Doosan DL420-5 Roco Wheel Loader Index:

Foreword …………………………………………………………………………0-1
Safety Messages ……………………………………………………………………. 0-2
AEM Safety Manual
(North America Only) ………………………………………………………………. 0-3
Product Information…………………………………………………………………. 0-4
Product Identification ………………………………………………………………. 0-5
Federal Emission Control Systems……………………………………………. 0-6
Safety………………………………………………………………………………1-1
Safety Decals…………………………………………………………………………. 1-2
General ……………………………………………………………………………….. 1-14
Operation …………………………………………………………………………….. 1-25
Maintenance ………………………………………………………………………… 1-40
Transportation………………………………………………………………………. 1-56
Environment and Circumstances …………………………………………….. 1-58
Operating Controls…………………………………………………………..2-1
Component Locations……………………………………………………………… 2-2
Operator’s Area………………………………………………………………………. 2-5
Steering Console and Pedals …………………………………………………… 2-6
Gauges ……………………………………………………………………………….. 2-16
Front Instrument Panel ………………………………………………………….. 2-19
Multifunction Gauge and Graphic Information Display………………… 2-24
Right Side Switch Panel…………………………………………………………. 2-56
Various Cabin Locations ………………………………………………………… 2-67
Heater and Air Conditioner Operation………………………………………. 2-73
Stereo/CD Player (Optional) …………………………………………………… 2-79
Seat Adjustment Mechanical Suspension…………………………………. 2-80
Seat Belt ……………………………………………………………………………… 2-83

Door Side Latch ……………………………………………………………………. 2-84
Arm Rest……………………………………………………………………………… 2-85
Fuse Box/Relay…………………………………………………………………….. 2-86
Electrical System Master Switch……………………………………………… 2-89
Engine Block Heater ……………………………………………………………… 2-90
Operation…………………………………………………………………………3-1
To Operate a New Wheel Loader ……………………………………………… 3-1
Starting and Stopping Engine …………………………………………………… 3-2
Emission Control System……………………………………………………….. 3-12
Machine Travel …………………………………………………………………….. 3-19
If Engine Stalls While Traveling ………………………………………………. 3-22
Working in Water ………………………………………………………………….. 3-22
Towing ………………………………………………………………………………… 3-23
Machine Shut Down………………………………………………………………. 3-30
Operation of Attachment ………………………………………………………… 3-32
Bucket Angle Indicator …………………………………………………………… 3-32
Boom Raise Kick-out …………………………………………………………….. 3-33
Adjustment of Bucket Position Switch………………………………………. 3-34
Operation Under Abnormal Conditions …………………………………….. 3-35
Long Term Storage ……………………………………………………………….. 3-40
Inspection, Maintenance and Adjustment………………………….4-1
Maintenance Information …………………………………………………………. 4-1
Machine Setup Position for Maintenance …………………………………… 4-5
Maintenance Handling Access………………………………………………….. 4-7
Handling Oil, Fuel, DEF (AdBlue®) Coolant ……………………………… 4-10
Electrical System Maintenance……………………………………………….. 4-14
Recommend Fuel, Coolant, and Lubricant ……………………………….. 4-15
Preventive Maintenance ………………………………………………………… 4-22
Table of Recommended Lubricants …………………………………………. 4-24
Transmission Oil …………………………………………………………………… 4-27
Axle Oils………………………………………………………………………………. 4-28
Fluid Capacities ……………………………………………………………………. 4-29
Table of Contents
III
DL420-5
Lubrication and Service Chart…………………………………………………. 4-30
Maintenance Intervals……………………………………………………………. 4-35
10 Hour / Daily Service ………………………………………………………….. 4-37
50 Hour / Weekly Service ………………………………………………………. 4-49
250 Hour / Monthly Service…………………………………………………….. 4-55
500 Hour / 3 Month Service ……………………………………………………. 4-65
1,000 Hour / 6 Month Service …………………………………………………. 4-74
1,500 Hour / 9 Month Service …………………………………………………. 4-92
2,000 Hour / Yearly Service ……………………………………………………. 4-94
Standard Bolt Torque Chart ………………………………………………….. 4-101
Electrical System ………………………………………………………………… 4-102
Engine Cooling System………………………………………………………… 4-103
Handling of Accumulator………………………………………………………. 4-106
Hydraulic Pressure Checks…………………………………………………… 4-108
Long Term Storage ……………………………………………………………… 4-114
Parking Brake Adjustment ……………………………………………………. 4-115
Severe Conditions Maintenance ……………………………………………. 4-118
Tires………………………………………………………………………………….. 4-119
Transmission Recalibration…………………………………………………… 4-123
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