Handling of Accumulator” on page 4-79.
The accumulator is charged with high-pressure nitrogen gas, so
it is extremely dangerous if it is handled in the wrong way.
Always observe the following precautions:
• Do not drill or make any holes in the accumulator or
expose it to any flames, fire or heat source.
• Do not weld on the accumulator, or try attaching anything
to it.
• When carrying out disassembly or maintenance of the
accumulator, or when disposing of the accumulator, the
charged gas must be properly released. Contact your
DOOSAN distributor.
• Wear safety goggles and protective gloves when working
on an accumulator. Hydraulic oil under pressure can
penetrate the skin and cause serious injuries.
Engine Ventilation
Engine exhaust gases can cause loss of judgment, loss of
alertness, and loss of motor control. These gases can also
cause unconsciousness, serious injury, fatal accidents and
death.
Make sure there is adequate ventilation before starting the
engine in any enclosed area.
You should also be aware of open windows, doors or ductwork
where exhaust may be carried, or blown by the wind, exposing
ARO1770L
others to danger.
Figure 14
DL420A Safety
1-21
BEFORE STARTING ENGINE
Safety DL420A
1-22
Newly laid earth and the soil near ditches is typically loose. It
can collapse under the weight of vibration of your machine and
cause your machine to tip over.
Install the safety guard if working in areas where there is a
danger of falling rocks.
Engine Starting
Walk around your machine before getting in the operator's
cabin. Look for evidence of leaking fluid, loose fasteners,
misaligned assemblies or any other indications of possible
equipment hazard.
All equipment covers and machinery safety guards must be in
place, to protect against injury while the machine is being
operated.
Look around the work site area for potential hazards, people or
property that could be at risk while operation is in progress.
NEVER start the engine if there is any indication that
maintenance or service work is in progress, or if a warning tag is
attached to controls in the cabin.
A machine that has not been used recently, or is being operated
in extremely cold temperatures, could require a warm-up or
maintenance service before start-up.
DL420A Safety
1-23
Check gauges and monitor displays for normal operation before
starting the engine. Listen for unusual noises and remain alert
for other potentially hazardous conditions at the start of the work
cycle.
Check tire inflation and check tires for damage or uneven wear.
Perform maintenance before operation.
Do not short-circuit the starting motor to start the engine. This is
not only dangerous, but may also damage the machine.
When starting the engine, sound the horn as an alert.
Start and operate the machine only while seated.
Safety DL420A
1-24
MACHINE OPERATION
IMPORTANT
If you need more information or have any questions or
concerns about safe operating procedures or working the
wheel loader correctly in a particular application or in the
specific conditions of your individual operating environment,
please consult your local DOOSAN representative.
Figure 17
Movement Alarms
If wheel loader is equipped with an audible travel movement
alarm, test alarm on a daily basis. Audible alarm should sound
as soon as travel system is engaged.
DL420A Safety
1-25
Travel Precautions
When traveling, wheel loader always keeps lights on; make sure
that you are in compliance with all state and local regulations
concerning warning flags and signs.
Never turn the starter switch to "O" (OFF) position when
traveling. It is dangerous if the engine stops while the machine is
traveling. It will be impossible to operate the steering unless the
unit is equipped with an emergency steering system.
Pilot control valve lever (joystick) should not be operated while
traveling.
Lower work equipment so that it is 400 mm (16 in) aboveground.
Never travel over obstacles or slopes that will cause machine to
tilt severely. Travel around any slope or obstacle that causes 10°
tilt, or more.
Do not operate the steering suddenly. The work equipment may
hit the ground and cause the machine to lose its balance, and
this can damage the machine or structures in the area.
When traveling on rough ground, travel at low speed, and avoid
sudden changes in direction.
Always keep to the permissible water depth. Refer to “Allowable
Water Depth” on page 3-20.
When traveling over bridges or structures on private land, check
first that bridge or structure can withstand the weight of the
machine. When traveling on public roads, check with the local
authorities and follow their instructions.
in)
12
(8 -
cm
- 30
20
FG026386
Figure 18
Safety DL420A
1-26
Avoid High-Voltage Cables
Serious injury or death can result from contact or proximity to
high-voltage electrical lines. The bucket does not have to make
physical contact with power lines for current to be transmitted.
Use a spotter and hand signals to stay away from power lines
not clearly visible to operator.
DL420A Safety
1-27
Use Care on Loose Support
Working heavy loads over loose, soft ground or uneven, broken
terrain can cause dangerous side load conditions and possible
tipover and injury. Travel without a load or balanced load may
also be hazardous.
If temperatures are changing, be cautious of dark and wet
patches when working or traveling over frozen ground. Stay
away from ditches, overhangs and all other weak support
surfaces. Halt work and install support mats or blocking if work is
required in an area of poor support.
Safety DL420A
1-28
Be Aware of and Conform to Local
Regulations
Minimum levels of insurance coverage, work permits or
certification, physical barriers around work site or restricted
hours of operation may be mandated by governing authorities.
There may also be guidelines, standards or restrictions on
equipment that may be used to perform certain kinds of work.
Check and follow all local requirements, which may also be
related to below ground hazards and power lines.
HAOA311P
Figure 22
DL420A Safety
1-29
Take Time to Provide Good Visibility
Be careful not to go close to the edge of a cliff by mistake.
Use the machine only for its main purpose. Using it for other
purposes will cause failures.
To ensure an ample view, do as follows:
• When working in dark areas, attach working lights and
front lights to the machine. If necessary, set up lighting at
the work site.
• Stop operations when the visibility is poor, such as in fog,
mist, snow, and rain. Wait for the visibility to improve to a
level which causes no problems for the operation.
• Keep dirt and dust off of windows and off lens surfaces of
work lights. Stop working if lights, windows or mirrors need
cleaning or adjustment.
To avoid hitting the work equipment, always do the following:
• When working in tunnels, on bridges, under electric wires,
or when parking the machine or carrying out other
operations in places with limited height, be extremely
careful not to hit the bucket or other parts.
• To prevent collisions, operate the machine at a safe speed
when working in confined spaces, indoors, or in crowded
areas.
• Do not pass the bucket over the heads of workers or over
the operator's compartment of dump truck.
FG026406
Figure 23
Safety DL420A
1-30
Operate Carefully on Snow and Ice, In Very
Cold Temperatures
In icy cold weather avoid sudden travel movements and stay
away from even very slight slopes. The machine could skid off to
one side very easily.
Snow accumulation could hide or obscure potential hazards.
Use care while operating or while using the machine to clear
snow.
Warming up the engine for a short period may be necessary, to
avoid operating with sluggish or reduced working capacity. The
jolting shocks and impact loads caused by bumping or
bottoming the boom or attachment are more likely to cause
severe stress in very cold temperatures. Reducing work cycle
rate and workload may be necessary.
When the temperature rises, frozen road surfaces become soft,
and machine travel becomes unstable.
In cold weather, do not touch metal surfaces with your bare
hands. If you touch a metal surface in extremely cold weather,
your skin may freeze to the metal surface.
Parking Machine
Avoid making sudden stops, or parking the machine wherever it
happens to be at the end of the workday. Plan so the wheel
loader will be on firm and level ground away from traffic and
away from high walls, cliff edges and any area of potential water
accumulation or runoff. If parking on inclines is unavoidable,
block the wheels to prevent movement. Lower the bucket or
other working attachment completely to the ground, or to an
overnight support saddle. There must be no possibility of
unintended or accidental movement.
When parking on public roads, provide fences, signs, flags, or
lights, and put up any other necessary signs to ensure that
passing traffic can see the machine clearly. Park the machine so
the machine, flags, and fences do not obstruct traffic.
DL420A Safety
1-31
Shutdown Control Functions
After bucket has been lowered to overnight storage position,
move all switches and controls to "OFF" position. Pull parking
brake knob to "APPLIED" position. This will apply parking brake.
Move pilot cutoff switch to "LOCK" position. This will disable pilot
control valve lever (joystick). Move key in starter switch to "OFF"
position, and remove key from switch.
Engage all lock-down security equipment that may have been
installed on machine.
IMPORTANT
When hydraulic system maintenance or service work must
be performed, be aware that accumulators in system store
fluid under pressure after system has been shut down. To
release hydraulic pressure in accumulators, operate control
with engine "OFF" until accumulator pressure is completely
dissipated.
HAAD4050
Figure 24
Safety DL420A
1-32
MAINTENANCE
EX1301177
Figure 25
DL420A Safety
1-33
Proper Tools
Use only tools suited to the task. Using damaged, low quality,
faulty, or makeshift tools could cause personal injury. There is a
danger that pieces from, chisels with crushed heads, or
hammers, may get into your eyes and cause blindness.
HDO1037L
Figure 27
Use of Lighting
When checking fuel, oil, battery electrolyte, or window washing
fluid, always use lighting with antiexplosion specifications. If
such lighting equipment is not used, there is a danger of an
explosion.
If work is carried out in dark places without using lighting, it may
lead to injury, so always use proper lighting.
Even if the place is dark, never use a lighter or flame instead of
lighting. There is a danger of fire. There is also danger that
HDO1040L
battery gas may catch fire and cause an explosion.
Figure 28
Safety DL420A
1-34
Burn Prevention
When checking the radiator coolant level, stop engine, let the
engine and radiator cool down, then check the coolant recovery
tank. If the coolant level in the coolant recovery tank is near the
upper limit, there is enough coolant in the radiator.
Loosen the radiator cap gradually to release the internal
pressure before removing the radiator cap.
If the coolant level in the coolant recovery tank is below the
lower limit, add coolant.
Cooling system conditioner contains alkali. Alkali can cause
personal injury. Do not allow alkali to contact the skin, the eyes,
or the mouth.
Allow cooling system components to cool before you drain the
cooling system.
Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact the skin.
Remove hydraulic tank filter plug only after the engine has been
stopped. Make sure that hydraulic tank filter plug is cool before
you remove it with your bare hand. Remove hydraulic tank filter
plug slowly to relieve pressure.
Relieve all pressure in the hydraulic oil system, in the fuel
system, or in the cooling system before you disconnect any
lines, fittings, or related items.
Batteries give off flammable fumes that can explode. HAAE1980
Figure 30
Do not smoke while you are checking the battery’s electrolyte
levels.
Electrolyte is an acid. Electrolyte can cause personal injury. Do
not allow electrolyte to contact the skin or the eyes.
Always wear protective glasses when you work on batteries.
DL420A Safety
1-35
Welding Repairs
When carrying out welding repairs, carry out the welding in a
properly equipped place. The welding must be performed by a
qualified worker. During welding operations, there is the danger
of, generation of gas, fire, or electric shock, so never let an
unqualified worker do welding.
The qualified welder must do the following:
• To prevent explosion of the battery, turn battery disconnect
switch to "OFF" position.
• To prevent generation of gas, remove paint from the
location of the weld.
• If hydraulic equipment, piping or places close to them are
heated, a flammable gas or mist will be generated and ON OFF
there is a danger of it catching fire. To avoid this, never
subject these places to heat.
FG020630
• Do not weld on pipes or on tubes that contain flammable Figure 31
fluids. Do not flame cut on pipes or on tubes that contain
flammable fluids. Before you weld on pipes or on tubes or
before you flame cut on pipes or on tubes, clean the pipes
or tubes thoroughly with a nonflammable solvent.
• If heat is applied directly to rubber hoses or piping under
pressure, they may suddenly break, so cover them with a
fireproof covering.
• Wear protective clothing.
• Make sure there is good ventilation.
• Remove all flammable objects and provide a fire
extinguisher.
Safety DL420A
1-36
Precautions When Working on Machine
When carrying out maintenance operations on the machine,
keep area around your feet clean and tidy to prevent falls.
Always do the following:
• Do not spill oil or grease.
• Do not leave tools laying about.
• Watch your step when walking.
