Doosan DL160 Operation And Maintenance Manual
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Doosan DL160 Operation And Maintenance Manual

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DL160
Operation and Maintenance Manual
K1040196E
Serial Number 5001 and Up
May 2008
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.
K1040196E Operation and Maintenance Manual
Copyright Doosan 2008

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  • Page 1 Serial Number 5001 and Up May 2008 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.
  • Page 3 Presentation PRESENTATION FG013087 Figure 1 K1040196E Presentation...
  • Page 4 Engine DL160 has a cummins QSB4.5 4.5 liter engine. The engine has intercooling and is fitted with a 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).
  • Page 5 DOOSAN Infracore Engineering Department. This department will decide whether the alteration may cause the approval to become void.
  • Page 6 Figure 2 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...
  • Page 7 INSTALLATION 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. Protection Against Electromagnetic Interference This machine has been tested in accordance with EU directive 89/336/EEC governing electromagnetic interference.
  • Page 8 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.

  • Page 9: Table Of Contents

    Table of Contents Safety..................1-1 To the Operator of a Wheel Loader ........... 1-1 General Safety Essentials..............1-4 Location of Safety Labels..............1-4 Unauthorized Modifications.............. 1-13 General Hazard Information............. 1-13 Before Starting Engine..............1-22 Machine Operation................1-26 Maintenance ..................1-34 Battery....................1-44 Towing .....................
  • Page 10 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 Boom Raise Kick-out ............... 3-15 Bucket Angle Indicator ..............3-15 Adjustment of Bucket Position Switch..........3-16 Towing Machine................
  • Page 11 Handling of Accumulator..............4-74 Hydraulic Pressure Checks.............. 4-75 Long Term Storage ................4-81 Parking Brake Adjustment ............... 4-82 Tires ....................4-83 Transportation ................5-1 Loading and Unloading ..............5-1 Summary of Safety Precautions for Lifting......... 5-2 Troubleshooting ................6-1 Engine....................6-1 Hydraulic System ................6-3 Travel System ..................
  • Page 12 Table of Contents K1040196E...

  • Page 13: Safety

    OP000753 Safety TO THE OPERATOR OF A WHEEL LOADER DANGER! Improper use of wheel loader could cause serious injury or death. Before operating wheel loader, or performing maintenance, operator or technician must read and understand entire Operation and Maintenance Manual. Any operation, maintenance, traveling or shipping methods that do not follow safety guidelines printed in this Manual could cause serious injury or death.
  • Page 14 SAFETY ALERT SYMBOL Be Prepared – Get to Know All Operating and Safety Instructions. This is the Safety Alert Symbol. Wherever it appears – in this manual or on safety signs on the machine – you must be alert to potential for personal injury or accidents. Always observe safety precautions and follow recommended procedures.
  • Page 15 Safety precautions are described in SAFETY from page 1-4 on. DOOSAN cannot predict every circumstance that might involve a potential hazard in operation and maintenance. Therefore the safety messages in this manual and on the machine may not include all possible safety precautions. If any procedures or...

  • Page 16: General Safety Essentials

    The wheel loader has been designed primarily for moving earth with a bucket. For use as a grapple or for other object handling, contact DOOSAN. Lifting-work applications are permitted in approved lift configuration, to rated capacity only, with no side-loading (unless prohibited by local regulation). Do not use machine for activities for which it was not intended.
  • Page 17 FG013042 Figure 1 OP000753 Safety...
  • Page 18 Set park brake. • Turn starter switch "OFF." Remove key from switch. • If hydraulic components and units are ABNORMAL, consult nearest DOOSAN dealer or authorized service shop. Do not attempt to make an overhaul. 2. Warnings for Cooling Fan (2190-3315, 190-00557)
  • Page 19 3. Warnings When Opening Engine Hood (190-00095) WARNING! Before opening hood, shut down engine. ACO1420L 4. Warnings for Using Wheel Block (4190-2547A, 190-00207) WARNING! Block wheels to prevent machine movement before disengaging park brake. AMO0400L Safety OP000753...
  • Page 20 5. Warnings for Handling Accumulator (190-00703, 190-00099) WARNING! Explosion hazard: • Keep away from flame. • Do not weld or drill. ACO1480L Accumulator Wheel loader pilot control system is equipped with an accumulator. Accumulator will store a pressure charge that may enable hydraulic controls to be activated for a brief period of time after engine has been shut down.
  • Page 21 6. Keep Out of Steering Turn Area (4190-1992A, 190-00120) DANGER! Keep out of steering turn area. AMO0410L 7. Warnings for High Temperature Hydraulic Oil (190-00691A, 190-00097) WARNING! HYDRAULIC OIL. Hot oil can cause injury or blindness. To prevent hot oil from spurting out: •...
  • Page 22 8. Warnings for High Temperature Coolant (190-00692, 190-00097) WARNING! To prevent hot water from spurting out: • Turn engine "OFF." • Allow water to cool. • Slowly loosen cap to relieve pressure before removing. ACO1410L 9. Warnings for Battery Maintenance (2190-2533A, 190-00100) DANGER! •...
  • Page 23 10. Warnings for Performing Maintenance On Front Attachment (4190-2546A, 190-00105) DANGER! To avoid injury, securely brace lift arm before disassembly of valve or piping. AMO0430L 11. Warnings to Use Safety Lock (4190-1993, 190-00121) WARNING! Safety lock must be in "LOCK" position when servicing pivot area or transporting machine.
  • Page 24 12. Warning Tag (190-00695A, 190-00098A) WARNING! DO NOT OPERATE When performing inspection or maintenance. ACO1450L Safety OP000753 1-12...

  • Page 25: Unauthorized Modifications

    UNAUTHORIZED MODIFICATIONS Any modification made without authorization or written approval from DOOSAN can create a safety hazard, for which the machine owner must be held responsible. For safety's sake, replace all OEM parts with the correct authorized or genuine DOOSAN part. For example, not taking...
  • Page 26 Inside Operator's Compartment When entering the operator's compartment, 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 may cause a serious accident. Clean grease and dirt from pedals and controls.
  • Page 27 Clothing and Personal Protective Items Contain long hair, and avoid loose clothing and jewelry. They can catch on controls or in protruding parts and cause serious injury or death. Do not wear oily clothes. They are highly flammable. Full eye protection, a hard hat, safety shoes and gloves may be required at the work site.
  • Page 28 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a genuine DOOSAN part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.
  • Page 29 Mounting and Dismounting Before getting on or off the machine, if there is any oil. grease, or mud on the handrails, steps, or track shoes, wipe it off immediately. Always keep these parts clean. Repair any damage and tighten any loose bolts. Never jump on or off the machine.
  • Page 30 Precautions When Handling Fluids at High Temperature Immediately after operations are stopped, the coolant, engine oil, and hydraulic oil are at high temperature and the radiator and hydraulic tank are still under pressure. Attempting to remove the cap, drain the oil or coolant, or replace the filters may lead to serious burns.
  • Page 31 Fire Extinguisher and First Aid Kit As a precaution if any injury or fire should occur, always do the following. • Be sure that fire extinguishers have been provided and read the labels to ensure that you know now to use them.
  • Page 32 1-2 through 1-4 of this section. Attachment Precautions Option kits are available through your dealer. Contact DOOSAN for information on available one-way (single-acting) and two-way (double-acting) piping / valving / auxiliary control kits. Because...
  • Page 33 When carrying out disassembly or maintenance of accumulator, when disposing 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.

