Doosan DL160 Operation And Maintenance Manual Download

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OP000756

Inspection, Maintenance and Adjustment
4-54

Clean Fuel Tank and Strainer

NOTE:

It is easier to clean the fuel tank when it is almost
empty.

Park the machine on a level surface, apply the parking
brake, lower the attachment to the ground, and shut down
engine.

Drain fuel tank.

Remove cover and strainer located on bottom of tank.

Use a nonflammable, nontoxic, parts cleaner to clean
strainer and any sediment inside tank.

Install strainer and cover.

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. Wash thoroughly with
soap and water.

Figure 83

Figure 84

Summary of Contents for DL160

Page 1: ...ommended 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 equi...

Page 2: ......

Page 3: ...K1040196E I I Presentation 1Presentation PRESENTATION FG013087 Figure 1 ...

Page 4: ...camshaft and a electronic control module ECM The cylinder head covers all cylinders The engine has four valves per cylinder The accelerator position is transferred electrically from accelerator pedal Electrical System The machine has three control units The Gauge Panel for the instrumentation is integrated with the display unit warning lights and instruments and provides the operator with informat...

Page 5: ...height drilling welding on brackets for fire extinguisher radio aerial or other equipment without first having discussed the alteration with personnel at the DOOSAN Infracore Engineering Department This department will decide whether the alteration may cause the approval to become void It is important that all parties concerned are aware of these regulations Hydraulic System The hydraulic system u...

Page 6: ...ty must at all times and in each separate case be maintained The person carrying out such action is also responsible for the action which in some cases may require a new CE marking and the issue of a new EU Declaration of Conformity The EU EMC Directive The electronic equipment of the machine may in some cases cause interference to other electronic equipment or suffer from external electromagnetic...

Page 7: ...ference It is therefore very important that all nonapproved electronic accessories such as communication equipment must be tested before installation and use since they can cause interference to the electronic systems of the machine IMPORTANT All installation of optional communication equipment must be carried out by trained professionals and in accordance with the DOOSAN CE instructions applicabl...

Page 8: ...Reference Number Description 1 Primary Marking The machine PIN stamped into right side 2 Product Plate The manufacturer s name and address machine PIN 3 Additional Plate for Product Plate Machine weight engine output year of manufacture year of delivery and position of CE mark EU EEA countries only 4 Cabin The manufacturer s name and address product number machine model designation max machine wei...

Page 9: ...ation 1 26 Maintenance 1 34 Battery 1 44 Towing 1 46 Shipping and Transportation 1 47 Operating Controls 2 1 Component Locations 2 2 Operator s Area 2 4 Steering Console and Pedals 2 5 Front Instrument Panel 2 13 Right Side Switch Panel 2 22 Various Cabin Locations 2 33 Heater and Air Conditioner Operation 2 37 Stereo CD Player Optional 2 42 Seat Adjustment 2 44 Seat Belt 2 46 Door Side Latch 2 47...

Page 10: ...tenance and Adjustment 4 1 Basic Preventive Maintenance 4 1 Safety When Servicing 4 4 Preventive Maintenance 4 12 Table of Recommended Lubricants 4 14 Fluid Capacities 4 16 Lubrication and Service Chart 4 17 Maintenance Intervals 4 20 10 Hour Daily Service 4 22 50 Hour Weekly Service 4 31 250 Hour Monthly Service 4 38 500 Hour 3 Month Service 4 43 1 000 Hour 6 Month Service 4 50 1 500 Hour 9 Month...

Page 11: ...nsportation 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 6 5 Steering 6 6 Braking 6 7 Electrical System 6 7 Specification 7 1 General Specifications 7 1 Working Range and Dimensions 7 2 Working Capacities 7 4 Approximate Weight of Workload Materials 7 4 Index 8 1 ...

Page 12: ...K1040196E Table of Contents IV ...

Page 13: ... page 1 13 4 General Hazard Information on page 1 13 5 Before Starting Engine on page 1 22 6 Machine Operation on page 1 26 7 Maintenance on page 1 34 8 Battery on page 1 44 9 Towing on page 1 46 10 Shipping and Transportation on page 1 47 DANGER Improper use of wheel loader could cause serious injury or death Before operating wheel loader or performing maintenance operator or technician must read...

Page 14: ...jury or accidents Always observe safety precautions and follow recommended procedures CAUTION This word is used on safety messages and safety labels and indicates potential of a hazardous situation that if not avoided could result in minor or moderate injury It may also be used to alert against a generally unsafe practice WARNING This word is used on safety messages and safety labels and indicates...

Page 15: ...fore the safety messages in this manual and on the machine may not include all possible safety precautions If any procedures or actions not specifically recommended or allowed in this manual are used you must be sure that you and others can do such procedures and actions safely and without damaging the machine If you are unsure about the safety of some procedures contact a DOOSAN distributor ...

Page 16: ...the machine There are several specific warning signs on this machine The exact location of hazards and the description of the hazards are reviewed in this section Please become familiarized with all warning signs Make sure that all of the warning signs are legible Clean the warning signs or replace the warning signs if you cannot read the words Replace the illustrations if the illustrations are no...

Page 17: ...OP000753 1 5 Safety FG013042 1 3 10 12 6 4 11 5 9 8 3 7 10 4 6 2 Figure 1 ...

Page 18: ...anual and on labels on machine Sound horn to alert people nearby before operating and make sure all persons are clear of area Always make sure when leaving operator s seat to Lower bucket or other working tools to ground LOCK transmission selector in NEUTRAL Set park brake Turn starter switch OFF Remove key from switch If hydraulic components and units are ABNORMAL consult nearest DOOSAN dealer or...

