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Summary of Contents for SunBear DL165
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SUNBEAR HEAVY EQUIPMENT DL165 Skid Steer Loader Ow n e r's an d Op e rato r's Man u al PUBLICATION NO. 16500 SEPTEMBER, 2009 Courtesy of Machine.Market...
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SUNBEAR HEAVY EQUIPMENT LIABILTY WARRANTY THE WARRANTY IS THE ONLY OBLIGATION OF SUNBEAR HEAVY EQUIPMENT OR A SUNBEAR HEAVY EQUIPMENT DEALER TO THE PURCHASER OR ANYONE ELSE CONCERNING A PRODUCT. IT'S USE OR PERFORMANCE OR ITS LOSS OF USE OR FAILURE TO PERFORM.
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FOREWORD This book has been written to give the Owner / Operator necessary operating, servicing and preventative maintenance instructions on the loader. Read this manual completely and know the loader before operating or servicing it. Do not do any service procedures that are not in the Operator•s manual. Only service personnel that have had training in the service of this loader can do these service procedures.
1. SAFETY PRECAUTIONS To avoid personal injury, lower the lift arms, shut off the engine, raise the seat bar and cycle the hydraulics to ensure they are locked. Then, unlatch the seat belt WARNING and exit the loader. Do not enter or exit with the engine running unless as specified in this manual or under...
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2. CONTROLS 2. CONTROLS 2. 1 Instrument Panel 2. 2 Control Lever Handles 2. 3 Seat and Seat Belt 2. 4 Seat Bar 2. 5 Parking Brake 2. 6 Throttle Control 2. 7 Lift Arm Support 2. 8 Steering Control 2.
2. CONTROLS INSTRUMENT PANEL ½ HOUR METER 0 0 0 0 3 2 H FULL 1/10 K5250A 1. Left Signal Indicator Light: This light will 12. Coolant Temperature Indicator Light: This light illuminate when the operator uses the optional left signal. will illuminate if there is a rise in engine temperature.
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2. CONTROLS CONTROL LEVER HANDLES Ensure liftarm brace is LH Control Handle RH Control Handle properly stowed before IMPORTANT raising or lowering lift arms 18. Back Light Switch: This switch is a toggle switch Push up to turn the dipped beam lights on. This light are located on the rear of the loader.
2. CONTROLS SEAT AND SEAT BELT The seat can be adjusted forward or back for operator comfort (Fig. 2.3A) For your safety the loader is equipped with a seat belt. Before starting the loader adjust and fasten the seat belt (Fig.
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2. CONTROLS 2. 4 SEAT BAR For operator protection the loader is equipped with a seat bar. The loader must be started with the operator seated in the loader and the seat bar in the up position. To raise the seat bar, lift up on the bar (Fig.
2. CONTROLS 2. 5 PARKING BRAKE The loader is equipped with park brakes, located inside the torque motor. The brakes are activated and de-activated by the seat bar, via charge pressure. When the seat bar is in the up position, the brake is activated (Fig. 2.5A). When the seat bar is in the down position, the brake is off (Fig.
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2. CONTROLS 2. 7 LIFT ARM SUPPORT Liftarm Support, For safety while performing regular service or Stored Position maintenance work the loader is equipped with a liftarm support. The liftarm support, when engaged, prevents the liftarms from dropping if hydraulic pressure is relieved or the right hand control lever is accidentally cycled.
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2. CONTROLS ELECTRIC SOLENOID AUXILIARY HYDRAULIC CONTROL AUXILIARY CONTROLS Auxiliary hydraulics (solenoid operated - standard) will only operate with the seat bar down. NEUTRAL A switch located on the R.H. steering control lever (Fig. 2.8A) is used to engage the loader's auxiliary hydraulic circuit to power attachments such as post hole augers, sweepers, etc.
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2. CONTROLS 2. 10 LIFTARM CONTROLS -Move the lever diagonally between raise and tilt forward (D-F) to do both at the same time (raise and tilt the work The right hand control lever (Fig. 2.10) operates the attachment forward). loader•s liftarm and bucket hydraulic system. Refer to section 2.8 for instructions on steering control.
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2. CONTROLS 2.11 QUICK - TACH Push the locking lever (1) fully down (Fig. 2.11D) extending the lock pins (Fig. 2.11E item 2) through the attachment and The quick-tach, which is standard equipment, allows securing the attachment. changing from one attachment to another quickly without Before operating the attachment check that the locking pins having to remove bolt or pins.
2. CONTROLS 2.12 ELECTRICAL PANEL The loader is equipped with a 12 volt, negative ground electrical system. The fuse and relay panel is located in the FUSE PANEL (3) engine compartment on the underside of the engine cover. 6. Rear Lamp. (10A) The panel consists of the following(Fig.2.12): 7.