  • Page 34: Before Starting Engine

    BEFORE STARTING ENGINE Work Site Precautions Before starting operations, thoroughly check the area for any unusual conditions that could be dangerous. Check the terrain and condition of the ground at the work site, and determine the best and safest method of operation. Make the ground surface as hard and horizontal as possible before carrying out operations.
  • Page 35 Avoid operating your machine to close to the edge of cliffs, overhangs, and deep ditches. The ground may be weak in such areas. If the ground should collapse, the machine could fall or tip over and this could result in serious injury or death. Remember that the soil after heavy rain, blasting or after earthquakes, is weakened in these areas.
  • Page 36 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.
  • Page 37 Before Operating Machine If checks are not carried out properly after starting the engine, it may result in a delay in discovering abnormalities in the machine, and this may lead to personal injury or damage to the machine. Carry out the checks in an open area where there are no obstructions.

  • Page 38: Machine Operation

    DOOSAN representative. Operate While Seated at Operator's Station Only Never reach in through a window to work a control. Do not try to operate wheel loader unless you're in command position - seated at controls. You should stay alert and focused on your work at all times.
  • Page 39 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 the "O" (OFF) position when traveling. It is dangerous if the engine stops when the machine is traveling.
  • Page 40 Avoid High Voltage Cables Serious injury or death can result from contact or proximity to high voltage electric 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.
  • Page 41 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.
  • Page 42 Stay Alert for People Moving Through Work Area When loading a truck you should always know where the driver is. Avoid loading over the cabin of a truck even if the driver is in a safe spot. Someone else could have gone inside, for any number of reasons.
  • Page 43 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: •...
  • Page 44 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.
  • Page 45 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).

  • Page 46: Maintenance

    Alert others that service or maintenance is being performed and tag operator's cabin controls - and other machine areas if required - with a warning notice. Warning tags for controls are available from DOOSAN when performing inspection distributors; see Figure 23.
  • Page 47 Proper Tools Use only tools suited to the task. Using damaged, low qualify, faulty, or makeshift tools could cause personal injury. There is danger that pieces from, chisels with crushed heads, or hammers, may get into your eyes and cause blindness. HDO1037L Figure 25 Use of Lighting...
  • Page 48 Do not weld on pipes or on tubes that contain flammable 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.
  • Page 49 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.
  • Page 50 Precautions When Working on Machine When carrying out maintenance operations on the machine, keep the area around your feet clean and tidy to prevent you from falling. Always do the following: • Do not spill oil or grease. • Do not leave tools laying about. •...
  • Page 51 95°C (203°F), however do not allow full cool down. Hydraulic Cylinder Seals Require Periodic Replacement Check cylinder drift rate at regular intervals. Overhaul seal kits are available through DOOSAN. High-pressure Hydraulic Lines Can Store a Great Deal of Energy Exposed hydraulic hoses on arm could react with explosive force if struck by a falling rock, overhead obstacle or other work site hazard.
  • Page 52 Cool Down Is Required Before Radiator or Reservoir Checks Shut down 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.
  • Page 53 Obtain Immediate Medical Attention if Pressurized Oil Pierces Skin. WARNING! Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue. Use Correct Replacement Fasteners Tightened to Proper Torque Refer to "General Maintenance" section of Shop Manual for information on tightening torques and recommended assembly compounds and always use correct part.
  • Page 54 Dispose of All Petroleum Based Oils and Fluids Properly Physical contact with used motor oil may pose a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil is an environmental contaminant and may only be disposed of at approved collection facilities.
  • Page 55 While operating a machine, do not let people enter the operational area. The sudden collapse of the front structure caused from a hose failure may result in injuries or death. Figure 34 When stopping or parking the machine, lower the front structure to the ground.

  • Page 56: Battery

    BATTERY Battery Hazard Prevention Battery electrolyte contains diluted sulfuric acid and batteries generate hydrogen gas. Hydrogen gas is highly explosive, and mistakes in handling them can cause serious injury or fire. To prevent problems, always do the following: • Do not smoke or bring any flame near the battery. •...
  • Page 57 Disconnect Batteries Before Electrical Service or Electrical Welding Remove cable to negative terminal first when disconnecting cable. Connect positive terminal cables first when installing a battery. Use Low Heat Portable Lighting Hot surfaces on trouble lights or portable work lights can set off fuel or battery explosive gases.

  • Page 58: Towing

    • If the engine on the problem machine will not start or there is a failure in the brake system. always contact your DOOSAN distributor. • Never go between the towing machine and the towed machine during the towing operation.

  • Page 59: Shipping And Transportation

    SHIPPING AND TRANSPORTATION Obey State and Local Over-the-Road Regulations Check state and local restrictions regarding weight, width and length of a load before making any other preparation for transport. The hauling vehicle, trailer and load must all be in compliance with local regulations governing the intended shipping route.
  • Page 60 Safety OP000753 1-48...

  • Page 61: Operating Controls

    OP000754 Operating Controls The "Operating Controls" section presented here consists of the following groups: “Component Locations” on page 2-2 “Operator's Area” on page 2-4 “Steering Console and Pedals” on page 2-5 “Front Instrument Panel” on page 2-13 “Right Side Switch Panel” on page 2-22 “Various Cabin Locations”...

  • Page 62: Component Locations

    COMPONENT LOCATIONS DL160 The following figure identifies the location of major machine components. 23 24 HAAA4070 Figure 1 Operating Controls OP000754...
  • Page 63 Reference Reference Description Description Number Number Front Wheel Cover Seat Oil Tank Muffler Operator’s Cab Radiator Transmission Oil Filter Air Conditioner Condenser Engine Oil Level Gauge (Located on R.h. Side) Rear Wheel Cover Engine Oil Filler Cap Main Pump (Located on R.h. Side) Air Cleaner Battery Engine...

  • Page 64: Operator's Area

    OPERATOR'S AREA Figure 2, identifies controls in operator's cabin. FG006189 Figure 2 Reference Reference Description Description Number Number Steering Console and Pedal Right Side Switch Panel (See page 2-5) (See page 2-22) Various Cabin Locations Seat Adjustment (See page 2-33) (See page 2-44) Operating Controls OP000754...

  • Page 65: Steering Console And Pedals

    STEERING CONSOLE AND PEDALS FG006191 Figure 3 Reference Reference Description Description Number Number Starter Switch Steering Wheel Horn Button Kick-down Switch Combination Switch Transmission Lever Accelerator Pedal Front Instrument Panel (See page 2-13) Steering Wheel Adjustment Lever Hour Meter Brake Pedals Hazard Warning Light Switch Operating Controls OP000754...
  • Page 66 1. Starter Switch A three-position starter switch is used to start or shut down engine for equipment operation. Turning the switch to this position turns the engine "OFF" along with its electrical system. In this position the engine is "OFF" but the interior cabin light and fuel tank transfer pump (if equipped) are functional.
  • Page 67 2. Horn Button (Two Places) Pressing the button at the end of the combination switch (Figure 5) or the left button at the tip of the pilot control valve lever (joystick) (Figure 6), the horn will sound. NOTE: Starter switch must be "ON." AHO0890L Figure 5 FG013047...
  • Page 68 NOTE: Using soapy water or synthetic detergent instead of window cleaning fluid, may damage the wiper blade or painted surfaces. Use standard window cleaning fluid: SSK703 Horn Button - The center button on end of lever activates horn. (Only while being pressed.) Wiper Switch - Activates wipers when outside area of lever is rotated.
  • Page 69 5. Steering Wheel Adjustment Lever Control lever (1, Figure 10) is used allow wheel to be moved to the most convenient position for the operator. Adjusting Steering Wheel Tilt Pull lever (1, Figure 11) upward and move wheel (2, Figure 11) to desired position.
  • Page 70 7. Steering Wheel Rotating steering wheel controls position of front wheels and this determines direction of machine travel. FG003939 Figure 13 8. Kick-down Switch (Two places) When transmission is in 2nd gear, pressing this switch will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement.
  • Page 71 9. Transmission Lever Forward - When the lever is pushed forward, transmission is in "FORWARD." 1st, 2nd, 3rd and 4th are available. Neutral - When the lever is returned to the center position, between forward reverse, transmission is in "NEUTRAL." Reverse When lever...
  • Page 72 11. 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. FG004112 Figure 19 12. Hazard Warning Light Switch This warning light is used when the equipment is stopped due to a malfunction or when an emergency occurs.

