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Doosan dl420 3 wheel loader service repair manual
1. Original Instructions
Copyright DOOSAN 2012
Serial Number 10001 and Up
Shop Manual
DL420-3 Wheel Loader
950106-00437E
April 2012
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
2. Table of Contents
Page I
1Table of Contents
Safety
Wheel Loader Safety ............................................................................ SP002397
Specifications
Specification for DL420-3 ..................................................................... SP002461
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Engine
Engine................................................................................................... SP002399
Engine Coolant Heater (Option) ........................................................... SP002328
Drivetrain
Transmission and Torque Converter (ZF 4WG-260-4)......................... SP002400
Transmission and Torque Converter (ZF 5WG-260) (Option).............. SP002401
Transmission Error Codes (ZF) ............................................................ SP002423
Front Axle (ZF - MT-L 3085 II / 3095 II)................................................ SP002462
Rear Axle ZF - Multitrac (MT-L 3105 II)................................................ SP002463
Driveshaft.............................................................................................. SP002424
Brake
Service Brake ....................................................................................... SP002426
Supply Valve......................................................................................... SP002427
Charging Block ..................................................................................... SP002428
Parking Brake ....................................................................................... SP002429
Brake Pedal Valve ................................................................................ SP002430
Accumulator.......................................................................................... SP002464
3. Table of Contents
Page II
Steering
Power Steering System ........................................................................ SP002465
Steering Unit......................................................................................... SP002425
Steering Pump...................................................................................... SP002433
Flow Amplifier ....................................................................................... SP002434
Jerk Softener and Accumulator ............................................................ SP002435
Emergency Steering ............................................................................. SP002466
Frame
Articulation Center ................................................................................ SP002467
Counterweight....................................................................................... SP002437
Tank
Oil Tank ................................................................................................ SP002468
Fuel Tank.............................................................................................. SP002469
Hydraulics
Main Pump............................................................................................ SP002470
Main Control Valve ............................................................................... SP002441
3rd Control Valve (Option).................................................................... SP002442
Load Isolation System .......................................................................... SP002536
Cooling System..................................................................................... SP002490
Pilot System.......................................................................................... SP002445
Hydraulic Schematic (DL420-3)............................................................ SP002471
Electrical System
Air Conditioner...................................................................................... SP002447
Electrical System .................................................................................. SP002575
Electrical Schematic DL350-3 / DL420-3 / DL450-3............................. SP002449
6. SP002397
Page 5
Wheel Loader Safety
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
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
DL200-3 10001 and Up
DL220-3 10001 and Up
DL250-3 10001 and Up
DL300-3 10001 and Up
DL350-3 10001 and Up
DL420-3 10001 and Up
DL450-3 10001 and Up
DL550-3 10001 and Up
7. SP002397
Wheel Loader Safety
Page 6
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.
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.
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.
8. SP002397
Page 7
Wheel Loader Safety
SAFETY DECALS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
GENERAL
Safe Operation is Operator's
Responsibility
Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the
influence of drugs or alcohol. An operator who is
taking prescription drugs must get medical advice to
determine if he or she can safely operate the
machine.
• When working with other personnel on a work site, be
sure that all personnel know the nature of work and
understand all hand signals that 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 check for and know the location of
underground and overhead utility lines before working.
• Failure to use and maintain safety features according
to instructions in this manual, Safety Manual and
Shop Manual can result in death or serious injury.
Know Your Machine
Know how to operate your machine. Know the purpose of all
controls, gauges, signals, indicators and monitor displays. Know
the rated load capacity, speed range, braking and steering
characteristics, turning radius and operating clearances. Keep in
mind that rain, snow, ice, loose gravel, soft ground, slopes etc.,
can change operating capabilities of your machine.
10. SP002399
Engine
Page 6
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
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
DL420-3 10001 and Up
DL450-3 10001 and Up
12. SP002399
Engine
Page 18
ENGINE IDENTIFICATION
Engine Data Plate
Applies to engines with cylinder block generation 2.
Engine data on plate, on 9 and 13 liter engines with XPI
A
B
C FG020225
Figure 3
Reference
Number
Description
A Smoke Value
B Engine type
C Engine serial number
FG020227
Figure 4
:
2
1
3 4
Typ/Type DC 13 06
Variant
Motor/Engine No
123 44XX
FG020228
Figure 5
Reference
Number
Description
1
Engine Type and Engine Serial
Number
2 Engine Serial Number, Stamped
3 Smoke Data
4 Valve Clearance
13. SP002399
Page 19
Engine
Mounting the Engine in a Universal Stand
Preparations before commencing work:
• Remove engine from the machine.