Never jump down from the machine. When getting on or off the
ARO1380L
machine, use the steps and handrails, and maintain a
Figure 33
three-point contact (both feet and one hand or both hands and
one foot) to support yourself securely.
If the job requires it, wear protective clothing.
To prevent injury from slipping or falling, when working on the
hood or covers, never use any area except the area equipped
with nonslip pads.
DL420A Safety
1-37
Do Not Run Engine If Repairs or Work are
Being Performed Alone
You should always have at least two people working together if
engine must be run during service. One person needs to remain
in operator's seat, ready to work controls or stop machine and
shut "OFF" engine.
Safety DL420A
1-38
Cool Down Is Required Before Radiator or
Reservoir Checks
Stop engine and allow heat to dissipate before performing
service on engine radiator or hydraulic fluid reservoir. Both
assemblies have air vent levers at or near fill cap for venting
built-up air pressure. Release levers before trying to take off fill
caps and LOOSEN CAPS SLOWLY, before removal.
HAOA060L
Figure 34
DL420A Safety
1-39
Obtain Immediate Medical Attention if
Pressurized Oil Pierces Skin.
WARNING
AVOID DEATH OR SERIOUS INJURY
Failure to obtain prompt medical assistance could result in
gangrene or other serious damage to tissue.
Safety DL420A
1-40
Check Tire Pressure and Condition
Maintain tire pressure but do not overinflate. Inspect tires and
wheels daily. When inflating tires, follow procedures in
Maintenance Section, which include using an extension to allow
you to avoid standing in front of or over a tire. Do not change a
tire unless you have both experience and proper equipment.
NOTE: Refer to “Recommended Air Pressure” on page 4-88
DL420A Safety
1-41
Decreasing Risk of Injuries or Death From
Boom and Bucket
DANGER
AVOID DEATH
When operating machine or making repairs, never allow
bystanders in the operational zone or repair area. Operation
and service personnel must be careful when working
around the machine, especially around the boom and
bucket.
FG022672
An unexpected fall of the front structure can cause injuries
Figure 37
or death.
FG023188
Figure 38
Safety DL420A
1-42
BATTERY
DL420A Safety
1-43
Use Low Heat Portable Lighting
Hot surfaces on trouble lights or portable work lights can set off
fuel or battery explosive gases.
Safety DL420A
1-44
TOWING
DL420A Safety
1-45
SHIPPING AND
TRANSPORTATION
Safety DL420A
1-46
3Operating Controls
The "Operating Controls" section presented here consists of the
following groups:
1. “Component Locations” on page 2-2
2. “Operator's Area” on page 2-4
3. “Steering Console and Pedals” on page 2-5
4. “Front Instrument Panel” on page 2-14
5. “Right Side Switch Panel” on page 2-26
6. “Various Cabin Locations” on page 2-39
7. “Heater and Air Conditioner Operation” on page 2-43
8. “Stereo / CD Player (Optional)” on page 2-48
9. “Seat Adjustment” on page 2-49
10. “Seat Belt” on page 2-51
11. “Door Side Latch” on page 2-52
12. “Arm Rest” on page 2-53
13. “Fuse Box/Relay” on page 2-53
WARNING
AVOID DEATH OR SERIOUS INJURY
Warning lights. When any one or more of the warning lights
on the control console come "ON", immediately stop
operation and shut down unit. Investigate and correct
problem before proceeding with operation.
1 2 3 4 5 6
13 14 14 15 16 17 18 19
9 10 11 12
20 21 22 23 24
25
42
26
27
28
41 40 39 38 37 36 35 34 33 32 31 30 29
FG025210
Figure 1
1 2
4 3
FG001659
Figure 2
Reference Reference
Description Description
Number Number
Steering Console and Pedal Right Side Switch Panel
1 3
(See page 3-5) (See page 3-26)
Various Cabin Locations Seat Adjustment
2 4
(See page 3-39) (See page 3-49)
10 1
12
11
1-4 A
MAN 2-4
8 2
9 3
6 5 13 7 6 4
FG001660
Figure 3
Reference Reference
Description Description
Number Number
1 Starter Switch 7 Steering Wheel
2 Horn Button 8 Kick-down Switch
3 Combination Switch 9 Transmission Lever
4 Accelerator Pedal Front Instrument Panel
10
Steering Wheel Adjustment (See page 3-14)
5
Lever 11 Hour Meter
6 Brake Pedals 12 Hazard Warning Light Switch
WARNING
AVOID DEATH OR SERIOUS INJURY
DO NOT USE STARTING FLUIDS. The preheat system
could cause the starting fluid to explode. Starting
fluids should never be used.
Figure 5
FG003941
Figure 6
FG003935
Figure 7
FG024688
Figure 8
NOTE: High and low beams will only function with the H
headlight switch in the "||" position.
FG015107
Figure 10
CAUTION
AVOID INJURY
The further the pedal is pressed, the more engine
FG006192
speed increases. However, do not press the pedal
more than necessary; otherwise it will increase fuel Figure 11
consumption, cause short life on the engine, and in
the worst case lead to a serious accident.
1
Release
Lock
FG003888
Figure 13
CAUTION
AVOID INJURY FG002183
IMPORTANT
Do not use brake pedal as a foot rest. This will cause
brake disk to wear faster than normal, and this could
cause brake failure.
7. Steering Wheel
Rotating steering wheel controls position of front wheels
and this determines direction of machine travel.
FG003939
Figure 15
FG003936
Figure 17
FG003940
Figure 18
FG025863
Figure 19
3 2 1
N
N Neutral - When the lever is returned to the center
position, between forward and reverse, the
transmission is in "NEUTRAL". R
CAUTION FG006196
Figure 21
AVOID INJURY
"LOCK" transmission lever. Whenever machine is
parked, "LOCK" transmission lever in "NEUTRAL" to
prevent accidental machine movement.
WL1400844
Figure 22
FG004112
Figure 23
24 16 22 23 21 14 11 7 13 17 9 19 20 18 26
12 25
8 15
10
2 4
1 5 6
WL1400843
Figure 25
Reference Reference
Description Description
Number Number
1 Fuel Gauge Engine Coolant Temperature
5
2 Speedometer Gauge
3 Hour Meter Transmission Oil Temperature
6
Gauge
4 Tachometer
7 Transmission Display
Reference Reference
Description Description
Number Number
8 Preheat Indicator Light Emergency Steering Indicator
18
Air Cleaner Clogged Warning Light (Optional)
9
Light 19 Engine Warning Light
10 Battery Warning Light 20 Engine Stop Light
Left Turn and Hazard Warning Engine Coolant Temperature
11 21
Light Warning Light
12 High Beam Indicator Light Engine Oil Pressure Warning
22
Right Turn and Hazard Warning Light
13
Light 23 Reverse Fan Indicator Light
14 Work Light Indicator Light Electric Steering Select Indicator
24
Brake Fluid Pressure Warning Light (Optional)
15
Light Quick Coupler Release Warning
25
F/R (Forward/Reverse) Selector Light
16
Indicator Light 26 Water in Fuel Warning Light
17 Parking Brake Indicator Light
IMPORTANT
All of gauge and warning lights (except for the turn lights,
high beam light, work light and transmission cutoff light)
turn "ON" for two seconds with a warning buzzer sound
when the starter switch is turned to "I" (ON) position.
If any light fails to turn "ON" at this time, check the cause
and replace.
WL1400845
Figure 26
2. Speedometer
This meter displays speed at which vehicle is traveling.
WL1400846
Figure 27
3. Hour Meter
A LCD meter that records total time. When engine is
running, the hourglass icon blinks every four seconds. This
shows that the hour meter is working.
1
10
HA0O2012
Figure 28
WL1400847
Figure 29
CAUTION
AVOID INJURY
When the pointer indicates red zone, it means the
engine is overheated. Stop the operation, let the
engine run at low rpm and wait for it to cool down. WL1400848
Figure 30
Do not stop engine. If engine is shut down heat surge
can occur.
CAUTION
AVOID INJURY
When the pointer indicates red zone, it means the
WL1400849
transmission is overheated. Stop the operation, let the
engine run at low rpm and wait for transmission to Figure 31
cool down.
WL1400850
Figure 32
REVERSE
INDICATOR
HAAA3774
Figure 34
HAOA639L
Figure 35
HAOA660L
Figure 36
HAOA610L
Figure 37
Figure 38
Figure 39
Figure 40
Figure 41
WARNING
AVOID DEATH OR SERIOUS INJURY
HA0O2024
Never operate or travel machine when this light is
"ON" or when alarm is sounding. Always investigate Figure 42
cause of the drop in brake fluid pressure, and repair
problem before operating or traveling machine.
WARNING P
AVOID DEATH OR SERIOUS INJURY
0717A
If vehicle is moved while this light is turned "ON", it
could cause premature wear or damage the brake. Figure 44
DANGER AJO0450L
NOTE: The light will also turn "ON" when the system is
being tested.
AQO0040L
Figure 46
: Flash : Pause
AQO0010L
Figure 48
IMPORTANT Figure 50
HAOA620L
FG004185
Figure 51
FG004186
Figure 52
WARNING
AVOID DEATH OR SERIOUS INJURY
DO NOT OPERATE machine and attachment if quick FG002195
coupler switch is in "I" ( ) position. Figure 53
FG013744
Figure 54
4 5 6 7 8 9 10 11 12 13 14 15 16 17
Standard 27
1A
26
25
3
24 18 19 20 21 22 23
1
Optional WL1300311
Figure 55
Reference Reference
Description Description
Number Number
Pilot Control Valve Lever 16 Not Used
1
(Joystick) (Optional) 17 Not Used
2 Kick-down Switch 18 Boom Float Switch (Optional)
3 Horn Button 19 LIS Switch (Optional)
4 Cigar Lighter 20 Not Used
5 Not Used 21 Not Used
6 Not Used Emergency Steering Test Switch
22
7 Headlight Switch (Optional)
8 Front Work Light Switch Rotating Beacon Light Switch
23
9 Rear Work Light Switch (Optional)
10 Rear Wiper Switch 24 Power Socket for 12 Volt
11 Pilot Cutoff Switch F/R (Forward/Reverse) Selector
25
Switch (Optional)
12 Parking Brake Switch
F/R (Forward/Reverse) Control
13 Transmission Cutoff Switch 26
Switch (Optional)
14 Mirror Heating Switch
27 Cup Holder
15 Not Used
FG003940
Figure 57
FG003935
Figure 58
Figure 60
L. Lower
R. Raise
AHO0900L
Figure 62
FG003941
Figure 63
AHO0890L
Figure 64
IMPORTANT
The cigar lighter is powered by a 24 volt circuit. Never HAOA780L
plug any 12 volt device into the cigar lighter. Figure 65
5. Not Used
6. Not Used
7. Headlight Switch
O. In this position, this switch turns "OFF" clearance, tail,
instrument panel, switch and headlights.
O
NOTE: If the switch is not in this position with the
engine not running, the pilot buzzer will I
sound to warn the operator that the II
batteries are being discharged.
I. In this position, this switch turns "ON" clearance, tail,
instrument panel and switch lights. FG003976
II. In this position, this switch turns "ON" clearance, tail, Figure 66
instrument panel, and headlights.
CAUTION
AVOID INJURY
Do not leave clearance, tail, instrument panel or
headlights "ON" when the engine is not running.
Leaving lights "ON" with the engine shut down will
discharge batteries.
I
CAUTION
HAOQ071L
AVOID INJURY
Figure 67
Do not turn "ON" the work light when traveling on
public roads.
CAUTION
AVOID INJURY
Do not turn "ON" the work light when traveling on
public roads.
Figure 72
IMPORTANT
Do not use the parking brake to stop the loader, except
in an emergency; otherwise, it might cause premature
wear or damage of the brake.
WARNING
AVOID DEATH OR SERIOUS INJURY
When pressing brake pedal while traveling or working
on a slope, set this switch to "O" for dynamic engine
braking.