  • Page 73: Front Instrument Panel

    FRONT INSTRUMENT PANEL x100r/min km/h FG013044 Figure 21 Gauges Reference Reference Description Description Number Number Transmission Display Engine Coolant Temperature Gauge Speedometer Transmission Oil Temperature Gauge Tachometer Hour Meter Fuel Gauge Warning and Indicator Lights Reference Reference Description Description Number Number Left Turn and Hazard Warning Light Parking Brake Indicator Light...
  • Page 74 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 the "I" (ON) position. If any light fails to turn "ON"...
  • Page 75 2. Speedometer This meter displays speed at which vehicle is traveling. FG004182 Figure 25 3. Tachometer This meter displays engine speed in revolutions per minute. FG004183 Figure 26 4. Fuel Gauge This gauge displays amount of fuel in tank. "F" means the tank is "full";...
  • Page 76 6. Transmission Oil Temperature Gauge This gauge displays temperature of oil in transmission converter and transmission circuit. CAUTION! When the pointer indicates red zone, it means the transmission is overheated. Stop the operation, let the engine run at low rpm and wait for transmission to FG003950 cool down.
  • Page 77 9. High Beam Indicator Light This indicator light will turn "ON," when the headlights are turned to "HIGH BEAM." HAOD394L Figure 32 10. Work Light Indicator Light This indicator light will turn "ON," when the front and/or rear work lights are activated. 2658A Figure 33 11.
  • Page 78 13. Not Used 14. Right Turn and Hazard Warning Light This light blinks when right turn signal is turned "ON." Both lights blink when warning lights are turned "ON." NOTE: If left and right turn indicators blink together, or if they blink faster than normal, a light bulb is not operating or flasher solenoid is damaged.
  • Page 79 17. Brake Fluid Pressure Warning Light This warning light will turn "ON," when pressure drops in brake fluid circuit. When light turns "ON," an alarm also sounds. WARNING! Never operate or travel machine when this light is "ON" or when alarm is sounding. Always investigate HA0O2024 cause of the drop in brake fluid pressure, and repair Figure 39...
  • Page 80 20. Engine Stop Light This light will turn "ON" when a fatal system error happens to the engine it self or peripherals. If this light turns "ON", check the engine as described under the engine diagnostic switch and repair the cause of the fault.
  • Page 81 22. Water in Fuel Warning Light This indicator light will turn "ON," when the water separator is full. When this light turns "ON," drain the water from the water separator as soon as possible. FG010520 Figure 45 Operating Controls OP000754 2-21...

  • Page 82: Right Side Switch Panel

    RIGHT SIDE SWITCH PANEL 10 11 12 13 14 15 16 FG013049 Figure 46 Reference Reference Description Description Number Number Pilot Control Valve Lever Parking Brake Switch (Joystick) Transmission Cutoff Switch Kick-down Switch Mirror Heating Switch Horn Button Engine Diagnostic Switch Cigar Lighter Idle Speed Control Switch Automatic Shift Mode Switch...
  • Page 83 1. Pilot Control Valve Lever (Joystick) If loader is equipped with log forks this lever controls boom, bucket and log forks. Used to position bucket and boom. This lever is capable of raising or lowering boom, and crowding or dumping bucket. When machine is being traveled, the lever (joystick) can be "LOCKED"...
  • Page 84 2. Kick-down Switch (Two Places) Kick-down Switch Function - When transmission is in 2nd gear, pressing this switch (Figure 50) will shift transmission into 1st gear. This will allow the driver to perform a quick digging movement. Kick-down function range: •...
  • Page 85 4. Cigar Lighter Push the lighter all the way into the socket and release your hand. After pushing it in, it will be ejected when it is heated. If it does not eject after a short time, pull it out and have it serviced.
  • Page 86 6. Economy Mode Switch This economy mode switch allows the operator to switch between 100% throttle torque and droop curve and about an 80% derated torque curve and droop. In the economy mode, fuel consumption is clearly reduced by utilising a reduced-power characteristic map for the engine.
  • Page 87 9. Front Work Light Switch In this position, this switch turns "OFF" work lights mounted on the front top of cabin. In this position, this switch turns "ON" work lights mounted on the front top of cabin. CAUTION! Do not turn "ON" the work light when traveling on HAOQ071L public roads.
  • Page 88 12. Pilot Cutoff Switch In this position the operator cannot operate the pilot control valve lever (joystick). In this position the operator can fully control the movement of the pilot control valve lever (joystick). CAUTION! HBOI110L When driving or parking, the pilot cutoff switch must Figure 61 be changed to "O"...
  • Page 89 14. Transmission Cutoff Switch This switch changes the mode of the brake pedal from "INCHING" to "NO INCHING." In this position, the "NO INCHING" mode is selected. In the "NO INCHING" mode, the power transmission line is still connected when the brake pedal is pressed, thus, making it easier to start off on an incline.
  • Page 90 16. Engine Diagnostic Switch If the engine warning light turns "ON" or "blinks," when the engine is running, it means a fault code has been recorded. When this occurs, the engine diagnostic switch allows the operator to view the fault codes. The active fault code is started after this switch turns "ON"...
  • Page 91 19. Emergency Steering Test Switch and Automatic Test (Optional) Emergency Steering Test Switch This switch is used to test whether the emergency steering system is properly functioning. The system must be tested during the start-up procedure to ensure that the system is properly functioning. Test emergency steering system using the following AJO0010L procedure:...
  • Page 92 21. Power Socket for 12 Volt This is a power socket for only 12V DC devices. This socket can be used for charging a cellular phone or powering a small 12V DC electrical device. Open the cap when using it. 12 V NOTE: This socket is designed for small electrical...

  • Page 93: Various Cabin Locations

    VARIOUS CABIN LOCATIONS FG006505 Figure 72 Reference Reference Description Description Number Number Cabin Light Storage Compartment Stereo / CD Player (Optional) Windshield Washer Tank Heater and Air Conditioner Electrical Box Control Panel Fuse Box Speakers Operating Controls OP000754 2-33...
  • Page 94 1. Cabin Light Located in the middle of front cabin, it illuminates the cabin for night work. Light turns on when the switch is in the "ON" "O" position but off in the "OFF" position. Cabin light may be turned "ON" and "OFF" irrespective of the position of the starter switch.
  • Page 95 4. Speakers Emits sound generated by stereo. HBOM350L Figure 76 5. Storage Compartments There are two storage compartments (1 and 2, Figure 77) located both sides behind of the operator's seat. Keep the operation manual other documents this compartment. FG003889 Figure 77 6.
  • Page 96 8. Fuse Box The fuse box is on the upper side of electric box. For a detailed explanation of fuses see “Fuse Box/Relay/Engine Emergency Stop Switch” on page 2-49. FG003959 Figure 79 Operating Controls OP000754 2-36...

  • Page 97: Heater And Air Conditioner Operation

    HEATER AND AIR CONDITIONER OPERATION Location of Controls and Vents FG006506 Figure 80 Reference Reference Description Description Number Number Operation Panel Foot Nozzle Front Nozzle (Air Conditioner) Rear Nozzle Front Nozzle (Defroster) The heater and air conditioner are combined into one unit to the right side of the operator's seat.
  • Page 98 Operation Panel FG003966 Figure 81 Reference Reference Description Description Number Number Fan and Air Conditioner Switch Selector Switch for Wind Direction Blower Fan Switches Ventilation Selector Switch Temperature Control Switch When a switch is selected, the LED above that switch will turn "ON"...
  • Page 99 2. Blower Fan Switches These switches are used to control the speed of the blower fan. "LO" Switch - Used for low blower speed. "MID" Switch - Used for intermediate blower speed. "HI" Switch - Used for high blower speed. NOTE: If you do not select a blower speed the heater and air conditioner will not work.
  • Page 100 Used to direct air flow to lower portion of operator's cabin. FG006508 Figure 86 Used to direct air flow for defrosting front window of operator's cabin. FG006509 Figure 87 5. Ventilation Selector Switch "A" Switch - Draws fresh air into operator's compartment.
  • Page 101 Memory Function of Used Mode The air conditioner panel has a memory function. When the starter switch is turned "OFF" the settings for the panel will be stored. When the excavator is started, the last setting will be used. Additional Operating Instruction A proper interior temperature in summer is 5 - 6°...