3. OPERATION STARTING INSTRUCTIONS This engine is equipped 1. Pre-Starting Inspection with glow plugs. Do not IMPORTANT use ether or any high Before starting the loader complete the following inspection: energy fuels to assist starting. (1) Check the hydraulic oil level, engine oil level, engine coolant level and fuel supply.
3. OPERATION To avoid personal injury, lower the lift arms, shut off Handle the engine, raise the seat bar and cycle the hydraulic controls to ensure they are locked. Then, unlatch the seat WARNING belt and exit the loader. Do not enter or exit with the engine running unless as specified in this manual or...
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3. OPERATION 3. 3 FILLING FROM A PILE Fig. 3.3A--Push ahead on the right hand control lever (1) and lower the lift arms completely down. Push to the right on the right hand control lever (2) and place the cutting edge of the bucket on the ground.
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3. OPERATION 3. 4 DIGGING WITH A BUCKET Fig. 3.4D--Push ahead on the right hand control lever (1) and lower the lift arms completely down. Push to the right on the right hand lever (2) and place the cutting edge of the bucket on the ground.
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3. OPERATION 3. 5 LEVELING AND BACKFILLING Fig. 3.5G--Spread dirt on uneven ground by pulling back on the right hand control lever (4) to raise the lift arms and push to the right on the right hand control lever (2) to tilt the bucket down as you drive forward.
3. OPERATION 3. 6 AUXILIARY HYDRAULICS C3022 Fig. 3.6J--To operate an attachment such as a grapple fork the Auxiliary Hydraulic Control Switch (rocker switch) on the Left Hand Control Lever will be used. Push right of neutral on the Auxiliary Hydraulic Control Switch to open the grapple.
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3. OPERATION 3. 7 LIFTING (Optional) The loader can be equipped with features to use in lifting (for example by crane onto a flatbed trailer or a flat car), for securing, and for extraction (from mud or snow). To facilitate this requires the optional lifting lugs. To lift using a crane, first follow the shut - off procedure in section 3.1-3.
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3. OPERATION SECURING AND TRANSPORTING There are three tie down points provided for securing the skid steer while transporting. One at the lower front and two at the rear (Fig. 3.9). Be sure the trailer and/or truck is of adequate size and capacity to safely transport your skid steer.
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3. OPERATION 3.10 LOWERING LIFT ARMS (ENGINE OFF) This section is currently under review. You will be notified and supplied with an updated section when it is available. To avoid personal injury: Do not leave lift arms up WARNING unless the lift arm support is engaged.
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3. OPERATION 3.11 BATTERY MAINTENANCE AND BOOSTING Inspect the battery on a regular basis for damage such as a cracked or broken case or cover which would allow electrolyte loss. (Fig. 3.11A) Check the battery cables for tightness and ensure they are corrosion free.
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3. OPERATION 3.12 ACCUMULATOR The accumulator (fig. 3.11A) stores system pressure until it is required. The key must be placed in the "On" position Accumulator to operate the electric auxiliary (engine not running). The electric auxiliary and stored system pressure can be used to activate the spools.
4. MAINTENANCE 4.1 PREVENTIVE MAINTENANCE SERVICE SCHEDULE ITEM SERVICE REQUIRED Engine Oil Check level and add if necessary. Use 10W30 API Classification SJ. Hydraulic Oil Check level and add if necessary. Use10W30 API Classification SJ. Radiator Check level and add if necessary. Fill with 50% mixture of ethylene glycol and water.
WARNING performed by an serious injury. authorized SUNBEAR € DO NOTuse your hand to check dealer. for leaks. Use a piece of cardboard or paper to search for leaks. € Stop engine and relieve pressure...
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4. MAINTENANCE Tilt Cab The cab assembly can be tilted up at the front to provide access to the controls, hydraulic and hydrostatic components. To tilt the cab assembly, remove the bolts located at the front corners of the cab,close and latch cab door if so equipped, tilt cab up and insert prop rod (Fig.4.2D and 4.2E).
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4. MAINTENANCE 4. 3 DAILY SERVICE CHECK Hydraulic Oil Level Check the oil level with the machine on a level surface with the lift arms down and the attachment grounded. Open the rear door and check the oil level sight tube (Fig. 4.3A).
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4. MAINTENANCE Tires and Wheel Nuts Torque Wheel Nuts 100 - 110 lbs. ft. (136 - 149 Nm) Inspect tires for wear or damage. Check and inflate tires to correct pressure: 10.00 x 16.5 ...40 - 45 PSI (276 - 310 kPa) To prevent shearing of the wheel studs and rim damage check wheel nuts for proper torque 100 -110 lbs.
