Daewoo Doosan DL420 Wheel Loader Operation and Maintenance Manual INSTANT

Copyright Doosan 2009 950106-00008E Operation and Maintenance Manual DOOSAN reserves the right to improve our products in a continuing process to provide the best possible product to the market place. These improvements can be implemented at any time with no obligation to change materials on previously sold products. It is recommended that consumers periodically contact their distributors for recent documentation on purchased equipment. This documentation may include attachments and optional equipment that is not available in your machine's package. Please call your distributor for additional items that you may require. Illustrations used throughout this manual are used only as a representation of the actual piece of equipment, and may vary from the actual item. Operation and Maintenance Manual 950106-00008E Serial Number 5001 and Up September 2009 DL420

950106-00008E I-I Presentation 1Presentation PRESENTATION FG015215 Figure 1

950106-00008E Presentation I-II Intended Use The machine is intended to be used under normal conditions for the applications described in the Operator's Manual. If it is used for other purposes or in potentially dangerous environments, for example explosive atmosphere or areas with dust containing asbestos, etc., special safety regulations must be followed and the machine must be equipped for such use. Contact the manufacturer/dealer for further information. The machine is designed for a maximum machine weight (includes equipment and attachments) of 22,300 kg (49,163 lb) for DL420. 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 DL420 has a Cummins QSM11 10.8 liter engine. The engine has intercooling and is fitted with common rail system. The common rail system is positioned at an angle above the pistons and are controlled via the camshaft and a electronic control module (ECM). The cylinder head covers all cylinders. The engine has four valves per cylinder. The accelerator position is transferred electrically from accelerator pedal. Electrical System The machine has three control units. The Gauge Panel for the instrumentation is integrated with the display unit, warning lights and instruments and provides the operator with information via there. The Control Unit (for the machine) receives signals from sensors on the machine and these are passed to the Gauge Panel. The E-ECU controls the engine. 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 drive shafts. The axles differentials use a LSD (Limited Slip Differential) design.

950106-00008E I-III Presentation 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, hydrodynamic 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. FOPS and ROPS The cabin is approved as a protective cabin according to FOPS and ROPS standards. FOPS is an abbreviation of Falling Object Protective Structure (roof protection) and ROPS is an abbreviation of Roll Over Protective Structure (roll over protection). Never carry out any unauthorized alterations to the cabin, e.g. lowering the roof height, drilling, welding on brackets for fire extinguisher, radio aerial or other equipment, without first having discussed the alteration with personnel at the DOOSAN Infracore Engineering Department. This department will decide whether the alteration may cause the approval to become void. It is important that all parties concerned are aware of these regulations. Hydraulic System The hydraulic system is load sensing with pumps in common for steering systems and the working hydraulics. However, the brake and steering systems are prioritized by one of the pumps.

950106-00008E Presentation I-IV 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. CE MARKING, EMC DIRECTIVE CE Marking (Declaration of Conformity) (Only applies to machines marketed within the EU/EEA) This machine is CE marked. This means that when delivered the machine meets the applicable "Essential Health and Safety Requirements," which are given in the Machinery Safety Directive, 98/37EC. Any person carrying out changes that affect the safety of the machine, is also responsible for the same. As proof that the requirements are met, the machine is supplied with an EU Declaration of Conformity, issued by DOOSAN CE for each separate machine. This EU declaration also covers attachments manufactured by DOOSAN CE. The documentation is a valuable document, which must be kept safe and retained for at least ten years. The document should always accompany the machine when it is sold. If the machine is used for other purposes or with other attachments than described in this manual, safety must at all times and in each separate case be maintained. The person carrying out such action is also responsible for the action which, in some cases, may require a new CE marking and the issue of a new EU Declaration of Conformity. The EU EMC Directive The electronic equipment of the machine may in some cases cause interference to other electronic equipment, or suffer from external electromagnetic interference, which may constitute safety risks. The EU EMC directive on "Electromagnetic Compatibility," 89/336/EEC, provides a general description of what demands can be made on the machine out of a safety point of view, where permitted limits have been determined and given according to international standards. A machine or device which meets the requirements must be CE marked. Our machines have been tested particularly for FG001781 Figure 2

950106-00008E I-V Presentation electromagnetic interference. The CE marking of the machine and the declaration of conformity also cover the EMC directive. If other electronic equipment is fitted to this machine, the equipment must be CE marked and tested on the machine with regard to electromagnetic interference. COMMUNICATION EQUIPMENT INSTALLATION Protection Against Electromagnetic Interference This machine has been tested in accordance with EU directive 89/336/EEC governing electromagnetic interference. It is therefore very important that all nonapproved electronic accessories, such as communication equipment, must be tested before installation and use, since they can cause interference to the electronic systems of the machine. IMPORTANT All installation of optional communication equipment must be carried out by trained professionals and in accordance with the DOOSAN CE instructions applicable to the machine.

950106-00008E Presentation I-VI 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.

950106-00008E I-VII Presentation When ordering spare parts, and in all telephone enquiries or correspondence the PIN and CIN must always be quoted. 1 2 3 5 6 7 4 FG015225 Figure 3 Reference Number Description 1 Primary Marking The machine PIN (stamped into right side). 2 Product Plate The manufacturer's name and address, machine PIN. 3 Additional Plate for Product Plate Machine weight, engine output year of manufacture, year of delivery and position of CE mark (EU/EEA countries only). 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.

950106-00008E Presentation I-VIII

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Daewoo Doosan DL420 Wheel Loader Operation and Maintenance Manual INSTANT

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