  • Page 102: Stereo / Cd Player (Optional)

    STEREO / CD PLAYER (OPTIONAL) Before operating the stereo or CD player, read operation manual enclosed with stereo or CD player. Stereo PROGRAM AM/FM SCAN SOUND TUNE FG000108 Figure 89 Reference Reference Description Description Number Number Power / Volume Control Preset Station Sound Mode Selector Tape Ejection...
  • Page 103 CD Player (Optional) AST/DIR FG000109 Figure 90 Operating Controls OP000754 2-43...

  • Page 104: Seat Adjustment

    SEAT ADJUSTMENT WARNING! 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 91 1.
  • Page 105 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a DOOSAN genuine part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.

  • Page 106: Seat Belt

    SEAT BELT WARNING! 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.

  • Page 107: Door Side Latch

    DOOR SIDE LATCH Door side latches (1. LH, Figure 96) and (2. RH, Figure 97) are used to secured the doors (RH, LH) to the side of the cabin when they are opened. NOTE: Keep the door closed and locked when machine is not in use.

  • Page 108: Arm Rest

    ARM REST Knob (1, Figure 100) is used to allow armrest to be moved to the most convenient position for the operator. Loosen knob and move armrest (2, Figure 100) to desired position. Tighten knob. FG003898 Figure 100 Operating Controls OP000754 2-48...

  • Page 109: Fuse Box/Relay/Engine Emergency Stop Switch

    FUSE BOX/RELAY/ENGINE EMERGENCY STOP SWITCH 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.
  • Page 110 Fuse Box Two Name Capacity Gauge Panel Stop Light Auto-detent (Optional) Electric Steering (Optional) Emergency Steer (Optional) Horn, Front Wiper Position Light (Left) Position Light (Right) Fuel Heater (Optional) Work Light (Rear) Mirror Heater Work Light (Front) Stereo, Clock, 12V Socket Memory Backup, Pilot Buzzer Operating Controls OP000754...
  • Page 111 Relays The relays are in the electrical box on the left side in the operator's cabin. If the problem is not solved after replacing the fuse, check the function of the relay. FG003973 Figure 103 FG003974 Figure 104 Circuit Breaker A circuit breaker is next to the relay by the batteries at back of unit under engine compartment hood.
  • Page 112 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. HAOB100L Figure 107 Engine Emergency Stop Switch...

  • Page 113: Operation

    OP000755 Operation WARNING! Before operating any wheel loader, read and understand "Operating Controls" section of this manual. INSTRUMENT PANEL CONTROL FUNCTIONS Monitoring System Monitoring system uses network circuits between control system and sensors installed at various machine system locations to monitor selected conditions.

  • Page 114: Engine Start And Stop

    ENGINE START AND STOP Engine Start Set parking brake switch to "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 1 Move all control levers to "NEUTRAL" position. IMPORTANT If transmission lever is not in "NEUTRAL" position, engine will not start.
  • Page 115 Set pilot cutoff switch to "O" (LOCK) position. This will "LOCK" pilot control valve lever (joystick). HBOI111L Figure 4 Rotate starter key to "I" (ON) position. All indicator lights should turn "ON." NOTE: If unit is equipped with and emergency steering system.
  • Page 116 After engine starts, check all indicator lights and gauges to be certain that all engine systems (oil pressure, oil temperature, coolant temperature, etc.) are in normal operating range. If any engine system is not normal, turn starter key to "OFF" position. Instrument Panel Light or Gauge Indicator Reading Fuel Gauge...
  • Page 117 Cold Weather Engine Start Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 8 Move all control levers to "NEUTRAL" position. IMPORTANT If transmission lever is not in "NEUTRAL" position, engine will not start.
  • Page 118 Turn starter switch to the "I" (ON) position (Figure 12). When preheat cycle is completed, the preheat indicator light (1, Figure 13) will turn "OFF." FG000084 Figure 12 CHECK FG013059 Figure 13 Rotate starter key to "START" position. Starter motor should crank immediately, and engine should start within a few seconds.
  • Page 119 Starting with Auxiliary Batteries WARNING! 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.
  • Page 120 Engine Shut Down Move transmission lever to "NEUTRAL" position. FG003979 Figure 17 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. FG003980 Figure 18 Set parking brake switch to the "I" (APPLIED) position. This will ensure that the parking brake is "APPLIED." HA0O2019 Figure 19 Set bucket on ground.
  • Page 121 Rotate starter key to "O" (OFF) position. Remove key. FG003900 Figure 21 Hydraulic System Warm-up 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. Run engine at idle (no load) for five minutes. Run engine for approximately five minutes at middle of speed range, without a load.

  • Page 122: Machine Travel

    MACHINE TRAVEL WARNING! 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.
  • Page 123 Set pilot cutoff switch to "O" (LOCKED) position. This will prevent boom and bucket from accidentally moving during travel, as a result of accidentally touching pilot control valve lever (joystick). HBOI111L Figure 24 Press brake pedal. FG002183 Figure 25 Set transmission neutral lock is in the "D" (DRIVE) position.
  • Page 124 Place transmission lever in desired gear. Shift gears one by one. Do not skip from 1st to 3rd, for example. Shift transmission lever to "FORWARD" position. FG003979 Figure 28 Release the brake pedal while slowly pressing the accelerator pedal. WARNING! When traveling at high speed or on a steep hill, do not make sharp changes in direction.

  • Page 125: Machine Shut Down

    MACHINE SHUT DOWN Ease off throttle and apply travel brakes. FG002183 Figure 30 Put transmission lever in "NEUTRAL." FG003979 Figure 31 Set transmission neutral lock is in the "N" (NEUTRAL LOCK) position. CAUTION! "LOCK" transmission lever. Whenever machine is parked, "LOCK" transmission lever in "NEUTRAL" to prevent accidental machine movement.
  • Page 126 Set bucket on ground. Set pilot cutoff switch to "O" (LOCKED) position. This will lock pilot control valve lever (joystick). Allow engine to idle for one - two minutes to cool down. Stopping a turbocharged engine without a cool down period can seriously damage turbocharger.

  • Page 127: Boom Raise Kick-Out

    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 37) makes contact with bucket height limit switch (2). When limit switch is tripped, boom will stop raising and bucket lever will automatically be returned to "NEUTRAL"...

  • Page 128: Adjustment Of Bucket Position Switch

    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,"...

  • Page 129: If Engine Stalls While Traveling

    NOTE: There are several requirements you must abide by when towing another vehicle. Learn the regulations and rules about towing another vehicle and observe them. If the loader is being towed by another vehicle and the engine will not start, remove the front and rear drive shafts; otherwise the transmission will rotate without being properly lubricated, causing seizure.

  • Page 130: Allowable Water Depth

    ALLOWABLE WATER DEPTH The water depth is an important factor to take into consideration when the loader is working in swampy areas. Do not enter water whose depth exceeds the loader's minimum ground clearance height or is high enough to wet the bottom of the axle housing. As a rule of thumb, the allowable water depth is about 400 mm.