FG004187
Figure 74
WARNING
AVOID DEATH OR SERIOUS INJURY
Do not press this switch continuously. Continuously
pressing switch will cause heavy battery discharge.
The emergency steering DC motor has a high
consumption of power.
HAOA750L
Figure 78
R
F
O. In this position, the machine is in "NEUTRAL"
I. In this position, the machine travels "FORWARD"
I II
II. In this position, the machine travels "REVERSE"
BSO0410L
NOTE: If the transmission lever is moved out of
Figure 81
"NEUTRAL" while operating the F/R control
switch, the transmission lever will override the
switch. The F/R control switch system will
require, that the F/R selector switch to be
pressed again, with the transmission lever in
"NEUTRAL".
3
2 4
FG004191
Figure 82
Reference Reference
Description Description
Number Number
1 Cabin Light 5 Storage Compartment
2 Stereo / CD Player (Optional) 6 Windshield Washer Tank
Heater and Air Conditioner 7 Electrical Box
3
Control Panel 8 Fuse Box
4 Speakers
FG004192
Figure 83
PUSHAST
FM VOLUME TUNE SOUND
MP3 ST RDS REG TA TP PTY AF DIR INT RPT RDM EQ
USB
USB
DISP
1 INT 2 RPT 3 RDM 4 DIR 5 DN 6 UP
FG017613
Figure 84
FG003955
Figure 85
HBOM350L
Figure 86
5. Storage Compartments
There are two storage compartments (1 and 2, Figure 87) 1 2
located both sides behind of the operator's seat. Keep the
operation manual and other documents in this
compartment. 3
FG003889
Figure 87
7. Electrical Box
Contains relays and electric components. It is located on
left side of cabin.
FG003956
Figure 88
FG003959
Figure 89
5
2 2
4
FG003960
Figure 90
Reference Reference
Description Description
Number Number
1 Operation Panel 4 Foot Nozzle
2 Front Nozzle (Air Conditioner) 5 Rear Nozzle
3 Front Nozzle (Defroster)
The heater and air conditioner are combined into one unit to the
right side of the operator's seat. If necessary, the operator can
control interior cabin temperature using the operation panel.
1 4 5
2 3
FG003966
Figure 91
Reference Reference
Description Description
Number Number
1 Fan and Air Conditioner Switch Selector Switch for Wind
4
2 Blower Fan Switches Direction
3 Temperature Control Switch 5 Ventilation Selector Switch
When a switch is selected, the LED above that switch will turn
"ON" and give an activation sound.
When the light switch is turned "ON", the panel LED's will turn
"ON".
HAOC930L
Figure 92
FG006507
Figure 95
FG006508
Figure 96
FG006509
Figure 97
HAOC981L
Figure 98
Stereo
AM RDS
7
PUSH AST
FM VOLUME TUNE SOUND
8 MP3 ST RDS REG TA TP PTY AF DIR INT RPT RDM EQ 5
USB
USB
9
10 DISP
1 INT 2 RPT 3 RDM 4 DIR 5 DN 6 UP 4
1 3
2 FG017016
Figure 99
Reference Reference
Description Description
Number Number
1 Power / Volume Control 6 LCD
2 Preset Station 7 AM Selection
3 Tuning Up / Down 8 FM Selection
4 USB Loading Port 9 USB Selection
5 Sound Mode Selector 10 Display Mode Control
CD Player (Optional)
CD
TUNE
AM/FM VOLUME TRACK SOUND
MP3 ST RDS REG TA TP PTY AF DIR INT RPT RDM EQ
USB
USB
DISP
1 INT 2 RPT 3 RDM 5 DN 6 UP
4 DIR
RDS
FG017017
Figure 100
WARNING
AVOID DEATH OR SERIOUS INJURY
Whenever operator or operating condition has changed,
check to see that seating position is suitable for the
condition at hand. Always fasten your seat belt while
operating vehicle. Adjust backrest so that the operator can
fully reach and operate pedals.
HAOB110L
Figure 101
2
5
4
1 3
HBOI350L
Figure 102
7. Headrest
Headrest (7, Figure 103) can be adjusted forward/
backward and up/down. Move it by holding both sides. HAOB130L
Figure 103
WARNING
AVOID DEATH OR SERIOUS INJURY
Seat belt is for operator's safety and should always be
worn. Before driving machine, adjust seat to desired
position for maximum comfort and machine control, then
fasten seat belt. Seat belts must be worn across pelvic
region and adjusted snugly to lessen chance and severity
of injury in event of an accident. Never fasten a seat belt
across abdomen.
Under no circumstances should operator be standing in
cabin when operating wheel loader.
Do not adjust seat position while vehicle is moving because
a loss of control can result. Stop machine, apply parking
brake, and then adjust seat.
Always, check condition of seat belt and belt bracket before
fastening it. Do not use it with twists in it. Replace belt or
bracket if damaged or worn.
HAOB140L
Figure 104
Press button (3, Figure 105) in center of buckle (2) and pull out
belt (1) to unlock. 1
2
HAOB150L
Figure 105
FG003894
Figure 106
FG003895
Figure 107
FG003896
Figure 108
FG003897
Figure 109
FG003898
Figure 110
FUSE BOX/RELAY
Fuse Boxes
There are two fuse boxes inside the cabin.
Fuse boxes are on the upper side of the electric box. A usage
diagram of fuses is shown inside of fuse box. Spare fuses are
mounted on the inside of fuse box cover (10A - Qty. 1, 15A - Qty.
1, 20A - Qty. 1 and 30A - Qty. 1).
WARNING
AVOID DEATH OR SERIOUS INJURY
If any fuse is blown, turn "OFF" the starter switch and shut
off the power supply. Remedy the cause if needed and FG003971
replace the fuse with a new one.
Figure 111
FG000542
Figure 112
WL1300310
Figure 113
FG024608
Figure 114
Circuit Breaker
A circuit breaker is next to the relay by the batteries at back of
unit under engine compartment hood. When a short circuit or an
overload occurs, the circuit breaker automatically cuts off
current, thus preventing electrical wires from burning.
FG024609
Figure 115
FG024610
Figure 116
WARNING
A
AVOID DEATH OR SERIOUS INJURY
When changing the fusible link, replace the fusible link with
the same capacity part. Otherwise, a fire could break out in
the wiring harness and/or other components of the circuit.
Always use original DOOSAN parts.
HAAE2120
Figure 117
WARNING
AVOID DEATH OR SERIOUS INJURY
Before operating any wheel loader, read and understand
"Operating Controls" section of this manual.
Monitoring System
Monitoring system uses network circuits between control system
and sensors installed at various machine system locations to
monitor selected conditions. The monitoring systems function is
to continually inform the operator of machine's condition.
Displays and gauge readouts on instrument panel provide
information such as engine speed, engine coolant temperature,
transmission oil pressure, and electrical charge status.
DL420A Operation
3-1
ENGINE START AND STOP
Engine Start
1. Set parking brake switch to "I" (APPLIED) position. This
will ensure that the parking brake is "APPLIED".
O
P
I
HA0O2019
Figure 1
IMPORTANT
If transmission lever is not in "NEUTRAL" position,
engine will not start.
FG003979
Figure 2
FG003980
Figure 3
Operation DL420A
3-2
4. Set pilot cutoff switch to "O" (LOCK) position. This will
"LOCK" pilot control valve lever (joystick).
O
I
HBOI111L
Figure 4
FG001372
Figure 5
FG001372-1
Figure 6
FG024561
Figure 7
DL420A Operation
3-3
8. After engine starts, check all indicator lights and gauges to
be certain that all engine systems (oil temperature, coolant
temperature, etc.) are in normal operating range. If any
engine system is not normal, turn starter key to "OFF"
position.
Operation DL420A
3-4
Cold Weather Engine Start
1. Set parking brake switch to "I" (APPLIED) position. This
will ensure that the parking brake is "APPLIED".
P
I
HA0O2019
Figure 8
IMPORTANT
If transmission lever is not in "NEUTRAL" position,
engine will not start.
FG003979
Figure 9
FG003980
Figure 10
O
I
HBOI111L
Figure 11
DL420A Operation
3-5
5. Turn starter key to "PREHEAT" position.
O I
FG008069
Figure 12
WL1400859
Figure 13
FG001372
Figure 14
FG001372-1
Figure 15
Operation DL420A
3-6
9. Release starter key when engine starts. Key will return to
"I" (ON) position. O I
IMPORTANT
If engine does not start after approximately fifteen
seconds of cranking, release starter key. Wait five
minutes for starter motor to cool down. Repeat step 7.
FG024561
10. After engine starts, check all indicator lights and gauges to
be certain that all engine systems (oil pressure, oil Figure 16
temperature, coolant temperature, etc.) are in normal
operating range. If any engine system is not normal, turn
starter key to "O" (OFF) position.
11. Perform “Hydraulic System Warm-up – Cold Weather” on
page 3-10.
DL420A Operation
3-7
Starting with Auxiliary Batteries
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear safety glasses.
Never connect negative leads to positive terminals and vice
versa.
DO NOT connect auxiliary or booster battery ground
terminal directly to battery terminal. Locate and use a
ground point on machine frame.
Depleted batteries generate hydrogen gas. Electrical sparks
around or near batteries can cause an explosion.
Reference
Description
Number
1 Auxiliary Batteries
2 Depleted Batteries
Ground Auxiliary Batteries to Machine
3
Frame
FG003979
Figure 18
Operation DL420A
3-8
2. Make sure transmission neutral lock is in the "N"
(NEUTRAL LOCK) position.
FG003980
Figure 19
P
I
HA0O2019
Figure 20
HBOI111L
Figure 21
FG008382
Figure 22
DL420A Operation
3-9
Hydraulic System Warm-up
1. Correct operating temperature of hydraulic oil is 50° - 80°C
(120° - 175°F). Make sure to follow procedures listed
below for hydraulic fluid warm-up.
2. Run engine at idle (no load) for five minutes.
3. Run engine for approximately five minutes at middle of
speed range, without a load.
4. Cycle bucket until bucket cylinder bottoms out (extended
and retracted) without a load to circulate the oil through the
system. Do this for five minutes.
NOTE: Do not allow cylinders to pass hydraulic oil over
relief valve for more than twenty seconds at a
time.
5. Cycle boom, and bucket about five times without a load to
circulate oil through system.
MACHINE TRAVEL
WARNING
AVOID DEATH OR SERIOUS INJURY
If vehicle is moved while parking brake is engaged, serious
damage to parking brake disk will result.
Select a transmission gear that is appropriate for top speed
that will be traveled. Choosing a gear that is too high will
reduce acceleration and will unnecessarily heat
transmission converter oil.
Never place transmission in "NEUTRAL" when going down
a hill. Over speeding transmission can damage
transmission gears.
Never change direction of vehicle travel at high speed.
Serious damage to transmission will result.
Operation DL420A
3-10
1. Unlatch frame lock plate between front and rear frames
before traveling. Secure lock plate to rear frame (Figure
23).
FG006216
Figure 23
O
I
HBOI110L
Figure 24
HBOI111L
Figure 25
FG002183
Figure 26
DL420A Operation
3-11
5. Set transmission neutral lock is in the "D" (DRIVE)
position.
FG003980
Figure 27
P
I
HAOP043L
Figure 28
FG003979
Figure 29
WARNING
AVOID DEATH OR SERIOUS INJURY
When traveling at high speed or on a steep hill, do not
make sharp changes in direction. This could cause
vehicle to overturn.
FG003980
When traveling or changing direction, always look Figure 30
carefully to be certain that no one is in path of vehicle.
Operation DL420A
3-12
MACHINE SHUT DOWN
1. Ease off throttle and apply travel brakes.
FG002183
Figure 31
FG003979
Figure 32
CAUTION
AVOID INJURY
"LOCK" transmission lever. Whenever machine is
parked, "LOCK" transmission lever in "NEUTRAL" to
prevent accidental machine movement.