4. MAINTENANCE Radiator / Oil Cooler Service Coolant Overflow With the engine cool, check the coolant level in the Reservoir overflow reservoir (fig. 4.3G). Ensure the coolant level is at the Full-Cold mark on the reservoir by adding 50% mixture of ethylene glycol and water if required. The radiator and oil cooler fins must be kept free of debris otherwise overheating of the engine will occur.
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4. MAINTENANCE Hydraulic/Hydrostatic Controls and Safety Equipment 2.1 Hydraulic Oil Filter: Change the hydraulic filter now and every 200 hours Seat Bar Switch Check: Raise the seat bar and check that the after the initial change. Lubricate the filter cartridge hydraulic controls are not functional.
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4. MAINTENANCE 7. 4 Condition of Shields and Safety Equipment: Electrical Inspect and ensure all shields are in place and 5.1 Battery (s): securely fastened. Inspect and ensure all safety Maintenance Free. equipment is working properly. Ensure owners and operators manual, safety manual and all safety and 5.2 Battery Terminals: instruction decals are in place.
4. MAINTENANCE 4. 6 FINAL DRIVE MAINTENANCE Check Plugs 1. Oil Level Check The loader has two independent final drive housings. Check the lubricating oil level with the loader on a level surface. Remove the check plug (Fig. 4.6A) located on the front of the loader to determine the oil level.
4. MAINTENANCE 4. 7 HYDRAULIC/ HYDROSTATIC SYSTEM MAINTENANCE 1. Oil Level Check Check the oil level of the hydraulic reservoir with the Oil Level machine on a level surface with the lift arms down and Sight tube the attachment grounded. Shut off the engine. Open the rear door and check the oil level sight glass (Fig.
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(Fig. 4.7D). Have a container(s) ready to hold approximately 20 gallons (76 liters) of fluid. Remove any metal particles stuck to the magnet. Seal the plug with teflon tape when replacing. Hydraulic Filter SUNBEAR recommends C5252 Fig. 4.7C that you abide by all IMPORTANT...
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Brake Service Override A service override has been incorporated for use by SUNBEAR Dealers. The normal position of the plunger is down and turned into the locked position (Fig. 4.7F). To release the park brake, turn the release button counter -clockwise (Fig.4.7F).
WARNING materials before servicing. Never service or adjust machine with engine running. Engine Oil Filter SUNBEAR recommends that you abide by all IMPOR T ANT applicable enviromental regulations when disposing of oil. Fig. 4.8B C5323 Courtesy of Machine.Market...
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4. MAINTENANCE 4. V-Belt Tension Check the V-belt tension midway between the crankshaft Alternator Fan Pulley pulley and alternator pulley (Fig. 4.8C). Deflection should Pulley be between 1/4 to 3/8 in. (7-9 mm). To avoid personal injury never add fuel to the WARNING loader when the engine is running or is hot.
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4. MAINTENANCE 7. Bleeding the Fuel System Push Down Air Bleed Screw Air must be removed from the fuel lines, after replacement of the fuel filter element, or when the tank has been run out of Plunger fuel, before starting the engine. To remove air, ensure the fuel inlet shut-off located on the side of the fuel tank is open (Pg.
4. MAINTENANCE 4. 9 AIR CLEANER MAINTENANCE Daily Maintenance Air Cleaner Hose Inspect the air cleaner canister for holes, dents, missing or mis-aligned gaskets. Check all hose clamps for tightness and inspect the hose and vacuator valve for damage (Fig. 4.9A). Servicing Cleaner Element (Fig.
4. MAINTENANCE 4. 10 ENGINE COOLING SYSTEM Engine OilCooler The engine cooling system fluid is a 50-50 mixture of ethylene glycol anti-freeze and water for both cold- weather protection and boil over protection. To drain the cooling system; locate the rad drain valve on the front right side of the radiator (Fig.
4. MAINTENANCE 4. 11 ELECTRICAL SYSTEM Battery Maintenance and Boosting Lead-acid batteries contain Inspect the batteries on a regular basis for damage such as sulfuric acid which will a cracked or broken case or cover which would allow damage the eyes or skin on electrolyte loss.
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4. MAINTENANCE 2. ELECTRICAL SCHEMATIC, 1 OF 3 Courtesy of Machine.Market...
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4. MAINTENANCE 2. ELECTRICAL SCHEMATIC, 2 OF 3 Courtesy of Machine.Market...
4. MAINTENANCE 4. 12 TIRE MAINTENANCE 1.13 Use jack stands or other suitable blocking to 1. Tire Inflation and Service support the loader while repairing tires Upon receiving your loader, check the air pressure 1.14 Insure jack has adequate capacity to lift your in the tires as indicated in the tables.