  • Page 131: Inspection, Maintenance And Adjustment

    OP000756 Inspection, 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.
  • Page 132 Service Programmes 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.
  • Page 133 Service Points FG013060 Figure 2 Reference Reference Description Description Number Number Level Sight Gauge Hydraulic Oil Draining, Engine Oil Breather of Hydraulic Oil Filling Point, Engine Air Cleaner Main Fuel Filter Pre Cleaner Battery Filling Point, Fuel Return Oil Filter Draining, Coolant Filling Point, Coolant Pre Fuel Filter...

  • Page 134: Safety When Servicing

    SAFETY WHEN SERVICING This section deals with the safety rules which must be followed when checking and servicing the machine. DOOSAN disclaims all responsibility if other tools, lifting devices or working methods are used other than those described in this publication.
  • Page 135 Service Position BEFORE beginning service work the machine must be parked on level ground and positioned as shown below. AFTER completing the service, all guards must be installed and all engine covers must be closed and locked. FG013061 Figure 3 Reference Description Number...
  • Page 136 Before Service Read • Read the Operator's Manual and the decals/labels and instructions found on the machine to obtain the required knowledge and information about the machine. • To be able to carry out the service work in a correct way, it is important that the correct tools and equipment be used.
  • Page 137 • The installation of two-way radio, lever steering or similar equipment must be carried out by a skilled person, as faulty installation may cause interference with the electronic components controlling vital machine functions. • When carrying out service work below raised lifting arm system, the lifting arms must first have been secured (lifting arm support).
  • Page 138 Fire Prevention Measures There is always a risk of fire. It is important that you use a fire extinguisher that suits your machine and working environment and that you learn how to use it. The fire extinguisher must be placed behind the seat or externally in a lockable box. If the machine is to be provided with a handheld fire extinguisher, it must be of the ABE type (ABC in the USA), which means that it is possible to extinguish fires in both solid and liquid carbonaceous...
  • Page 139 temperature. Protect electrical leads appropriate way. Take extra care when cleaning the machine after it has been used in a fire sensitive environment, e.g. sawmill and refuse dumps. Reduce the risk of spontaneous combustion by installing for example silencer guard or high capacity cyclone precleaner. Sound absorbing material in the engine compartment must be kept clean to minimize the fire hazard.
  • Page 140 Methods and Precautionary Measures When Removing Paint: Blasting • use respirator and eye protection Paint remover or other chemicals • use a portable air extractor, respirator and protective gloves Grinding machine • use a portable air extractor, respirator and protective gloves and eye protection Floor Rubber Observe extra great care when it is suspected that you may...
  • Page 141 Rubber and Plastics Polymer materials when heated, can form compounds which are dangerous to health and environment and must therefore never be burned when scrapped. Also take care when handling machines which have been subjected to fire or other extreme heat.

  • Page 142: Preventive Maintenance

    Please make note of these numbers and their locations. These will be required whenever warranty or service work is requested. Keep this number on file, in case the mathine is stolen. Doosan Infracore Co., Ltd. 7-11, Hwasu-dong, Dong-gu, Incheon, Korea FG013062...
  • Page 143 The number is also stamped in the rear frame on the left side just below the cabin (Figure 10). FG008058 Figure 10 Engine Serial Number The engine name plate (identification label) is attached to engine headcover (1, Figure 11). The engine serial number is stamped on the right rear of the engine block, under exhaust manifold (2, Figure 11).

  • Page 144: Table Of Recommended Lubricants

    TABLE OF RECOMMENDED LUBRICANTS IMPORTANT Do not use lubricants other than those recommended, without prior written approval from DOOSAN. NOTE: Refer to the Maintenance Intervals Table for application points. LUBRICANT LUBRICANT HYDRAULIC OIL ENGINE OIL AXLE GEAR OIL MANUFACTURER GREASE...
  • Page 145 Alugard G48 by BASF Others meeting or exceeding ASTM D3306 CAUTION! Do not mix oils from different manufacturers. DOOSAN does not endorse specific brands but does suggest that owners select quality oils whose suppliers provide assurance that required standards will always be met or exceeded.

  • Page 146: Fluid Capacities

    QSB4.5 Industrial Engines Oil Drain Intervals by Duty Cycle (Hours) Heavy ACEA E5 (API CI-4) CES 20078 NOTE: Limit oil change interval to 250 hour maximum for oil grades if 40% of the operating time is in ambient temperatures above 38°C (100°F) to prevent engine damage to oil degradation resulting from high oil temperature.

  • Page 147: Lubrication And Service Chart

    LUBRICATION AND SERVICE CHART 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.
  • Page 148 Lubrication and Service Chart 250h 500h 1000h 1500h 2000h FG013088 Figure 12 Inspection, Maintenance and Adjustment OP000756 4-18...
  • Page 149 Service Data Service Interval Items To Check Service Qty. 1000 1500 2000 Front Joint Pin Grease F100 Articulation Pin Grease Rear Axle Pivot Grease Steering Cylinder Grease Front Drive Shaft Grease Bearing Fuel Tank Diesel 185 L Hydraulic Hydraulic Oil Tank 100 L Engine Oil Engine Oil Pan...

  • Page 150: Maintenance Intervals

    MAINTENANCE INTERVALS SERVICE ITEM PAGE 10 Hour / Daily Service Grease Front Attachment Pins (for First 100 Hours) 4-22 Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear 4-22 Check Engine Oil Level 4-22 Check Transmission Oil Level 4-23 Check Hydraulic System Oil Level 4-24...
  • Page 151 Replace Axle Differential and Planetaries Oil (After First 250 Hours) 4-40 Clean Outer Filter of Air Cleaner 4-41 Water Trap 4-42 500 Hour / 3 Month Service Perform All Daily, 10, 50 and 250 Hour Service Checks 4-43 Replace Hydraulic System Brake and Pilot Filter 4-43 Replace Fuel Prefilter 4-44...

  • Page 152: 10 Hour / Daily Service

    10 HOUR / DAILY SERVICE Grease Front Attachment Pins (for First 100 Hours) NOTE: Fittings are greased daily, or every 10 hours, for the first 100 hours of operation to comply with new machine break-in requirements. After that, greasing must be done every 50 hours. If bucket is being used in water, grease fittings immediately after machine is removed from water.

  • Page 153: Check Transmission Oil Level

    Check Transmission Oil Level NOTE: When checking level using a dipstick always remove and wipe it clean before making final level check. Use two people to perform this operation. Start machine and drive it until transmission fluid has warmed to 80°C (176°F). Park machine on firm, level ground.

  • Page 154: Check Hydraulic System Oil Level

    Check Hydraulic System Oil Level WARNING! The hydraulic oil will be hot after normal machine operation. Allow the system to cool before attempting to service any of the hydraulic components. The hydraulic tank is pressurized. Loosen the cap of breather to allow the pressurized air to vent. After the pressure has been released, it is safe to remove either the fill cap or service covers.

  • Page 155: Check For Leaks In Hydraulic System

    Place the cover on the access hole. Make sure the spring retaining cup (1, Figure 20) in the lower section of the cover is lined up with the spring. The filter assembly rod must be in a vertical position and perpendicular to the base of the tank.

  • Page 156: Check For Leaks In Fuel System

    Check for Leaks in Fuel System Perform an inspection of engine compartment to verify that fuel system is not leaking. If any is noted, determine the source of leak and repair. Drain Fuel Condensation Open fuel tank drain valve. (Figure 23). Allow any condensed water or sediment to drain out of tank.

  • Page 157: Check Level Of Windshield Washer Liquid

    Do not allow replaceable bucket teeth to wear down to the point that bucket base edge is exposed. (Figure 27) NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers' buckets, refer to their specific instructions.

  • Page 158: Check The Operation Of All Exterior Lights, Horn And Control Console Indicator And Monitor

    Check the Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights Turn engine starter switch to "I" (ON) position and observe all indicator lights. Restore operation of any light bulbs that do not turn "ON" at this time. Sound the horn.