FG003980
Figure 33
O
P
HA0O2019
Figure 34
DL420A Operation
3-13
5. Set bucket on ground.
6. Set pilot cutoff switch to "O" (LOCKED) position. This will
lock pilot control valve lever (joystick).
7. Allow engine to idle for one - two minutes to cool down. O
Stopping a turbocharged engine without a cool down
period can seriously damage turbocharger.
I
HBOI111L
Figure 35
FG008382
Figure 36
WARNING
AVOID DEATH OR SERIOUS INJURY
Always secure machine with wheel chocks when
parked on a slope. Leaving machine in gear will
provide no braking effect because transmission clutch 2876A
is hydraulically operated. When engine is turned
Figure 37
"OFF", there is no hydraulic pressure in transmission
and clutch is not engaged.
Operation DL420A
3-14
F/R (FORWARD/REVERSE)
TRAVEL CONTROL SYSTEM
(OPTIONAL)
An optional F/R (Forward/Reverse) travel control system can be
installed as an option on the machine. With this system installed,
the operator's light-hand can remain on the steering wheel
during operation, and not have to manually move the
transmission lever between forward and reverse.
To activate system perform the following steps:
1. Place transmission lever in "NEUTRAL".
NOTE: Do not move the transmission lever out of
"NEUTRAL". If the lever is moved, the system
will be deactivated.
FG003979
Figure 38
FG008125
Figure 39
WL1400860
Figure 40
DL420A Operation
3-15
3. The F/R control switch is then used to control the travel
direction of the machine.
O. In this position, the machine is in "NEUTRAL".
I. In this position, the machine travels "FORWARD".
II. In this position, the machine travels in "REVERSE". O O
R
F
4. The F/R travel control system will stay activated until one II
of two things happen.
I
A. The transmission lever is moved out of "NEUTRAL"
into "FORWARD" or "REVERSE". BSO0410L
Figure 41
B. The starter switch is turned "OFF".
When the system is deactivated, the F/R selector indicator
light (Figure 40) will be turned "OFF".
ADDITIONAL BRAKING
Machine hydraulic system can supply additional dynamic
braking force during travel. To accomplish this, move pilot
control valve lever (joystick) to crowd position and hold it there.
Hydraulic pump will be driven to supply output at maximum
pressure (relief pressure). Energy expended to drive pump, will
slow engine speed. Additional dynamic braking, along with
proper gear selection, can be used to slow a vehicle that is being
driven down an incline.
Operation DL420A
3-16
BOOM RAISE KICK-OUT
Placing bucket lever in "Boom Raise Detent" position will lock
bucket lever in raise boom position. Boom will raise until trip
plate (1, Figure 42) makes contact with bucket height limit switch 2
(2, Figure 42). When limit switch is tripped, boom will stop
raising and bucket lever will automatically be returned to
"NEUTRAL" position. Trip plate can be adjusted to control
maximum height that boom can be raised.
1
FG024796
Figure 42
IMPORTANT
Trip plate (1, Figure 44) must always be set to contact limit
switch (2) before boom cylinders reach maximum
extension. Maximum extension causes pump to force fluid
over relief valve.
FG024793
Figure 44
DL420A Operation
3-17
BOOM LOWER KICK-OUT
(OPTIONAL)
Placing bucket lever in "L" position will lock control lever in lower
boom position. Boom will move downward until trip plate (1,
Figure 45) makes contact with bucket lower limit switch (2,
Figure 45). When limit switch is tripped, boom will stop lowering
and bucket lever will automatically be returned to "NEUTRAL"
position. Trip plate can be adjusted to control maximum height
that boom can be lowered. 2
1
IMPORTANT
FG024798
Trip plate must always be set to contact limit switch before Figure 45
boom cylinders reach maximum extension. Maximum
extension causes pump to force fluid over relief valve.
ADJUSTMENT OF BUCKET
POSITION SWITCH
When bucket lever is held in crowd detent position, after bucket
has been dumped, bucket will pivot toward crowd position. Once
full crowd position has been reached, bucket lever will
automatically return to "NEUTRAL" position. If bucket is lowered
after lever returns to "NEUTRAL", bucket will automatically
position itself to be in a preselected digging position (usually
flat). To adjust bucket to desired preselected digging position,
perform the following steps.
1. Operate controls to place bucket on ground and in desired 3
1
digging position (usually flat). Return bucket lever to its 2 4
"NEUTRAL" position. FG024795
Figure 46
2. Stop engine.
3. Loosen bolts (1, Figure 46) on bracket (2, Figure 46).
4. Position bracket (2, Figure 46) so that end of arm (3,
Figure 46) is aligned with center of magnetic switch (4,
Figure 46).
5. Tighten bolts (1, Figure 46).
6. Start engine. Raise boom, dump bucket, then move bucket
lever into crowd detent position. Now lower boom and
check to see that bucket has stopped at required position.
A small readjustment of bracket (2, Figure 46) may be
necessary.
Operation DL420A
3-18
TOWING MACHINE
When necessary to tow another vehicle, the tow rope must be
tied to the towing pin on the counterweight at the rear of vehicle.
NOTE: The loader must be used for towing only in an
emergency.
WARNING
AVOID DEATH OR SERIOUS INJURY
Do not tow machine at a speed over 10 km/h (6 MPH) and do FG001662
not tow machine farther than 10 km (6 mi). This will prevent Figure 47
damage to machine transmission that would result from
lack of lubrication.
WARNING
AVOID DEATH OR SERIOUS INJURY
When towing another vehicle on a public road, take
necessary measures to let other vehicles and people know
that you are towing another vehicle. Use a flag, rotating
beacon light, or hazard light.
DL420A Operation
3-19
When towing make sure you are doing the following:
• Start slowly. A sudden start can lead to a broken tow rope.
• The tow line must be along the center line of both your
loader and the vehicle to be towed.
• If you use any other towing device, refer to the Instruction
Manual supplied with the towing device.
• If it is difficult to tow the loader, transport it by a trailer truck
to your nearest repair shop.
• In addition to the above measures, release the parking
brake if the engine will not start or the hydraulic pumps are
defective.
CAUTION
AVOID INJURY
Avoid use of the loader in salt water. Salt water will
cause the development of rust which will shorten the
life of the loader.
Operation DL420A
3-20
OPERATION UNDER
ABNORMAL CONDITIONS
NOTE: See “Severe Conditions Maintenance” on page 4-72
for other recommendations.
WARNING
AVOID DEATH OR SERIOUS INJURY
Explosion of the battery may cause serious injury or
death. Never attempt to directly heat the battery with
open fire.
DL420A Operation
3-21
5. Always keep the fuel tank fully filled after completion of the
operation. Always drain water from the fuel tank before and
after the operation. In addition, check the water separator,
and drain it if required. The fuel filter, if frozen, may
interrupt the flow of fuel. Periodically remove water from
the fuel tank, drain water from the filter, and replace the
filter upon regular basis. To prevent fuel from being
clogged due to formation of wax in fuel, make sure that
wax formation point of fuel is lower than atmospheric
temperature.
WARNING
AVOID DEATH OR SERIOUS INJURY
Explosion of the fuel tank may cause serious injury or
death. Never attempt to directly heat the fuel tank with
open fire.
Operation DL420A
3-22
Operation in Extreme Heat
Continuous operation of machine in high temperatures can
cause machine to overheat. Monitor engine and hydraulic
system temperatures and stop machine to let it cool, when
necessary.
1. Make frequent inspections and services of fan and
radiator. Check coolant level in radiator. Check grilles and
radiator fins for accumulation of dirt, debris and insects
which could block cooling passages.
• Formation of scale and rust in cooling system occurs
more rapidly in extremely high temperatures. Change
antifreeze each year to keep corrosion inhibitor at full
strength.
• If necessary, flush cooling system periodically to
keep passages clear. Avoid use of water with a high
alkali content which increases scale and rust
formation.
2. Check level of battery electrolyte daily. Keep electrolyte
above plates to prevent damage to batteries. Use a slightly
weaker electrolyte solution in hot climates. Batteries
self-discharge at a higher rate if left standing for long
periods at high temperatures. If machine is to stand for
several days, remove batteries and store in a cool place.
IMPORTANT
Do not store acid type storage batteries near stacks of
tires. Acid fumes can damage rubber.
DL420A Operation
3-23
terminals with ignition insulation compound. Apply
paint or suitable rust preventive to damaged surfaces
to protect them from rust and corrosion.
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear goggles when using compressed air to prevent
face or eye injury.
Operation DL420A
3-24
2. Keep all exposed surfaces coated with preservative
lubricating oil. Pay attention to damaged paint surfaces.
3. Keep all painted surfaces in good repair.
4. Lubricate machine as prescribed on lubrication chart on
machine or Periodic Service Table and Chart, Section 4, in
this manual. Shorten lubricating intervals for parts exposed
to salt water.
5. Check operating controls to ensure proper functionality
and that they return to "NEUTRAL" when released.
DL420A Operation
3-25
Operation DL420A
3-26
5Inspection, Maintenance
and Adjustment
BASIC PREVENTIVE
MAINTENANCE
For the machine to function satisfactorily and at lowest possible
cost, a thorough maintenance program is required. This section
of the manual describes the maintenance work which the
operator can carry out. If certain operations require trained
workshop personnel and special equipment, this will be
indicated.
The intervals recommended between checks, oil changes and
lubrication apply provided that the machine is used under
normal environmental and operating conditions. See
“Lubrication and Service Chart” on page 5-19
Figure 1
Delivery Instructions
When handing the machine over, the dealer must give the buyer
"Delivery Instructions" according to applicable form, which must
be signed, if the warranty is to apply.
Warranty Inspection
Two Warranty Inspections must be carried out if the warranties
are to apply. The first within 100 operating hours and the second
at the latest at 1000 operating hours.
The carrying out of these inspections is a condition for the
warranty to apply.
Condition Test
A "Condition Test" is carried out at authorized dealer workshops
and provides information about the general condition of the
machine.
23 22
24
7 17 18 19 21
1 2 3
16 4 5
6
20
15 14 13 12 11 10 9 8 7
FG024690
Figure 2
Reference Reference
Description Description
Number Number
1 Breather of Hydraulic Oil 13 Suction Strainer, Transmission
2 Filling Point, Hydraulic Oil 14 Oil Filter, Transmission
3 Air Cleaner Return Oil Filter 15 Filling Point, Transmission
4 Level Sight Gauge Hydraulic Oil 16 Filing Point, Washer Fluid
5 Draining, Hydraulic Oil 17 Pre Fuel Filter
6 Filling Point, Coolant 18 Filling Point, Engine
7 Battery 19 Oil Dipstick
8 Filling Point, Fuel 20 Pilot Filterl
9 Draining, Coolant 21 Ventilation Filters, Cabin
10 Draining, Coolant 22 Pre Cleaner
11 Main Fuel Filter 23 Air Cleaner
12 Oil Filter, Engine 24 Alternator Belt
WARNING
AVOID DEATH OR SERIOUS INJURY
If work has to be carried out on the machine before it has
cooled down, care must be observed with regard to risk of
burns from hot liquids and hot machine parts.
2 4
3
6 7
FG0025211
Figure 3
Reference
Description
Number
1 The bucket/attachment must be resting on the ground.
2 Apply the parking brake.
Stop engine and take out the ignition key. (Does not apply when checking oil level in
3
transmission).
4 Carefully release the pressure in pressure lines and pressure vessels to avoid risks.
5 Attach a black and yellow "Warning Tag" to the steering wheel.
6 Connect the frame joint lock.
7 Block the wheels in a suitable way (with, for example, wedges).
8 Allow the machine to cool.
Figure 4
Figure 5
Floor Rubber
Observe extra great care when it is suspected that you may
have to handle floor rubber.
Certain seals which have to withstand high operating
temperatures (e.g. in engines, transmissions, axles, hydraulic
motors and pumps) may be made from floor rubber, which,
when exposed to high heat (fire), forms hydrogen fluoride and
hydrofluoric acid. This acid is very corrosive and cannot be
rinsed or washed off from the skin. It causes very severe burns
which take a long time to heal.