4. MAINTENANCE 4. 13 TROUBLESHOOTING 1. Hydraulic System Problem Cause Remedy Reservoir low on fluid. Add oil and check for leaks. Loss of hydraulic power (no flow from gear pump) Coupling between engine and pump Inspect and replace damaged parts. failure.
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Inspect couplings for sheared splines, replace. Also check support rear pump failure. bearings in pumps. Check system pressure. If low contact your SUNBEAR dealer. Excessive internal leakage in pump Consult your Thomas SUNBEAR dealer. and/or motor. Air in system due to low oil level in...
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4. MAINTENANCE 3. Final Drive Transmission Problem Cause Remedy Final drive transmission noisy No lubricating oil Check and bring oil to the proper level. Axles have too much end play Check and adjust. Parking brake damaged or out af Inspect and adjust or replace adjustment damaged parts.
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4. MAINTENANCE 5. Electrical (Continued) Problem Cause Remedy Engine cranks over, but will not Auxiliary hydraulics engaged Engine will smoke, but not run start. unassisted by starter. Disengage auxiliary hydraulics. Defective glow plug relay. Check continuity and if defective, replace. Defective glow plug.
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4. MAINTENANCE 6. Engine (Continued) Problem Cause Remedy Starter does not run. Battery discharged. Charge. Starter malfunctioning. Repair or replace. Key switch malfunctioning. Repair or replace. Wiring disconnected. Connect. Fuel filter clogged or dirty. Clean or change. Engine revolution is not smooth. Air cleaner clogged.
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4. MAINTENANCE 6. Engine (Continued) Problem Cause Remedy Engine overheated. Engine oil insufficient. Replenish. Fan belt broken or elongated. Change or adjust. Cooling water insufficient. Replenish. Radiator net and radiator fin clogged Clean. with dust. Inside of radiator corroded. Clean or replace. Cooling water flow route corroded.
4. MAINTENANCE 4.15 SPECIAL TOOLS Part # DESCRIPTION OPTION(O/X) ILLUSTRATION SEAL INSTALLATION TOOL: To install axle seal in final drive housing. 962201 Qty. 3 required C3651 AXLE EXTRACTOR TOOL: 955283 To remove axle from final drive housing. (6 Bolt) Qty. 1 C3652 AXLE EXTRACTOR TOOL: To remove axle from final drive housing.
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4. MAINTENANCE 4.15 SPECIAL TOOLS (Cont'd) Part # ILLUSTRATION DESCRIPTION OPTION (O/X) MULTI METER: For measuring continuity, voltage, etc. C2342 ANGLE FINDER: For measuring control angles, U-joint and chassis angles etc. C2343 HYDRAULIC FLOW and 960456 PRESSURE GAUGE ASSEMBLY Courtesy of Machine.Market...
5. SPECIFICATIONS LOADER SPECIFICATIONS Dimensions: (With Std. Tires & Dirt Bucket) A. Overall operating height ........................152.4" (3870mm) B. Height to hinge pin ..........................188.4" (3008mm) C. Overall vehicle height..........................76.2" (1935mm) D. Overall length with bucket ........................135.4" (3438mm) E. Dump angle ................................42° F.
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5. SPECIFICATIONS Controls VEHICLE: Steering direction and speed controlled by left control lever. HYDRAULICS: Lift and bucket tilt are controlled by right control lever. Auxiliary hydraulics controlled by electical switches on right control lever and left dash panel. ENGINE: Hand throttle lever, key type ignition switch and shutoff. Engine Make and model............................Cummins A2300T Cylinder....................
5. SPECIFICATIONS TORQUE SPECIFICATIONS FOR NON-CRITICAL AND NOT OTHERWISE MENTIONED APPLICATIONS. THE FOLLOWING GENERAL ASSEMBLY TORQUES WILL APPLY: BOLTS AND NUTS TORQUE SPECIFICATIONS General Application Only SAE GRADE 5 TORQUE SAE GRADE 8 TORQUE ft.lb. (Nm) ft.lb. (Nm) ft.lb. (Nm) ft.lb.
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23324 DL165 1632 lbs (740 KG) 42107 23325 SUNBEAR PULL 39196 FAST SPEED SPEED PUSH 31291 35866 41066 32275 23326 36598 39192 Courtesy of Machine.Market...
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39191 23312 41064 23310 46301 LIFT ARM DOWN VALVE PUSH 23308 HYDRAULIC HYDRAULISCH HYRAULICO HYDRAULIQUE 23307 Courtesy of Machine.Market...
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Do you have a question about the DL165 and is the answer not in the manual?
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