  • Page 159: Inspect Cooling Fan Blade

    Inspect Cooling Fan Blade WARNING! 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. An inspection of the cooling fan is required daily. Check for cracks, loose rivets, bent or loose blades, and for contact Figure 28 between the blade tips and the fan shroud.

  • Page 160: Check Air Intake System

    Check the engine intake hose, and hose clamps for damage and tightness. 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. Figure 31 Do not operate engine if any leaks or defects are found on air intake system.

  • Page 161: 50 Hour / Weekly Service

    50 HOUR / WEEKLY SERVICE Perform All Daily, 10 Hour Service Checks Grease Front Attachment Pins Following fittings are greased daily, or every 10 hours, for first 100 hours of operation to comply with new machine break-in requirements. After that, greasing should be done every 50 hours.
  • Page 162 Bucket link connecting pin, 1 location (Figure 34). Figure 34 Lever link connecting pin, 1 location (Figure 35). Figure 35 Lift cylinder rod ends, 2 locations (1 each side) (Figure 36). Figure 36 Arm to lever connecting pin, 1 location. (Figure 37). Figure 37 Inspection, Maintenance and Adjustment OP000756...
  • Page 163 Bucket cylinder rod end, 1 location. (Figure 38) Figure 38 Lift cylinder heads, 2 locations (1 each side) (Figure 39). Figure 39 Remote grease fittings. Reference Number DL160 1, Figure 40 Right Arm 50 Hour 2, Figure 40 Bucket Cylinder Head End 50 Hour...
  • Page 164 1, 3) Loader arm foot end, 2 locations (1 each side) (Figure 41). NOTE: Greased from two remote grease points (1 and 3, Figure 40). Figure 41 Bucket cylinder head end. Greased from one remote grease point (Figure 42). Figure 42 Steering cylinder rod ends, 2 locations (1 each side).

  • Page 165: Grease Upper And Lower Center Pins

    Grease rear axle pivot, 2 locations. Use remote grease fittings mounted on left side of frame (Figure 45). Figure 45 Grease Upper and Lower Center Pins Center pins, upper (Figure 46) and lower (Figure 47). Two locations on right side of machine. FG001641 Figure 46 FG001642...

  • Page 166: Replace Hydraulic Full Flow Filter (After First 50 Hours)

    Replace Hydraulic Full Flow Filter (After First 50 Hours) NOTE: Replace hydraulic full flow filter after first 50 hours of operation rebuild every 1,000 Hours thereafter. Follow procedure under 1,000 hour maintenance interval (See page 4-57). Check Air Conditioner and Alternator Belt Tension (After First 50 Hours) Air conditioner and alternator belt tension must be checked after first 50 hours of operation to comply with new...

  • Page 167: Clean Air Conditioner Outer Filter

    Clean Air Conditioner Outer Filter This unit is equipped with an air-conditioning system. There are two filters (1 and 2, Figure 49) for air conditioner. They filter out dirt and dust particles from air being circulated into operator's cabin. They are located under the right side control panel. Open access cover on the lower right side of cabin on the outside, to gain access filter.

  • Page 168: 250 Hour / Monthly Service

    250 HOUR / MONTHLY SERVICE Perform All Daily, 10 Hour and 50 Hour Service Checks Check Engine Air Intake Precleaner The engine is equipped with a precleaner. Dust, insects, rainwater etc., can be present in the air. The precleaner collects this material and discharges it. This prevents material from being drawn into air cleaner.

  • Page 169: Turbocharger

    Turbocharger The turbocharger is lubricated and cooled by the engine lubrication system. Important for the function of the turbocharger is that: • lubrication and cooling is safeguarded by – not racing the engine immediately after it has been started. – the engine is allowed to run at low idle for a couple of minutes before it is turned off.

  • Page 170: Grease Drive Shaft

    Grease Drive Shaft Grease drive shaft center bearing using one grease point. Figure 54 Replace Transmission Oil and Filter (After First 250 Hours) NOTE: Transmission oil and filter must be changed after first 250 hours of operation to comply with new machine break-in requirements.
  • Page 171 Clean Outer Filter of Air Cleaner NOTE: Clean outer filter every 250 hours / monthly service. NOTE: If air cleaner clogged warning light (Figure 55) on instrument panel comes "ON" the air cleaner must be x100r/min serviced. km/h NOTE: When working in severely dusty conditions, the service interval should be shortened.
  • Page 172 Clean the outer filter (4, Figure 57) by blowing compressed air from the inside of the filter towards the outside. Do not use more than 205 kPa (30 psi) air pressure. WARNING! If using compressed an to clean the filter, make sure that proper eye protection is worn.

  • Page 173: 500 Hour / 3 Month Service

    500 HOUR / 3 MONTH SERVICE Perform All Daily, 10, 50 and 250 Hour Service Checks Replace Hydraulic System Brake and Pilot Filter Replace filter in pilot filter. Perform the following steps: Vent hydraulic oil tank. FG008104 Figure 62 Unscrew element cover (5, Figure 63). Cover is filled with oil.
  • Page 174 Replace Fuel Prefilter WARNING! Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Locate fuel filter inside engine compartment. Position a small container under prefilter. Drain fuel by opening drain valve on bottom of filter. NOTE: Dispose of drained fluids according to local regulations.
  • Page 175 Fuel Filter (Spin-On Type) General Information Cummins Common Rail Fuel System The Cummins Common Rail fuel system requires the use of two fuel filters. The prefuel filter have the following characteristics: • water separating • 30-micron rating • hand priming pump •...
  • Page 176 Replace Fuel Filter WARNING! Exchange filter after waiting for engine to cool. Be careful of fire hazards. Do not smoke. Locate fuel filter inside engine compartment. Position a small container under fuel filter. Figure 68 Unscrew fuel filter from head assembly. Discard fuel filter. NOTE: Dispose of drained fluids according to local regulations.
  • Page 177 NOTE: You can swing the fan guard for cleaning it‘s fan blades or radiator easily and efficiently. NOTE: Before cleaning, please stop the cooling fan by turning off it‘s engine in order to prevent any injury from fan rotation. Figure 71 Clean Air Conditioner Inner Filter This unit is equipped with an air-conditioning system.
  • Page 178 Replace Engine Oil and Filter CAUTION! 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. NOTE: Change engine oil and filter after first 50 hours on a new machine and every 500 hours thereafter.
  • Page 179 Replace Air Conditioner Outer Filter Clean air-conditioning outer filter every 50 hours and replace with a new one every 500 hours of service. See “Clean Air Conditioner Outer Filter” on page 4-37 Inspection, Maintenance and Adjustment OP000756 4-49...

  • Page 180: 1,000 Hour / 6 Month Service

    1,000 HOUR / 6 MONTH SERVICE Perform All Daily, 10, 50, 250 and 500 Hour Service Checks Air Cleaner CAUTION! Never remove air cleaner filter while engine is running. This will allow dirt to be sucked into engine and cause serious engine damage.
  • Page 181 Do not, under any circumstances, run the engine without a filter or with a damaged one. Always have a spare filter on hand and keep the filter well protected from dirt. CAUTION! Never clean the inside of air filter housing while the inner filter is not installed.
  • Page 182 Remove outer filter (4, Figure 78) from the air cleaner housing. Clean the air cleaner cover and the inside of the air cleaner housing. Do not use compressed air to blow out housing. Install new outer filter. Install air cleaner cover and evacuator valve. NOTE: Make sure that all gaskets on wing nuts and cover are properly installed and seated.
  • Page 183 Rotate filter counterclockwise to remove it (Figure 80). 10. Clean filter head. 11. Grease filter gasket and gasket mating surface on filter head. 12. Thread filter onto filter head. Tighten filter 1/2 turn after filter gasket contacts filter head. Filter must be torque to 1.6 - 2.1 kg•m (11.5 - 15 ft lb).
  • Page 184 Clean Fuel Tank and Strainer WARNING! 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.
  • Page 185 Replace Air Conditioner Inner Filter NOTE: This unit is equipped with an air filtration system which filters out dirt and dust particles from air being circulated into operator's cabin. This filter must be cleaned out every 500 hours and replaced with a new one every 1,000 hours.
  • Page 186 DOOSAN loader dealer for inspection and recharging refrigerant. A flow of bubbles is visible. Check and Adjust Engine Contact your nearest DOOSAN loader dealer. Contact engine manufacturer for checking and adjusting the following items: • Engine Compression Pressure. •...
  • Page 187 Replace Hydraulic Full Flow Filter WARNING! 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.
  • Page 188 Remove bolts (1, Figure 89) from cover (2). Lift cover (2, Figure 89) and O-ring (4) off hydraulic oil tank. Control spring (3) sits beneath cover. Remove spring (3). Remove valve (5, Figure 89) and filter element (6) from hydraulic oil tank. Clean underside of cover (2, Figure 89).