It usually means that damaged tissue must be surgically
removed. Several hours may pass after contact with the acid,
before any symptoms appear and therefore one is not given any
immediate warning. The acid may remain on the machine parts
for several years after a fire.
If swelling, redness or a stinging feeling appears and one
suspects that the cause may be contact with heated floor rubber,
contact a medical doctor immediately. If a machine, or part of a
machine, has been exposed to fire or severe heat, it must be
handled by specially trained personnel. In all handling of
machines after a fire, thick rubber gloves and effective goggles
must be used.
The area around a part which has been very hot and which may
be made of floor rubber must be decontaminated by thorough
and ample washing with lime water (a solution or suspension of
calcium hydroxide, i.e. slaked lime in water). After the work has
been completed, gloves must be washed in lime water and then
discarded.
MODEL
⣆㔲ᬯ
Figure 9 WL1300289
The number is also stamped in the rear frame on the right side
just below the cabin (Figure 10).
FG025213
Figure 10
eki
left rear of the engine block, under exhaust manifold.
da
10
.9
10 10 10 10
.9 .9 .9 .9
FG026012
Figure 11
Safety Precautions
1. Before performing any maintenance checks, move pilot
cutoff switch to "LOCKED" position. Place a Warning Tag
on controls so that no one begins to operate machine while
maintenance checks are being performed.
2. Clean up all fuel spills. Fuel spills are hazardous,
especially around engine.
3. Inspect all fuel lines for leakage. Replace any lines, fittings,
O-rings, or filters that show signs of wear or damage.
4. If a test procedure requires engine to be running, use two
people and keep all unnecessary personnel away from
machine.
IMPORTANT
It is highly recommend to use DOOSAN Genuine Products,
or products which meet the specifications below. Using
other products can damage equipment.
Ambient Temperature
Kind of
Reservoir -58 -40 -22 -4 14 32 50 68 86 104 122 °F
Fluid
-50 -40 -30 -20 -10 0 10 20 30 40 50 °C
ISO VG. 15
ISO VG. 32
Hydraulic Oil ***
Tank Hydraulic Oil
ISO VG. 46
ISO VG. 68
Cooling
Coolant * (50% antifreeze - 50% distilled water)
System
IMPORTANT
Unsuitable grease choice causes the fault of low level
monitoring in the pump.
Check the grease quantity in the central lubrication
pump before starting a machine.
°C °F
Grease Type NLGI Grade
Min. Min.
SAE 15W40
API CD-4 and above
Same as engine oil
NOTE: Oil grade for transmission is different from engine oil
grade (CH-4 and above).
Antifreeze
Recommended Concentration Manufacturers Meeting ASTM D3306
DOOSAN Genuine Solution
Dexcool ELC by Chevron Texaco
50% Antifreeze - 50% Distilled Water
Alugard G48 by BASF
Others meeting or exceeding ASTM D3306
IMPORTANT
Do not mix oils from different manufacturers. DOOSAN
does not endorse specific brands but does recommend that
owners select quality oils whose manufacturers provide
assurance that the required standards will always be met or
exceeded.
IMPORTANT
Fluctuating daily or weekly extremes of temperature, or
operation in subzero freezing weather, may make it
impractical to use straight weight lubricants. Select
lubricant types that are appropriate for climate conditions.
Load Class
Greasing Bearing
The service life of bushings and pivot pins can be extended
considerably, if the machine is greased regularly and in the
correct way.
The greasing of bearings has two main purposes:
• Add grease to the bearing to reduce friction between pin
and bushing.
• Replace old grease which may contain dirt. The grease in
the space inside the outer seal collects dirt and prevents
dirt and also water from penetrating into the bearing.
Therefore, grease the bearing until new, clean grease is forced
out through the outer seal.
Between 10 and 15 strokes with a normal handheld grease gun
is required to grease one of the bearings for the lifting arms.
Wipe off grease fittings and grease gun before greasing, so that
dirt and sand is not introduced through the grease fittings.
15 18 21 21 2 1
2000h
1500h
1000h
500h
250h
50h
10h
16
3 7
6
4
19
19
5
9
1
23
14
10 8
11
10h
50h
250h
500h
1000h
1500h
2000h
1 1,4 12 22 13 FG024697
Figure 12
WL1300302
Figure 13
HAOC280L
Figure 14
HAOC280L
Figure 16
WARNING
AVOID DEATH OR SERIOUS INJURY
The hydraulic oil will be hot after machine operation. Allow
system to cool before attempting to service any of the
hydraulic components.
The hydraulic tank is pressurized. Press button in center of HAOA060L
breather to allow the pressurized air to vent. After the Figure 17
pressure has been released, it is safe to remove either the
fill cap or service covers.
FG001623
Figure 18
5. To add hydraulic oil, turn breather cap (1, Figure 19) slowly
to allow pressurized air to vent.
6. Remove upper cover (2, Figure 20) from hydraulic oil tank
and raise boom at max. height and replenish oil to the top
of sight gauge (Figure 18).
IMPORTANT
1 2
The hydraulic oil fill cover also serves as the hydraulic oil
strainer access cover. It is important to replace this cover and 4
the components in the proper order and alignment.
The filter (2, Figure 20), retaining rod (3) and spring (4) are 3
assembled as shown in Figure 20. The hole (1) in the base of
the filter fits over a circular base in the bottom of the tank. The
retaining rod (3) screws into the top of the filter (2), but the
spring (4) slides over the top of the rod. Be certain that this 2
spring does not fall into the tank during reassembly.
1. If filter assembly was removed, insert assembly into the FG002188
1
tank and check to make sure it is securely in place.
Figure 20
FG002189
Figure 21
WARNING
AVOID DEATH OR SERIOUS INJURY
Use extreme safety precautions while refueling to prevent
explosions or fire.
Immediately clean up any spilt fuel. FG001689
Figure 22
1. At end of each work day, fill fuel tank. Add fuel through fuel
fill cap (Figure 22). When working at a temperature of 0°C
(32°F) or higher, use ASTM No. 2-D or its equivalent. At
temperatures below 0°C (32°F) use ASTM No. 1-D or its
equivalent.
2. Securely tighten cap after fueling.
NOTE: If breather holes in cap are clogged, a vacuum
may form in the tank preventing proper fuel flow
to engine. Keep holes in fuel cap clean.
FG001690
Figure 23
FG026407
Figure 24
WARNING FG001692
Figure 25
AVOID DEATH OR SERIOUS INJURY
Allow the engine to cool before opening the radiator cap.
Loosen the cap slowly to release any remaining pressure.
Figure 26
FG001693
Figure 27
IMPORTANT
Cold weather operation requires that the operator fully
warm up the hydraulic oil before beginning machine
operation. Follow all warm up instructions listed in the
Operating Instruction section of this manual. Make sure to
cycle oil through all of the components, including all
cylinders, both travel motors and the swing motor. Cold
hydraulic oil in the lines and components needs to be
warmed before beginning full operation. If this is not done,
damage to the cylinders or hydraulic motors can occur.
WARNING
AVOID DEATH OR SERIOUS INJURY
Personal injury can result from a fan blade failure. Never
pull or pry on the fan. This can damage the fan blade(s) and
cause fan failure.
WARNING
AVOID DEATH OR SERIOUS INJURY
When checking, adjusting or replacing drive belts, care
must be taken to prevent accidental cranking of the engine.
Be sure the starter switch is in the "O" (OFF) position and
the controls are tagged.
WARNING
AVOID DEATH OR SERIOUS INJURY
Hot engine components can cause burns.
Avoid contact with hot engine components.
HAOA050L
1. Park the machine on a level surface, apply the parking Figure 31
brake, lower the attachment to the ground, and stop
engine.
2. Check the engine intake hose, and hose clamps for
damage and tightness.
3. If damaged, wrinkled or loose, replace, tighten or contact
your nearest DOOSAN loader dealer.
IMPORTANT
Severe engine damage will result from running with
unfiltered air.
Do not operate engine if any leaks or defects are found Figure 32
on air intake system.
Figure 33 FG025214
FG025997
Figure34
FG001697
Figure 35
FG002237
Figure 36
FG024574
Figure 37
FG024577
Figure 38
FG024578
Figure 39
2
FG006255
Figure 40
FG017601
Figure 41
Pivot Cover
Rear Pivot
Front Pivot
FG006257
Figure 42
FG006246
Figure 43
FG024699
Figure 44
FG001641
Figure 45
FG001642
Figure 46
Figure 48
WARNING
AVOID DEATH OR SERIOUS INJURY
All service and inspection of the air-conditioning
system must be performed with the starter switch in
the "O" (OFF) position.
Braking - Test
WARNING
AVOID DEATH OR SERIOUS INJURY
• Fasten your seat belt when testing the brake system.
• Park the machine on firm and level ground.
• Check the area around the machine to ensure it is
clear of all personnel and bystanders.
• Make sure that articulated frame lock is in the
unlocked position.
WL1400677
Figure 49
P
I
HA0O2019
Figure 50
HA3O2018
Figure 51
R
FG019004
Figure 52
WARNING
AVOID DEATH OR SERIOUS INJURY
If the machine begins to move during the test, reduce
the engine speed immediately and engage the parking
brake. WL1400678
Figure 53
8. Reduce the engine speed to low idle. Move the 1. Brake Pedal
transmission lever to the neutral position. Engage the
parking brake. Lower the work equipment to the ground. 2. Accelerator Pedal
WARNING
AVOID DEATH OR SERIOUS INJURY
• Keep the heavy end of the machine uphill.
• Do not travel on slopes greater than 30 degrees.
• Do not exceed Rated Operating Capacity (ROC).
• Check for adequate traction.
4. Drive the wheel loader up the incline with the heavy end of
the machine facing uphill. (Figure 54)
WL1400681
Figure 54
WL1400677
Figure 55
HA3O2018
Figure 56
P
I
HA0O2019
Figure 57
WARNING
AVOID DEATH OR SERIOUS INJURY
If the machine begins to move, immediately reapply
the service brake.
9. Apply the service brake and release the parking brake. WL1400679
Figure 58
Move the machine to a flat area.
10. Reduce the engine speed to low idle. Move the
transmission lever to the neutral position. Engage the
parking brake. Lower the work equipment to the ground.
11. Stop engine. Remove key.
If the machine moved during the test, contact your dealer for a
brake inspection. Make any necessary repairs before the
machine is returned to operation.
FG014041
Figure 59
WARNING
AVOID DEATH OR SERIOUS INJURY
Be certain that hydraulic oil has cooled before draining
water and sediment. Hot oil could splash and cause burns.
The hydraulic tank is pressurized. Unscrew the cap of
breather on the top of hydraulic tank to allow pressurized
air to vent. After pressure has been released, it is safe to
remove either the fill cap or service covers.
FG002211
Figure 60
Grease Driveshafts
Grease fitting for center bearing, 1 location. Use remote grease
fitting mounted on front frame (3, Figure 62). 1
FG002212
Figure 63
3
1 FG000702
Figure 66
WARNING
AVOID DEATH OR SERIOUS INJURY
If using compressed an to clean the filter, make sure
that proper eye protection is worn.
HAOC570L
Figure 67
CAUTION
AVOID INJURY
Never attempt to change oil or filter on a hot engine. Hot oil
could splash and cause burns. Allow engine to cool down
before changing oil or filter.
FG025710
Figure 71
HA0O5042
Figure 72
WARNING
AVOID DEATH OR SERIOUS INJURY
Exchange filter after waiting for engine to cool. Be careful of
fire hazards. Do not smoke.
FG026004
Figure 75
WARNING
AVOID DEATH OR SERIOUS INJURY
All service and inspection of the air-conditioning
system must be performed with the starter switch in
the "O" (OFF) position.
