Doosan DL420A, Shop Manual

Page 1: ...OOSAN 2012 Serial Number 10001 and Up Shop Manual DL420A Wheel Loader 950106 00817E June 2012 DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the world ...

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Page 3: ...vetrain Transmission and Torque Converter SP002705 Transmission Error Codes ZF SP002673 Front Axle ZF MT L 3105 II SP002402 Rear Axle ZF MT L 3095 II SP002474 Driveshaft SP002674 Brake Service Brake SP002727 Brake Supply Valve SP002728 Parking Brake SP002729 Brake Pedal Valve SP000123 Accumulator SP002677 Steering Power Steering System SP002730 Steering Unit SP002731 Flow Amplifier SP002434 Emerge...

Page 4: ...draulics Cylinders SP001027 Main Pump SP002734 Main Control Valve SP002735 Load Isolation System SP002736 Fan Drive Hydraulic Motor SP002737 Unloader Valve SP002738 Pilot System SP002739 Hydraulic Schematic DL420A SP002740 Electrical System Air Conditioner SP000172 Electrical System SP002712 Electrical Schematic DL420A SP002742 ...

Page 5: ...1Safety ...

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Page 7: ...SP002667 Page 1 Wheel Loader Safety SP002667 WHEEL LOADER SAFETYSP002667 Wheel Loader Safety Edition 1 ...

Page 8: ...SP002667 Wheel Loader Safety Page 2 MEMO ...

Page 9: ...eel Loader Safety Table of Contents Wheel Loader Safety Safety Instructions 5 Applicable Models 5 Safety Messages 6 Safety Decals 7 General 7 Transportation 17 Operation 19 Maintenance 37 Environment and Circumstances 52 ...

Page 10: ...SP002667 Wheel Loader Safety Page 4 MEMO ...

Page 11: ...cing machine Read and understand the Operation and 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 MODEL SERIAL NUMBER RANGE DL250A 10001 and Up DL300A 100...

Page 12: ...r a Safety Alert Symbol is present no matter which signal word appears next to it SAFETY ALERT SYMBOL Be Prepared Get to Know All Operating and Safety Instructions This is a Safety Alert Symbol Wherever it appears in this manual or on safety decals on the machine you must be alert to the potential for personal injury or accidents Always observe safety precautions and follow recommended procedures ...

Page 13: ...are to be used Be sure that all guards and shields are installed in their proper location Have guards and shields repaired or replaced immediately if damaged Be sure that you understand the use and maintenance of all safety features such as pilot cutoff switch and seat belt Use them at all times Never remove modify or disable any safety features Always keep them in good operating condition Always ...

Page 14: ...s stay clear of the following areas cutting edges pinch points and crushing surfaces Never use attachment as a work platform or manlift Contact your DOOSAN distributor about auxiliary hydraulic kits for attachments installation If you are in doubt about the compatibility of a particular attachment with the machine consult your DOOSAN distributor Pressurized Fluids Pressurized air or fluids can cau...

Page 15: ...ction for operator s cabin may be required such as a Falling Object Protective Structure FOPS or window guards Contact your DOOSAN distributor for information on available protective guards To prevent personnel from being struck by flying objects keep personnel out of work area Personal Protective Equipment PPE Do not wear loose clothing and accessories Secure long hair These items can snag on con...

Page 16: ...ble parts If going between movable parts is necessary always position and secure work equipment so it cannot move Properly support equipment before performing any work or maintenance under raised equipment If control levers are operated clearance between machine and work equipment will change and this may lead to serious damage or can result in death or serious injury Stay clear of areas that may ...

Page 17: ... are flammable and can cause a fire resulting in death or serious injury and property damage Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause fire Inspect for and remove all flammable materials such as spilled fuel and oil and debris from machine Do not allow any flammable materials to accumulate on machine Always observe the following Add fuel...

Page 18: ...xhaust components from oil spray or fuel spray in case of a break in a line hose or seal Exhaust shields must be correctly installed and maintained properly Electrical Check all electrical wiring and connections for damage daily Keep battery terminals clean and tight Repair or replace any damaged parts or wires that are loose or frayed Clean all electrical connections and tighten all electrical co...

Page 19: ...olvents Fueling Use caution when you are refueling a machine Fuel is flammable and can catch fire if it is brought close to a flame Stop engine and let it cool before adding fuel Do not smoke while you are refueling a machine Do not refuel a machine near flames or sparks Fill fuel tank outdoors Keep fuel and other fluid reservoir caps tight and do not start engine until caps have been secured Stor...

Page 20: ...when grinding painted parts Dust generated from repairing nonmetallic parts such as hoods fenders or covers can be flammable or explosive Repair such components in a well ventilated area away from flames or sparks Do not weld on lines or on tanks that contain flammable fluids Do not flame cut lines or tanks that contain flammable fluid Clean any such lines or tanks thoroughly with a nonflammable s...

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