  • Page 189: 1,500 Hour / 9 Month Service

    1,500 HOUR / 9 MONTH SERVICE Perform All Daily, 10, 50, 250 and 500 Hour Service Checks Replace Axle Differential and Planetaries NOTE: Oil in both front and rear axles must be replaced after first 500 hours of operation to comply with new machine break-in requirements.
  • Page 190 Go to level plug holes (1, Figure 92) on axle ends. Add oil to these openings until oil level is even with bottom of plug hole. Recheck level on center differential. Add oil if necessary. When oil level is satisfactory at all three level plug holes, install and tighten level plugs at all three locations.

  • Page 191: 2,000 Hour / Yearly Service

    2,000 HOUR / YEARLY SERVICE Perform All Daily, 10, 50, 250, 500 and 1,000 Hour Service Checks Replace Inner Air Cleaner Element CAUTION! Never remove air cleaner element while engine is running. This will allow dirt to be sucked into engine and cause serious engine damage.
  • Page 192 Replace Pipes and Hoses Replace hoses that carry brake fluid to wheel brakes. Also replace hoses that carry hydraulic fluid to steering cylinders. It is difficult to determine condition of many hoses. The best way to ensure safe operation and to maintain maximum performance is to replace hoses on a regular basis.
  • Page 193 Replace Radiator Coolant NOTE: Do not mix ethylene glycol and propylene glycol antifreeze together. If the two are mixed, the protection level will be reduced to the level of the ethylene glycol. See “Engine Cooling System” on page 4-72, for further details. NOTE: This unit was factory filled with propylene glycol.
  • Page 194 Replace Hydraulic Oil and Clean Oil Suction Strainer CAUTION! Be certain that hydraulic oil has cooled before draining it. Hot oil could splash and cause burns. Raise boom to its highest position. Tilt bucket back as far as possible, and shut down engine. NOTE: “Fluid Capacities”...
  • Page 195 Figure 100 Without starting engine, operate controls to dump bucket. (Figure 99). Then operate controls to lower boom. (Figure 100). This will drain oil out of boom and bucket cylinders. Replace full flow hydraulic filters as described under “Replace Hydraulic Full Flow Filter” on page 4-57. Remove and clean pump inlet strainer (7, Figure 101) that is located inside hydraulic oil tank.
  • Page 196 Count the number of times you can depress the right-hand brake pedal before the brake warning light comes on. If the number counted is less than five (5), there is some problem with the accumulator. Contact your nearest DOOSAN dealer. Inspection, Maintenance and Adjustment OP000756 4-66...

  • Page 197: Hour / Six Year Service

    Standard ISO 8331 and EN982 CEN) European regulations state that the in-service life of any hydraulic hose exceed years. DOOSAN recommends the following: • Hoses at the customer premises cannot be stored more than 2 years before being discarded or installed on a machine.

  • Page 198: Severe Conditions Maintenance

    SEVERE CONDITIONS MAINTENANCE Operating Condition Required Maintenance Mud, Water, Rain Check for loose fittings, obvious damage to machine, or any fluid leakage. After completing operations, clean mud, rocks, or debris from machine. Inspect for damage, cracked welds, or loosened parts. Perform all daily lubrication and service.

  • Page 199: Bolt Torque Chart

    BOLT TORQUE CHART Tightening Torque Specifications for Metric Bolts (For coated threads, prelubricated assemblies) Grade Gr. 8.8 Gr. 10.9 Gr. 12.9 Dia. kg•m ft lb kg•m ft lb kg•m ft lb 5 mm x std. 0.59 0.79 6 mm x std. 1.00 1.38 1.66...

  • Page 200: Electrical System

    ELECTRICAL SYSTEM Check Battery Condition WARNING! Before starting any battery service work, make sure to shut the engine off and turn the starter switch to the "I" (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.
  • Page 201 Inspect charge condition of battery by looking at the indicator light built into battery. • GREEN: Normal. • BLACK: Insufficient charging - check alternator. • TRANSPARENT: Insufficient battery electrolyte - replace with new battery. NOTE: Colors may vary from one battery manufacturer to another.

  • Page 202: Engine Cooling System

    ENGINE COOLING SYSTEM General Keeping an engine's cooling system in peak operating condition, can have many benefits to 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.
  • Page 203 (extended life antifreeze) does. Ethylene glycol is also very hazardous to the environment, people and animals. DOOSAN recommends that ethylene glycol be replaced with propylene glycol. The newer propylene glycol antifreeze comes in many different colors.

  • Page 204: Handling Of Accumulator

    Do not weld on accumulator, or try attaching anything to it. • When replacing an accumulator, contact a DOOSAN distributor or sales agency so the gas can be properly released. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure can penetrate the skin and cause serious injuries.

  • Page 205: Hydraulic Pressure Checks

    HYDRAULIC PRESSURE CHECKS Hydraulic pressures for most systems can be check by using the remote test ports shown in Figure 107. Port Number Description Specification Steering Pump Pressure 175 ± 5 Bar Main Pump Pressure 200 ± 5 Bar Transmission System 16 ~ 18 Bar Pressure Brake Charge Pressure...
  • Page 206 Brake Charge Pressure Attach gauge to (Port 2, Figure 107). Figure 110 Loosen lock nut on adjusting screw of unloader valve cartridge (Figure 111). Turn adjusting screw clockwise to raise relief pressure. Turn adjusting screw counterclockwise to lower relief pressure. Relief pressure should be set at 120 kg/cm (1,710 psi) cut-in and 140 kg/cm...
  • Page 207 Steering Pump Pressure Attach gauge to (Port 4, Figure 107). Adjust relief valve cartridge on steering valve (Figure 113). Cartridge must be adjusted to open at 170 - 175 kg/cm (2420 - 2490 psi). Figure 113 Remove plug and washer (Figure 114). Adjust screw that is located beneath plug.
  • Page 208 Service Brake Outlet Pressure Attach gauge to brake pressure test port (1, Figure 117) of front axle. Outlet pressure should be 34 - 40 kg/cm (484 - 569 psi). Figure 117 Inspection, Maintenance and Adjustment OP000756 4-78...
  • Page 209 Fan Motor Pressure and Fan rpm The motor intergrates a proportional pressure relief valve, the fan speed (and thus the cooling performance) can be infinitely controlled depending on two different simultaneous input signals from temperature sensors. The cooling fan controller processes the two input signals and controls the valve coil current.
  • Page 210 Checking the Relief Pressure of Fan Motor FG013090 Figure 119 Reference Reference Description Description Number Number Fan Motor Outlet Line Fan Guard Relief Valve Inlet Line Maximum Fan Speed, Checking Open the radiator grille in order to connect the pressure gauge.

  • Page 211: Long Term Storage

    LONG TERM STORAGE 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.