Air Cleaner
CAUTION
AVOID INJURY
Never remove air cleaner filter while engine is running. This
will allow dirt to be sucked into engine and cause serious
engine damage. Always turn engine "OFF" before servicing
air cleaner.
WL1300297
Figure 77
CAUTION
AVOID INJURY
Never clean the inside of air filter housing while the inner
filter is not installed.
Secondary Filter
Replace the filter every 2,000 hours or when the main filter has
been replaced three times.
The filter cannot be cleaned, but must be replaced.
The secondary filter works as a protective filter if the main filter is
damaged.
Never remove the secondary filter unless it is to be replaced.
Figure 79
CAUTION 2
AVOID INJURY
Never remove air cleaner element while engine is running.
4
This will allow dirt to be sucked into engine and cause
serious engine damage. Always turn engine "OFF" before 1
servicing air cleaner. FG000425
Figure 80
1. Open the side access cover at the rear of the cabin.
2. Remove the evacuator valve (1, Figure 80) and air cleaner
cover (2, Figure 80).
NOTE: Inspect evacuator valve seal lips for wear or
damage. Replace valve if necessary. Install
evacuator valve with lips parallel to the cover.
3. Remove outer filter (4, Figure 80) from the air cleaner
housing.
4. Clean the air cleaner cover and the inside of the air cleaner
housing. Do not use compressed air to blow out housing.
5. Install new outer filter.
6. Install air cleaner cover and evacuator valve.
NOTE: Make sure that all gaskets on wing nuts and
cover are properly installed and seated.
Figure 82
12. Fill transmission with fluid through fluid supply pipe. Add
fluid until fluid level reaches low mark on dipstick.
13. Start engine. Idle engine for two minutes.
14. With engine idling, check transmission fluid level. Add fluid
until level reaches high mark on dipstick.
15. Idle engine until transmission fluid temperature reaches 82
– 93°C (180 – 200°F). Check fluid level with engine idling.
Level must reach high mark on dipstick.
16. Check filter for leaks while engine is running.
Figure 83
WARNING
AVOID DEATH OR SERIOUS INJURY
Fuel is flammable and harmful to skin.
• Do not smoke while draining moisture and
sediment from fuel tank.
• Do not drain fuel with engine running.
• Do not allow fuel to remain on skin for an
extended period of time. Wash thoroughly with
soap and water.
WARNING
AVOID DEATH OR SERIOUS INJURY
Mixing of tobacco smoke and freon is deadly.
Do not smoke while servicing or recharging
air-conditioning system.
IMPORTANT
Overfilling refrigerant can cause dangerous
high-pressure and poor cooling action; and low
refrigerant level can cause compressor damage.
Always maintain refrigerant at normal level. FG025856
Figure 86
Amount of
Appearance of the Sight Glass Solutions
Refrigerant
Almost clear.
Normal Any bubbles disappear if the engine
speed is increased to 1,500 rpm.
WARNING
AVOID DEATH OR SERIOUS INJURY
The hydraulic oil will be hot after normal machine
operation. Allow system to cool before attempting to
service any of the hydraulic components.
The hydraulic tank is pressurized. Loosen hydraulic oil fill
cap slightly to allow pressurized air to vent. After pressure
has been released, it is safe to remove either the fill cap or
service covers or drain water from the tank.
IMPORTANT
Make sure to clean any dirt or water from top of the
hydraulic tank, especially around fill port and filter ports.
WARNING
AVOID DEATH OR SERIOUS INJURY
External shock or damages to fuel cap may lead to
permanent damage to filter.
FG019059
Figure 89
FG015684
Figure 90
FG015685
Figure 91
FG015686
Figure 92
FG015687
Figure 93
FG015688
Figure 94
FG002222
Figure 97
FG002219
Figure 98
FG008078
Figure 99
CAUTION
AVOID INJURY
Never remove air cleaner element while engine is running.
This will allow dirt to be sucked into engine and cause
serious engine damage. Always turn engine "OFF" before
servicing air cleaner.
WARNING
AVOID DEATH OR SERIOUS INJURY
Allow the engine to cool before releasing the radiator cap.
Make sure to loosen the cap slowly to release any
remaining pressure.
Radiator cleaning is performed while the engine is running.
Take extreme caution when working on or near a running FG002206
engine. Make sure to lock out and tag the controls notifying
personnel that service work is being performed. Figure 100
IMPORTANT
Do not mix ethylene glycol and propylene glycol when
changing the antifreeze solution. Flushing must be
performed to minimize volume of mixing between the two
columns. Mixing the two compounds can cause generation
of foreign which can to damage the system.
Do not mix antifreeze solutions from different
manufacturers. Mixed solution may degrade the capabilities
of the system. It is recommended to use the standard
product from DOOSAN.
In bitterly cold working conditions, the customer should
frequently check the performance of the coolant for
appropriateness for the weather and then determine change
cycle of the coolant.
CAUTION
AVOID INJURY
Be certain that hydraulic oil has cooled before draining it.
Hot oil could splash and cause burns.
FG004076
Figure 103
FG024954
Figure 104
FG024957
Figure 105
FG023228
Figure 107
FG024846
Figure 108
Bleed Brakes
When brake hoses or brake tubes are replaced, air can be
introduced into brake hydraulic system and can cause brakes to
operate intermittently. Never operate machine with air in brake
hydraulic system. A spongy feel when pressing brake pedal is a
sign that air is present in the brake hydraulic system.
To bleed air out of brake hydraulic system, perform the following
steps:
1. Start engine and place transmission in "NEUTRAL".
FG002224
Figure 109
WARNING
AVOID DEATH OR SERIOUS INJURY
Pressurized Nitrogen gas in brake accumulator may
explode causing serious injury or death.
Never service brake accumulator unless properly trained.
WARNING
AVOID DEATH OR SERIOUS INJURY
Before starting any battery service work, make sure to shut
the engine off and turn the starter key to "OFF" position.
The batteries create hydrogen gas. An explosion hazard
exists, particularly with a deeply discharged battery. Make
sure that open flames, burning objects or sparks are kept
away from the battery compartment.
Battery electrolyte is diluted sulfuric acid. Take extreme
caution when handling the batteries. The electrolyte can
cause severe chemical burns. If any electrolyte gets on
your clothing or skin, wash it off immediately with large
quantities of water. If the electrolyte gets into your eyes,
flush them immediately with a large quantity of water and
seek immediate medical attention.
When installing a battery, wear safety goggles at all times.
When removing a battery, remove negative (-) or ground
terminal first, and then the positive (+) terminal. This will
prevent sparks or arcing that could cause an explosion.
When installing a battery, connect the positive terminal first
and then the negative terminal. Make sure to fully tighten
the terminal clamps.
General
Keeping an engine's cooling system in peak operating condition
can have many benefits in keeping a machine in good operating
condition. A properly functioning cooling system will improve fuel
efficiency, reduce engine wear, and extend component life.
Always use distilled water in the radiator. Contaminants in tap
water neutralize the corrosion inhibitor components. If tap water
must be used, Refer to “Table of Standards for Allowed Tap
Water” on page 4-78. Water that has been treated with a water
softener also contains salt that will cause corrosion of
components. Water from creeks and stagnant pools usually
contain dirt, minerals and/or organic material that are deposited
in the cooling system and impair cooling efficiency. As such, the
use of distilled water is recommended.
Engine coolant shall be mixed with antifreeze solution and water
in ratio of 50 : 50.
Coolant shall be checked every 500 hours of operation for
ensuring adequate concentration of antifreeze solution and
additives.
Engine overheating is often caused by bent or clogged radiator
fins. The spaces between the fins can be cleaned by use of air
or water under pressure. When straightening bent fins, use care
not to damage the tubes or break the bonding joint between the
fins and the tubes.
WARNING
AVOID DEATH OR SERIOUS INJURY
Pressure at air nozzle must not exceed 2 kg/cm2 (28 psi).
Always wear goggles when using compressed air.
Do not pour cold water into radiator when engine is hot and
water level is below the top of the tubes. Such action could
result in damage to engine cylinder heads.
IMPORTANT
Do not mix solutions from different manufacturers.
Otherwise, the performance may be deteriorated. It is
recommended to use the standard product from DOOSAN.
In extreme temperatures, the performance of the coolant
must be checked frequently and the coolant change cycle
adjusted as necessary.
Engine parts that are made of aluminum are quickly worn
out by nitrite, and therefore you should make sure to use
nitrite-free coolant.
CAUTION
AVOID INJURY
The standard of tap water is for reference only, and may not
be regarded as a standard.
If quality of the water is not trustable, stop using tap water
whenever possible and use distilled water.
WARNING
AVOID DEATH OR SERIOUS INJURY
Even though the engine is stopped, the hydraulic
accumulators for the pilot, brake and LIS system are still
charged. Do not disconnect any hoses until accumulator
pressure has been released from the circuit. To release
pressure, turn the starter switch to "I" (ON) position and
operate pilot control valve lever and brake pedal. Even
though the engine is stopped, components actuated by
hydraulic pressure may move while releasing pilot
pressure. Keep all personnel and bystanders away from
machine while performing this operation.
• Set pilot cutoff switch to "O" (OFF) position after
stopping engine.
• Do not mishandle accumulators. They contain
high-pressure nitrogen gas.
• Do not punch a hole or apply heat or fire to
accumulators.
• Do not weld on accumulators, or try attaching
anything to them.
• When replacing an accumulators, contact a DOOSAN
distributor to ensure that the gas is properly released.
• Wear safety goggles and protective gloves when
working on an accumulator. Hydraulic oil under the
pressure can penetrate the skin and cause serious
injuries.
Figure 113
Reference 3 2 1
Description Pressure
Number
30 bar
1 Pilot Pressure (TP1)
(31 kg/cm2)
Brake Charging Pressure 120 bar above
2 4 5 6
(TP2) (122 kg/cm2)
200 bar FG026358
3 Main Pump Pressure (TPM)
(204 kg/cm2)
Figure 115
Steering Pump Pressure 200 bar
4
(TPU) (204 kg/cm2)
Transmission Clutch 16 bar
5
Pressure (TM) (16 kg/cm2)
6 Steering LS (TPSLS) 185 bar
FG026359
Figure 116
FG005115
Figure 117
(228+28
0 psi).
FG005115
Figure 118
FG002231
Figure 121
FG026011
Figure 122
Standard
Fan Motor Pressure 185 ± 5 bar
(189 ± 5 kg/cm2)
Fan rpm 1,550± 50 rpm
2
FG024722
Figure 123
Reference Reference
Description Description
Number Number
1 Fan Motor 4 Outlet Line
2 Fan Guard 5 Relief Valve
3 Inlet Line
Cleaning
Pressure wash machine. Inspect machine for any damage or
missing parts. Drive machine to check steering linkage for
damage.
Hydraulic System
Start engine and allow it to idle for a few minutes. Drive machine
around for two - three minutes. Raise and lower boom two -
three times. Crowd and dump bucket two - three times. This will
circulate hydraulic fluid through all hydraulic systems.
Lubrication
Perform all daily maintenance procedures listed in this section
(Section 4.) Grease all grease fittings in steering linkage. Apply
a coating of light oil to all exposed cylinder rods. Apply a coating
of light oil to all control linkages and all control valve spools.
Check condition of oil coating each month and add to coating
where necessary.
Battery
Disconnect cables from battery, or remove battery from
machine. If battery is removed, fully charge battery and store it.
Inflating Tires
Recommended tire pressures should normally be followed.
Special operations may justify a different pressure. In such
cases, follow the instructions from the tire manufacturer and do
not exceed the maximum permissible pressures, (See page
5-88)
The tire pressure may have been raised before the machine was
delivered from the factory. Therefore, check and adjust the tire
pressure according to recommendations, before putting the
machine to work for the first time.
WARNING
AVOID DEATH OR SERIOUS INJURY
Repair work on tires and rims must be carried out by
persons who have been especially trained for this.