1. Mount the engine in the universal stand.
1 4
3
2
FG020231
Figure 6
Reference
Number
Description
1 Engine Control Unit
2 Fuel Filter
3
High-pressure Pump and Feed
Pump
4 Starter Motor
Reference
Number
Description
1
2 3
99 331
FG020232
Figure 7
Reference
Number
Description
1 Bolt M10x30 (8 off)
2 Nut M16 (4 off)
3 Bolt M16x50 (4 off)
14. SP002399
Engine
Page 20
ENGINE SPECIFICATION
ITEMS SPECIFICATION
Engine
Type
4-Cycle Water Cooled, Waste Gate Turbocharge,
Air to Air Intercooled Direct Injection
Emission US EPA Tier 4i (EU Stage IIIB)
Maker and Model SCANIA / DC 13
Injection System Extra high-pressure fuel injection system, XPI
Rated Net Power 264 kW (354 HP) @ 1,800 rpm (SAE J1995)
Valve Clearance
Intake Valve 0.45 mm
Exhaust valve 0.70 mm
Number of cylinders and Configuration 6, Straight
Rotating Direction (from Flywheel) Counterclockwise
Oil Pressure (bar, kg/cm²)
Normal with the engine
at operating temperature,
operating speed
3 - 6
Min. permitted at idling
speed
0.7
Crankcase pressure with closed
crankcase ventilation
-55 - +20
Using Lubrication Oil
ACEA-E3, E4, E5 or E7
(for fuel with ultra low sulfur)
Oil Filter Paper filter form Scania
Interval between oil changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 130 mm
Piston Stroke 140 mm
Displacement 12.7 dm3
Compression Ratio 17.3:1
Number of teeth on the flywheel 158
Low Idle Speed 600 - 750 rpm
Max. full load speed 2,100 rpm
Weight, without Coolant and Oil 1050 kg
Cooling System
Volume, excluding
radiator 16 dm3
Coolant Temperature 90 - 95
Number of Thermostats 1
Thermostat, Opening
Temperature
80/87
Electrical System Type 1-pin, 24V, DC
Starter Motor (Standard
Equipment)
1-pin, 24V, 6 kW
Alternator
(Standard Equipment)
1-pin, 28V, 100 A
15. SP002399
Page 21
Engine
MOTOR
Removal and Installation of Motor
NOTE: Replace coolant hoses if there is clear damage to the
coolant hoses which were removed.
1. Drain the oil and coolant.
2. Remove air filter and inlet pipe between the turbocharger
and air filter. Cover the turbocharger inlet pipe.
3. Undo the connections for coolant, charge air pipes
between engine and charge air cooler, and bleed pipe for
the expansion tank.
4. Undo the cable harness with clamping.
NOTE: The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
5. Fasten the lifting chain 98 094 to the rear lifting eyes 99
637.
6. Fasten the lever block 587 308 to the front lifting eye.
NOTE: The lifting eyes 99 637 are designed to manage
a maximum inclination angle of 30° when lifting
an engine.
7. Undo the engine insulator bolts and lift away/out the
engine.
Installing Engine
1. Fasten the lifting chain 98 094 to the rear lifting eyes.
NOTE: The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
NOTE: The lifting eyes 99 637 are designed to manage
a maximum inclination angle of 30° when lifting
an engine.
2. Fasten the lever block 587 308 to the front lifting eye.
3. Lift the engine, position it on the engine insulators and
screw it into place.
FG020236
Figure 8
FG020237
max 30
max 20
Figure 9
FG020237
max 30
max 20
Figure 10
16. SP002399
Engine
Page 22
4. Attach the cable harness with clamping.
5. Install the connections for coolant, charge air pipes
between engine and charge air cooler, and bleed pipe for
the expansion tank.
6. Install the air filter and inlet pipe between the turbocharger
and air filter.
7. Fill with oil and coolant as directed in booklet 00:03-01.
8. Test run the engine to check that no leakage occurs. Top
up with coolant if necessary.
17. SP002399
Page 23
Engine
TIGHTENING TORQUES
Normal Tightening Torque
The specifications in the tables below show the normal
tightening torque for screws, nuts and unions. The values are to
be used unless other values are specified in the inspection
information. Always check whether there are special tightening
torques given in the descriptions for the respective areas in the
inspection information before using the general values for
normal and special tightening torques respectively.
The following conditions apply:
• A tolerance of ±15 % applies to all values unless
otherwise specified.
• All contact surfaces are to be clean and free of paint.
• Bolts and nuts are normally not lubricated regardless
of surface treatment. All exceptions are specified in
the inspection information.
Union Assemblies
The specified values apply with a tolerance of ±5 %. The values
apply to tightening with a counterhold.
Thread Inserts
The specified tightening torques also apply to bolted joints with a
thread insert (Heli-Coil).
Thread inserts often provide greater strength compared to a
directly screwed thread. This generates a stronger bolted joint in
aluminium or the like. For this reason, thread inserts are used in
certain joints in Scania's production.
NOTE: When a damaged thread is repaired with a thread
insert, the normal screw and prescribed tightening
torque are to be maintained. Install the thread insert
as instructed in the inspection information.
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20. SP002399
Page 25
Engine
Stud tap end in threaded hole, strength class 8.8/8
(Metric thread, course pitch)
Tightening the stud tap end in the threaded hole must be done so
the stud does not come loose when undoing the nut. To tighten the
stud in the threaded hole, the torque must just overcome the friction
in the thread and generate a preload. The torque for locking is 50%
of the normal torque for hexagonal screws, hexagon socket screws,
six-point socket screws, hexagon nuts.
Union nuts for ferrule
Thread
Thread Tightening torque ( ±15% Nm)
For pipe
diameter
Steel pipe
with
greased
steel nut
Plastic
pipe with
steel
ferrule and
brass or
steel nut
Plastic
pipe with
brass
ferrule and
nut with
rubber seal
M10x1 5 15 10 -
M12x1.5 6 20 10 -
M14x1.5 8 30 20 -
M16x1.5 10 40 25 15
M18x1.5 12 50 30 20
M20x1.5 12 55 35 -
M24x1.5 16 60 50 40
M130x2 22 120 - -
Nuts for lead-in union
Thread Thread Tightening Torque ( ±15% Nm)
M12x1.5 20
M14x1.5 25
M16x1.5 35
M18x1.5 50
M24x1.5 70
M130x2 80
Unions with tapered thread for port connection
Thread
Thread Tightening Torque
( ±15% Nm)
Tightening Torque
(Nm)
Straight Unions Elbow Unions
M10x1k 10 8
M12x1.5k 10 8
M14x1.5k 15 10
M16x1.5k 15 10
M18x1.5k 20 15
M20x1.5k 25 20
M22x1.5k 25 20
M26x1.5k 45 40
FG020242
FG020243
FG020244
FG020245