  • Page 212: Parking Brake Adjustment

    PARKING BRAKE ADJUSTMENT To adjust parking brake, perform the following steps: Jack up machine enough to allow tires to rotate freely. Turn “OFF” engine and place transmission lever in “NEUTRAL.” Turn ignition switch to “ON” position. Move parking brake switch to “UNLOCKED”...

  • Page 213: Tires

    TIRES 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 4-85) The tire pressure may have been raised before the machine was delivered from the factory.
  • Page 214 Stay away until tire and rim cool down. If the following defects are found in tires, for safety reasons the tires must be replaced with new tires. For the replacement contact DOOSAN loader dealer or a tire manufacturer's local dealer. •...
  • Page 215 • Tire layers are separated. • Radial cracks reach the carcass. • Deformation or damage which makes the tire unsuitable for use. Recommended Air Pressure Working Pressure Driving Pressure Tires Remarks Front Rear Front Rear +0.1 +0.1 +0.1 +0.1 17.5R25(L2) Radial Ply Tire (Standard) psi)
  • Page 216 Inspection, Maintenance and Adjustment OP000756 4-86...

  • Page 217: Transportation

    OP000039 Transportation LOADING AND UNLOADING When transporting the machine observe the various road rules, road transportation vehicle laws and vehicle limit ordinances, etc. It is a good idea to obtain special platform for loading and unloading the machine. Park the trailer on a flat firm roadbed. Keep a fairly long distance between the road shoulder and the machine.

  • Page 218: Summary Of Safety Precautions For Lifting

    SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING To make safe lifts, the following items must be evaluated by operator and work site crew. • Condition of ground support. • Wheel loader configuration and attachments. • Weight, lifting height and lifting radius. •...

  • Page 219: Troubleshooting

    Add oil. or surges. Plugged air intake system. Clean system and replace filter. Injection pump out of Contact your DOOSAN dealer. adjustment. Plugged fuel filter. Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel.
  • Page 220 Clogged or dirty fuel injectors. Clean injectors. Fuel filters plugged. Replace filters. Engine speed control cable Readjust. out of adjustment. Injection pump out of Contact your DOOSAN dealer. adjustment. Valve backlash faulty. Adjust backlash. Engine runs hot. Low coolant level. Add coolant. Thermostat faulty.

  • Page 221: Hydraulic System

    Air in fuel lines. Tighten fuel connections and filter. Fuel filter clogged. Replace fuel filter. Fuel pump failure. Contact your DOOSAN dealer. Incorrect fuel injection timing. Insufficient power. Air cleaner filter clogged. Clean or replace element. Fuel filer element clogged.
  • Page 222 Wrong pilot line connection. Reconnect pilot lines. Oil temperature too high. Debris in exterior of cooler. Clean exterior of cooler. Oil cooler faulty. Contact your DOOSAN dealer. Fan belt loose. Tighten fan belting as required. Actuators on one side of Overload relief valve is not Repair valve or replace.

  • Page 223: Travel System

    TRAVEL SYSTEM General Problem Possible Cause Remedy Machine will not travel. Transmission clutch pressure Adjust pressure. incorrect. Transmission charge pump Replace pump. damaged. Damage to transmission control Repair wiring. valve wiring harness. Burned travel relay or fuse. Replace relay or fuse. Forward/Reverse solenoid for Clean and repair.

  • Page 224: Steering

    STEERING Problem Possible Cause Remedy Steering Wheel is hard to turn. Sediment blocking direction Clean and repair. change spool orifice, inside priority valve. Sediment blocking amplifying spool Clean and repair. orifice, inside priority valve. Sediment blocking load sensing Clean and repair. line orifice, inside priority valve.

  • Page 225: Braking

    BRAKING Problem Possible Cause Remedy Reduced brake action. Low secondary pressure in brake Repair or replace brake valve. valve. Worn brake disks. Replace brake disks. Damaged brake disks. Replace brake disks. Damaged brake valve block. Replace valve. Air in brake hydraulics due to leak Repair leak, bleed system.
  • Page 226 Troubleshooting OP000040...

  • Page 227: Specification

    OP000757 Specification GENERAL SPECIFICATIONS DL160 ITEM SPECIFICATION Standard Bucket Capacity (BOT / BOC) 1.5 m (2.0 yd ) / 1.6 m (2.1 yd Vehicle Weight (STD / OPT) 8,730 kg (19,246 lb) / 8,760 kg (19,313 lb) Engine (SAE J1995 Gross) Emission U.S EPA Tier3 (EU Stage IIIA)

  • Page 228: Working Range And Dimensions

    WORKING RANGE AND DIMENSIONS Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. HBOM630I Figure 1 Specification OP000757...
  • Page 229 DIMENSION CATEGORY WITH BOLT-ON CUTTING EDGE WITH BOLT-ON TEETH Overall Length (A) 6,510 mm (21' - 4'') 6,590 mm (21' - 7'') Overall Width, without bucket (B) 2,450 mm (8' - 0'') 2,450 mm (8' - 0'') Overall Height (C) 3,139 mm (10' - 4'') 3,139 mm (10' - 4'') Bucket Width (D)

  • Page 230: Working Capacities

    WORKING CAPACITIES Bucket Capacity Standard cutting edged bucket has a capacity of 1.6 m (2.1 yd Tipping Load Static Tipping Load with bucket in Over Front position is 6,500 kg (14,330 lb). With bucket in Fully Turned position, Static Tipping Load is 5,300 kg (11,685 lb). Material Weight The data below describes weight of a cubic meter (cubic yard) of many types of workload materials.
  • Page 231 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS Clay, DAMP, natural 1,746 kg/m --------------------- --------------------- (2,943 lb/yd Cement, Portland, DRY...
  • Page 232 LOW WEIGHT OR MEDIUM WEIGHT OR HIGH WEIGHT OR DENSITY DENSITY DENSITY MATERIAL 1,100 KG/M 1,600 KG/M 2,000 KG/M (1,850 LB/YD ), OR (2,700 LB/YD ), OR (3,370 LB/YD ), OR LESS LESS LESS 929 kg/m Salt --------------------- --------------------- (1,566 lb/yd 529 kg/m Snow, light density ---------------------...

  • Page 233: Index

    Index 2-19 Numerics Brake Fluid Warning Light 4-50 Brake Pedal 1,000 Hour / 6 Month Service 4-59 Troubleshooting 1,500 Hour / 9 Month Service 4-67 Bucket 12,000 Hour / Six Year Service 3-15 Angle Indicator 4-61 2,000 Hour / Annually Service Capacity 4-31 50 Hour / Weekly Service...
  • Page 234 4-29 Drive Belt Wear Hydraulic Oil Tank 4-48 4-38 Filter Change Drain Water 4-35 Oil and Filter Hydraulic System 4-48 4-24 Oil Change Check Oil Level 4-22 4-80 Oil Level Check Fan Motor Pressure 4-13 4-36, 4-57 Serial Number Full Flow Filter - Replace 4-64 Start Hydraulic Oil - Replace...
  • Page 235 4-18 2-46 Lubrication and Service Chart Seat Belt 4-27 Seat Belt Inspection 1-47 Shipping and Transportation Shutdown Machine Engine Stop 3-13 Shutdown 3-13 Machine 3-10 Travel 1-33 Shutdown Control Functions 1-34 Maintenance 1-27 Sloping Terrain 4-20 Maintenance Intervals 2-35 Speakers Material Weight 2-15 Speedometer...
  • Page 236 2-11 Lever 4-40, 4-52 Oil - Drain and Replace 2-45 Vibration 4-40, 4-52 1-15 Oil Filter Replacement Vibration Level 4-23 Oil Level Check 1-31 Visibility 2-16 Oil Temperature Gauge Transportation Travel 2-21 Water in Fuel Warning Light 1-27 Precautions Weight of Workload Materials Travel System 4-84 Wheel Nut Torque...

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