The instructions stated below apply to an inflated tire where
the pressure needs to be increased. If the tire has lost all
pressure, a trained service engineer must be called in.
• When checking the air pressure, the tire must be cold and
the machine not have a load.
• Ask all other persons to leave the danger area (in front of
the rim).
• Stand by the tire tread as shown in the figure. Tire installed
on a split rim may explode causing injury or in the worst
case death.
• Use a long air hose (with a self attaching air chuck) which
allows you to stand outside the danger area.
• Tires on stored wheels (spare wheels) must be kept laying
down on their side, and only be inflated sufficiently to keep
the rim parts in position.
WARNING
AVOID DEATH OR SERIOUS INJURY
If a wheel and tire must be removed from machine and
replaced, or if a tire must be replaced on wheel, allow this
task to be performed only by experienced service
personnel. A tire rim could be propelled off wheel and
cause serious bodily injury or death. See Figure 124.
Figure 124
WARNING
AVOID DEATH OR SERIOUS INJURY
Improper servicing or changing tires and rims can cause
explosion resulting in serious injury or death.
Do not service or change tires and rims unless properly
trained and equipped.
Contact your nearest DOOSAN loader dealer or tire
manufacturer's local dealer for tire servicing or changing.
WARNING
AVOID DEATH OR SERIOUS INJURY
An overheated tire may explode causing serious injury or
death.
If overheated tire is suspected, do not approach tire to
distance of less than 15 m (50 ft).
Stay away until tire and rim cool down.
4.1 +0.1
+0
Bar 3.5 +0.1
+0
Bar 4.1 +0.1
+0
Bar 3.5 +0.1
+0
Bar 26.5-25-20PR
Bias Ply Tire
(60 +2 psi) (50 +2 psi) (60 +2 psi) (50 +2 psi) (Standard)
+0 +0 +0 +0
3.5 +0.1
+0
Bar 3.0 +0.1
+0
Bar 3.5 +0.1
+0
Bar 3.0 +0.1
+0
Bar 26.5R25
Radial Ply Tire
(50 +2 psi) (44 +2 psi) (50 +2 psi) (44 +2 psi) (Optional)
+0 +0 +0 +0
TRANSPORTING MACHINE
WARNING
AVOID DEATH OR SERIOUS INJURY
When transporting the machine, know the width, height,
length, and weight.
When loading or unloading the machine, make sure to run
the engine at the lowest speed setting and travel at the
slowest speed possible.
Machine must be operated by a qualified operator.
Make sure that ramp being used can handle the weight of
the machine. If required, add blocking under the ramp for
additional support.
Make sure that the ramp surface is free of grease, debris, or
mud that could cause the machine to slip or slide.
Make sure that trailer is parked on firm, and level ground
before attempting to load/unload the machine.
Never correct your steering on the ramps. There is a danger
that the machine may tip over. If necessary, drive off the
ramps or back on to the bed of the trailer and correct the
direction.
Make sure to secure the machine onto the trailer as
required by local transportation laws and regulations.
DL420A Transportation
5-1
4. Set the travel direction toward the ramps and drive slowly
for loading.
5. Load the machine correctly in the specified position on the
trailer.
6. Set parking brake switch to "I" (ENGAGED) position. O
P
(Figure 2).
I
HA0O2019
Figure 2
HBOI110L
Figure 3
FG001364
Figure 4
FG028839
Figure 5
Transportation DL420A
5-2
12. Turn battery disconnect switch to "OFF" direction (Figure 6).
13. Lock all doors and covers.
14. Adjust direction of rotating beacon and TMS antenna.
ON OFF
FG020630
Figure 6
15. Make sure to secure the machine onto the trailer before
transporting. Use the wheel chocks (1, Figure 7) supplied
with the machine to secure machine. Tie front and rear tie
down point (3, Figure 8) on the frame with wire cables or
2
chains as required by local transportation regulations.
IMPORTANT
When tying down the machine, ensure machine does 1
not come into contact with cables and chains. Machine FG028820
can be damaged by inappropriate tie down method. Do Figure 7
not use the cylinder as tie down points.
3
3
3
FG028822
Figure 8
DL420A Transportation
5-3
Unloading
1. Make sure that trailer is parked on firm and level ground.
See Figure 9.
2. Make sure that ramps that are being used are designed to
handle the weight of the machine. If required, add blocking
under the ramp to provide additional support.
3. The ramp angle must be less than a 15° angle. Ramps
steeper than this can cause traction or stability problems
15
when loading or unloading. FG028819
Figure 9
Transportation DL420A
5-4
LIFTING MACHINE
WARNING
AVOID DEATH OR SERIOUS INJURY
Never lift the machine with a person in the cabin or on the
machine.
Never enter the area under or around a raised machine.
Improper lifting can allow load to shift and cause death or
serious injury or property damage.
Do not use handrails or ladders to lift the machine.
DL420A Transportation
5-5
Transportation DL420A
5-6
7Troubleshooting
Whenever an operating problem with the machine occurs, take
corrective action immediately by checking for the cause of the
problem.
If the cause of the operating problem cannot be determined,
contact your DOOSAN distributor. Never perform an adjustment
or the disassembly of the hydraulic, electrical or electronic
components without first contacting a DOOSAN distributor.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation &
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments, repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
BRAKING
Problem Cause Remedy
After bleeding brakes, brakes are Damaged brake disks. Replace disks.
not fully released.
Damaged brake disk return spring. Replace return springs.
DL420A Troubleshooting
6-1
ELECTRICAL SYSTEM
Problem Cause Remedy
Battery will not hold a charge. Low battery power. Clean and retighten.
ENGINE
Problem Cause Remedy
Starter engages, engine does not Fuel gelled in cold weather. Replace fuel.
start.
Fuel filters plugged. Replace filters.
Engine starts, runs only at low Engine oil viscosity incorrect. Change oil.
speed or shuts down.
Clogged or dirty fuel injectors. Contact your DOOSAN dealer.
Troubleshooting DL420A
6-2
Problem Cause Remedy
Water or dirt in fuel system. Clean system and add new fuel.
Engine has poor power. Plugged air intake system. Clean system and replace filter.
Engine oil pressure warning light Low engine oil level. Add oil.
turns "ON", and buzzer sounds.
Wrong grade oil for weather. Change oil.
DL420A Troubleshooting
6-3
Problem Cause Remedy
Coolant temp. warning light turns Low engine coolant level. Add coolant.
"ON".
Loose/slipping/broken fan belt. Adjust or replace belt.
Engine does not start when the Fuel filter clogged. Replace fuel filter.
starter motor is turning. (Also see
ELECTRICAL Starter motor speed too low. Booster Battery may be used.
TROUBLESHOOTING.) Defective engine shutoff solenoid. Contact your DOOSAN distributor.
Defective injectors.
Unstable (rough) idling. Air in fuel lines. Tighten fuel connections and filter.
Engine oil level too high. Check dipstick and correct level.
Defective injectors.
Troubleshooting DL420A
6-4
HYDRAULIC SYSTEM
Problem Cause Remedy
None of the controls function (loud Hydraulic pump failed. Contact your DOOSAN dealer.
noise from pumps).
Low hydraulic oil level. Add hydraulic oil as required.
None of the controls function (no Pilot pump failure. Contact your DOOSAN distributor.
noise from pumps).
Cutoff solenoid valve failed. Replace solenoid.
All actuators have low power. Low hydraulic oil level. Add hydraulic oil as required.
Only one or two actuators have Overload relief pressure too low. Reset pressure.
little or no power.
Makeup check valve leaking. Clean or replace as required.
Oil temperature too high. Debris in exterior of cooler. Clean exterior of cooler.
DL420A Troubleshooting
6-5
Problem Cause Remedy
Troubleshooting DL420A
6-6
STEERING
Problem Cause Remedy
DL420A Troubleshooting
6-7
TRAVEL SYSTEM
General
Machine will travel but has little Fluid pressure low in transmission
Repair clutch.
power. clutch.
Troubleshooting DL420A
6-8
Problem Cause Remedy
Low oil level, poor quality oil. Add oil, change oil.
DL420A Troubleshooting
6-9
Troubleshooting DL420A
6-10
8Specification
GENERAL SPECIFICATIONS
Item Specification
Standard Bucket Capacity (BOT / BOC) 3.9 m3 (5.1 yd3) / 4.1 m3 (5.36 yd3)
Vehicle Weight 21,955 kg (48,402 lb) / 22,060 kg (48,634 lb)
Engine (SAE J1995 Gross)
Type DOOSAN DE12TIS
Displacement 11.05 liter
Rated Power 210 kW (282 Hp) @ 2,100 rpm
Max. Torque 1,275 N•m (940 lbf. ft ) @ 1200 rpm
Emission Tier-II
Transmission
Full Automatic Power -Shift Full Automatic Power Shift
Speeds 4 Forward, 3 Reverse
Brake Systems
Travel Brakes Full Hydraulic, Separate Dual Line Wet Disks
Parking Brake Spring Applied / Oil Release on Transmission, Dry Disk
Performance
Forward 8.3(5.2)/13.6(8.5)/29(18)/40(24.9)
Travel Speed (km/h)
Reverse 8.3(5.2)/13.6(8.5)/29(18)
Steering Angle ± 40°
Tire Turning Radius
6,380 mm (20' 11")
(Out Tire Edge)
Rated Operating Load 7,745 kg (17,075 lb)
Max. Breakout Force 197 kN (44,287 lb.f)
Boom Rise Time 6.0 ± 0.5 sec.
Bucket Dump Time 1.3 ± 0.3 sec
Boom Down Time 4.2 ± 0.4 sec.
Maximum Gradeability 30° (58%)
DL420A Specification
7-1
WORKING RANGE AND
DIMENSIONS
Figure 1, illustrates exterior machine dimensions and working
range of machine when it is equipped with a standard bucket.
O
P
40
Q
45
I"
I
C
K
H"
H
G
B(D) E F
J
A
M
N
L
FG026499
Figure 1
Specification DL420A
7-2
Category DL420A
8,890 mm 8,700 mm
Overall Length (A)
(29' 2") (28' 7")
3,200 mm
Overall Width (B)
(9' 6")
3,535 mm
Overall Height (C)
(11' 7")
3,200 mm
Bucket Width (D)
(9' 6")
3,500 mm
Wheel Base (E)
(11' 6")
2,300 mm
Tread (F)
(7' 6")
4,295 mm
Bucket Hinge Height (K)
(14' 1")
Turning Radius
6,380 mm
(Out Tire Edge) (O)
(20' 11")
6,395 mm
(C/Weight Edge) (P)
(21')
6,860 mm 6,845 mm
(Bucket Edge) (Q)
(22' 6") (22' 5")
DL420A Specification
7-3
WORKING CAPACITIES
Bucket Capacity
Standard toothed bucket has a capacity of 3.9 m3 (5.1 yd3) .
Material Weight
The data below describes weight of a cubic meter (cubic yard) of
many types of workload materials.
Specification DL420A
7-4
APPROXIMATE WEIGHT OF
WORKLOAD MATERIALS
IMPORTANT
Weights are approximations of estimated average volume
and mass. Exposure to rain, snow or ground water; settling
or compaction because of overhead weight and chemical or
industrial processing or changes because of thermal or
chemical transformations could all increase value of
weights listed in table.
DL420A Specification
7-5
Density Density Density Density
1,200 kg/m3 1,500 kg/m3 1,800 kg/m3 2,100 kg/m3
Material
(2,000 lb/yd3), (2,500 lb/yd3), (3,000 lb/yd3), (3,500 lb/yd3),
or less or less or less or less
1,522 kg/m3
Gypsum, crushed to 3 inch size - - -
(2,565 lb/yd3)
1,810 kg/m3
Gravel, DRY, packed fragments - - -
(3,051 lb/yd3)
1,922 kg/m3
Gravel, WET, packed fragments - - -
(3,240 lb/yd3)
1,282 kg/m3
Limestone, graded above 2 - - -
(2,160 lb/yd3)
1,362 kg/m3
Limestone, graded 1-1/2 or 2 - - -
(2,295 lb/yd3)
1,522 kg/m3
Limestone, crushed - - -
(2,565 lb/yd3)
1,602 kg/m3
limestone, fine - - -
(2,705 lb/yd3)
1,282 kg/m3
Phosphate, rock - - -
(2,160 lb/yd3)
929 kg/m3
Salt - - -
(1,566 lb/yd3)
529 kg/m3
Snow, light density - - -
(891 lb/yd3)
1,522 kg/m3
Sand, DRY, loose - - -
(2,565 lb/yd3)
1,922 kg/m3
Sand, WET, packed - - -
(3,240 lb/yd3)
1,362 kg/m3
Shale, broken - - -
(2,295 lb/yd3)
529 kg/m3
Sulfur, broken - - -
(891 lb/yd3)
Specification DL420A
7-6
1Index
Numerics Brake Pedal 2-10
1,000 Hour / 6 Month Service 4-53 Brakes
1,500 Hour / 9 Month Service 4-63 Accumulator 4-70
10 Hour / Daily Service 4-25 Bleeding 4-69
12,000 Hour / 6 Year Service 4-71 Brake Fluid Warning 2-21
2,000 Hour / Yearly Service 4-65 Brake Fluid Warning Light 2-21
50 Hour / Weekly Service 4-34 Brake Pedal 2-10
500 Hour / 3 Month Service 4-49 System 0-2
Bucket
Angle Indicator 3-17
A
Capacity 7-4
Accelerator Pedal 2-9
Position Switch 3-18
Accumulator 4-70, 4-79
Teeth and Side Cutters 4-30
Air Conditioner
Filter 4-52, 4-57
Refrigerant - Check 4-58 C
Air conditioner Condenser Cleaning 4-38 Cab Light 2-40
Air Filter Indicator Light 2-19 Cabin 0-2
Air Intake System Capacities
Check Engine Air Precleaner 4-44 Fluid 4-18
Inspection 4-33 Center Pins 4-37
Replace Outer Air Cleaner Element 4-55, 4-65 Cigarette Lighter 2-31
Antifreeze Concentration Tables 4-78 Circuit Breaker 2-55
Attachment Pins 4-34 Cold Weather Engine Start 3-5
Attachment Precautions 1-21 Combination Switch 2-8
Auxiliary Batteries 3-8 Communication Equipment Installation 0-3
Axle Component Locations 2-2
Differential 4-55 Conditions - Severe Maintenance 4-86
Oil Change 4-52 Conditions - Severe Maintenance 4-72
Planetaries 4-63 Cooling System
Axle Differential 4-52 Care 4-85
Coolant Level 4-29
Coolant Temperature Gauge 2-17
B
Engine 4-76
Battery
Radiator Coolant 4-66
Auxiliary Batteries 3-8
Cracks and Faulty Welds 4-30
Condition 4-74
Cup Holder 2-38
Long Term Storage 4-85
Warning Light 2-19
Battery Disconnection 1-10 D
Battery Explosion 1-7 Dismounting and Mounting Machine 1-17
Boom Door Side Latch 2-52
Lower Kickout 3-18 Drive Belt Wear 4-32
Raise Kickout 3-17 Driveshaft - Grease 4-45
Boom Float Switch 2-35
Brake E
Charge Pressure 4-81, 4-82 Electric Welding Attention 1-9
DL420A Index
8-1
Electrical System 4-74 H
Box 2-41 Headlight Switch 2-31
Troubleshooting 6-2 Heater and Air Conditioner
Emergency Steering Switch 2-36 Additional Operating Instruction 2-47
Engine 0-1 Blower Fan Switches 2-45
Air Conditioner and Alternator Belt Tension 4- Fan and Air-Conditioner Switch 2-45
38, 4-45 Memory Function of Used Mode 2-47
Check and Adjust 4-59 Selection Switch for Wind Direction 2-46
Drive Belt Wear 4-32 Temperature Control Switch 2-45
Oil and Filter 4-38 Ventilation Selection Switch 2-46
Oil Change 4-48 Heater and Air Conditioner Operation 2-43
Oil Level Check 4-25 High Beam Indicator Light 2-20
Serial Number 4-13 Horn Button 2-7, 2-30
Start 3-2 Hot Pressurized Fluid 1-9
Stop 3-8 Hour Meter 2-16
Stop Lamp 2-22 Hydraulic Oil Tank
Troubleshooting 6-2 Drain Water 4-44
Ventilation 1-21 Hydraulic System
Warning Light 2-22 Check Oil Level 4-27
Entanglement in Rotating Parts 1-7 Control Lever Activation Pressure 4-82
Full Flow Filter - Replace 4-46, 4-60
F Hydraulic Oil - Change 4-67
F/R (Forward/Reverse) Control Switch 2-38 Hydraulic Pressures 4-81
F/R (Forward/Reverse) Selector Switch 2-37 Leaks in the Hydraulic System 4-28
Fan Blade Inspection 4-32 Long Term Storage 4-85
Fluid Capacities 4-18 Service Brake Outlet Pressure 4-83
FOPS and ROPS 0-2 Steering Pump Pressure 4-82
Foreword 0-1 System Pilot Filter - Replace 4-49
Front Instrument Panel 2-15 System Warm-up 3-10
Front Work Light Switch 2-32 System Warm-up – Cold Weather 3-10
Fuel System Transmission Clutch Pressure 4-82
Condensation - Draining 4-29 Troubleshooting 6-5
fill 4-28
Gauge 2-16 I
Leaks 4-29 Indicator Lights
Tank - Cleaning 4-57 Air Filter Indicator Light 2-19
Fuse Battery Warning Light 2-19
Box One 2-42 Brake Oil Pressure Warning Light 2-21
Boxes 2-53 Emergency Steering Indicator Light 2-22
Identification 2-54 Engine Stop Lamp 2-22, 2-23, 2-24
Fusible Link 2-56 Engine Warning Light 2-22
High Beam Indicator Light 2-20
G Left Turn and Hazard Warning Light 2-19
Gauges Parking Brake Indicator Light 2-21
Coolant Temperature 2-17 Preheat Cycle Indicator Light 2-18
Fuel Gauge 2-16 Right Turn and Hazard Warning Light 2-20
Hour Meter 2-16 Work Light Indicator Light 2-20
Speedometer 2-16 Inner Air Cleaner Element 4-65
Tachometer 2-17 Inspection, Maintenance and Adjustment 4-1
Transmission Oil Temperature 2-17 Instrument Panel Monitoring System 3-1
General Hazard 1-5 Intended Use 0-1
K
Kick-down Switch 2-11, 2-30
Index DL420A
8-2
L Pilot Cut-off Switch 2-33
Leaks in Fuel System 4-29 Planetaries 4-52
Leaks in Hydraulic System 4-28 Power Socket 2-37
Left Turn and Hazard Warning Light 2-19 Power Transmission 0-2
Levers Preheat Cycle Indicator Light 2-18
Adjusting Seat Forward/Backward 2-49 Pressurized Gas and Fluid 1-8
Adjusting Seat's Angle 2-49 Preventive Maintenance 4-1
Angle Adjustment of Armrest 2-50 Product Plates 0-4
Backrest Adjustment 2-49 Protection Against Electromagnetic Interference 0-3
Log Forks Control Lever 2-28
Pilot Control Valve Lever 2-27 R
Transmission Lever 2-12 Radio
Weight Adjustment Knob 2-49 Speaker 2-41
Lift/Tie down (Optional) 1-11 Rear Wiper Switch 2-32
Lifting Machine 5-5 Rear Work Light Switch 2-32
Log Fork Control Lever 2-27, 2-28 Regulations, Local 1-29
Long Term Storage 4-85 Relay 2-55
Lubricants 4-14 Right Turn and Hazard Warning Light 2-20
Lubrication and Service Chart 4-21 Rotating Fan 1-9
Rotating Light (Beacon) 2-37
M
Machine S
Shutdown 3-13 Safety Decals 1-2
Travel 3-10 Safety Decals With Text 1-2
Maintenance 1-33 Safety Decals Without Text (No-Text) 1-3
Maintenance Intervals 4-23 Safety Messages 0-5
Material Weight 7-4 Safety Precautions 4-13
Mirror Heating Switch 2-35 Seat Adjustment
Mounting and Dismounting 1-17 Adjusting Seat Forward/Backward 2-49
Adjusting Seat's Angle 2-49
N Angle Adjustment of Armrest 2-50
New Machine Break-in Procedures 3-1 Backrest Adjustment 2-49
Headrest 2-50
Weight Adjustment 2-49
O
Seat Belt 2-51
Operation 1-25, 3-1
Seat Belt Inspection 4-30
Operation at High Altitudes 3-25
Shipping and Transportation 1-46
Operation During Electrical Storms 3-25
Shutdown
Operation In
Engine Stop 3-8
Dusty and Sandy Areas 3-24
Machine 3-13
Extreme Cold 3-21
Shutdown Control Functions 1-32
Rainy or Humid Conditions 3-24
Signal Words 0-5
Saltwater Areas 3-24
Sloping Terrain 1-26
Operational Controls and Panels 2-5
Speakers 2-41
Operator's Area 2-4
Speedometer 2-16
Other Signal Words 0-6
Stability Data 7-4
Outer Air Cleaner Element 4-55
Starter Switch 2-6
Start-up
P Cold Weather Engine Start 3-5
Parking Brake 0-2 Engine Start 3-2
Release Pressure 4-83 Hydraulic System Warm-up 3-10
Parking Brake Indicator Light 2-21 Hydraulic System Warm-up – Cold Weather 3-
Parking Brake Switch 2-33 10
Parking Machine 1-31 Steering
DL420A Index
8-3
Troubleshooting 6-7 Towing Machine 3-19
Wheel 2-10 Transmission
Steering System 0-2 Cut-off Switch 2-34
Switch Panel 2-26 Display 2-15
Switches Lever 2-12
Blower Fan Switches 2-45 Oil - Drain and Change 4-56
Combination Switch 2-8 Oil - Drain and Replace 4-45, 4-48
Emergency Steering Switch 2-36 Oil Filter Replacement 4-45, 4-48, 4-56
F/R (Forward/Reverse) Control Switch 2-38 Oil Level Check 4-26
F/R (Forward/Reverse) Selector Switch Oil Temperature Gauge 2-17
(Optional) 2-37 Transportation 5-1
Front Work Light Switch 2-32 Transporting Machine 5-1
Headlight Switch 2-31 Travel
Heater and Air Conditioner Fan Switch 2-45 Precautions 1-26
Heater and Air Conditioner Selection Switch for Travel System Troubleshooting 6-8
Wind Direction 2-46 Troubleshooting 6-1
Heater and Air Conditioner Ventilation Selection Braking 6-1
Switch 2-46
Horn Button 2-7 U
Kick-down Switch 2-11, 2-30 Unauthorized Modifications 1-14
Load Isolation System (LIS) Switch (Optional) 2-
35
Parking Brake Switch 2-33 V
Pilot Cut-off Switch 2-33 Vibration 2-50
Power Socket 2-37 Vibration Level 1-16
Rear Wiper Switch 2-32 Visibility 1-30
Rear Work Light Switch 2-32 Visibility Information 1-12
Rotating Light (Beacon) 2-37
Starter Switch 2-6 W
Temperature Control Switch 2-45 Warning Tag - "Do Not Operate" 1-7
Transmission Cut-off Switch 2-34 Weight of Workload Materials 7-5
Switches and Levers Wheel Nut Torque 4-87
Boom Float Switch (Optional) 2-35 Window Washer Liquid 4-30
Work Area 1-28
T Work Light Indicator Light 2-20
Tachometer 2-17 Working Capacities 7-4
Tire Damage 4-88 Working Range and Dimensions 7-2
Tire Pressure Inspection 4-25
Index DL420A
8-4