Page 19: ... When Opening Engine Hood 190 00095 4 Warnings for Using Wheel Block 4190 2547A 190 00207 WARNING Before opening hood shut down engine ACO1420L WARNING Block wheels to prevent machine movement before disengaging park brake AMO0400L ...

Page 20: ...able selected function to operate under force of gravity When shutting machine down lower front attachment to ground After engine has been shut down turn key to ON position and move joystick controls to release pressure in accumulator Remove key WARNING Explosion hazard Keep away from flame Do not weld or drill ACO1480L CAUTION Any raised attachment will lower to ground if accumulator holds a char...

Page 21: ...ngs for High Temperature Hydraulic Oil 190 00691A 190 00097 DANGER Keep out of steering turn area AMO0410L WARNING HYDRAULIC OIL Hot oil can cause injury or blindness To prevent hot oil from spurting out Turn engine off Allow oil to cool Slowly Lift cap to relieve pressure ACO1410L ...

Page 22: ... sparks and flames away from batteries Always avoid storing metals like tools or inflammable materials around or on batteries Explosion or fire can be caused by short circuiting batteries Sulfuric acid in battery is poisonous It is strong enough to burn skin eat holes in clothing and cause blindness if splashed in eyes If you spill acid on yourself 1 Flush your skin with water 2 Apply baking soda ...

Page 23: ...hment 4190 2546A 190 00105 11 Warnings to Use Safety Lock 4190 1993 190 00121 DANGER To avoid injury securely brace lift arm before disassembly of valve or piping AMO0430L WARNING Safety lock must be in LOCK position when servicing pivot area or transporting machine AMO0440L ...

Page 24: ...OP000753 Safety 1 12 12 Warning Tag 190 00695A 190 00098A WARNING DO NOT OPERATE When performing inspection or maintenance ACO1450L ...

Page 25: ... you are taking medication that makes you feel sleepy if you have been drinking or if you are suffering from emotional problems These problems will interfere with your sense of judgement in emergencies and may cause accidents When working with another operator or with a person on work site traffic duty be sure that all personnel know the nature of the work and understand all hand signals that are ...

Page 26: ...ar telephones inside the operator s compartment when driving or operating the machine There is danger that this may lead to an unexpected accident Never bring any dangerous objects such as flammable or explosive items into the operator s cabin To ensure safety do not use the radio or music headphones when operating the machine There is danger that this may lead to a serious accident When operating...

Page 27: ...ds can cause disabling or permanent injuries NOTE The equivalent continuous A weighted sound pressure level at the workstation for this machine is 76 dB A Measurement is obtained on a dynamic machine following the procedures and cabin conditions as described in ISO 6396 NOTE The guaranteed sound power level emitted by the machinery for this machine is 104 dB A Measurement is obtained on a dynamic ...

Page 28: ...tes where the machine is working and traveling in good condition Remove any large rocks or obstacles Fill any ditches and holes Provide machines for and schedule time to maintain the terrain conditions 7 Travel over longer distance e g on public roads at adjusted medium speed Always adjust the speed for preventing bouncing Asbestos Dust Hazard Prevention Asbestos dust can be HAZARDOUS to your heal...

Page 29: ...gine is running Fuel Oil and Hydraulic Fluid Fire Hazards Fuel oil and antifreeze will catch fire if it is brought close to a flame Fuel is particularly flammable and can be hazardous Always strictly observe the following Add fuel oil antifreeze and hydraulic fluid to the machine only in a well ventilated area The machine must be parked with controls lights and switches turned OFF The engine must ...

Page 30: ...r the coolant to cool then loosen the cap slowly to relieve the pressure To prevent hot oil from spurting out shut down engine wait for the oil to cool then lift the cap to relieve the pressure Injury from Work Equipment Do not enter or put your hand arm or any other part of your body between movable parts such as between the work equipment and cylinders or between the machine and work equipment I...

Page 31: ...ous personal injury or death If a fire occurs during operation escape from the machine as follows Turn the starter switch to the O OFF position and shut down engine If there is time use the fire extinguisher to extinguish as much of the fire as possible Use the handrails and steps to escape from the machine The above is the basic method for escaping from the machine but changing the method may be ...

Page 32: ...re is any danger of getting hit by objects that could strike the operator s cabin Make sure that all other work site crew members are kept well away from wheel loader and safe from potential hazards Maintain Standard Safety Equipment in Good Condition Machinery guards and body panel covers must be in place at all times Keep well clear of rotating parts Pinch point hazards such as cooling fan and a...

Page 33: ...les in the accumulator or expose it any flame fire or heat source Do not weld on the accumulator or try attaching anything to it When carrying out disassembly or maintenance of the accumulator or when disposing of the 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 pre...

Page 34: ...ility and identify their locations Be careful not to damage or cut any of these lines Check the condition of the river bed and the depth and flow of the water before operating in water or crossing a river NEVER be in water that is in excess of the permissible water depth Refer to Allowable Water Depth on page 3 18 Any type of object in the vicinity of the boom could represent a potential hazard or...

Page 35: ...rass paper and other flammable materials accumulated in the engine compartment and around the battery They could cause a fire Remove any dirt from the window glass mirrors handrails and steps Do not leave tools or spare parts laying around in the operator s compartment The vibration of the machine when traveling or during operations may cause them to fall and damage or break the control levers or ...

Page 36: ...vice work is in progress or if a warning tag is attached to controls in the cabin A machine that has not been used recently or is being operated in extremely cold temperatures could require a warm up or maintenance service before start up Check gauges and monitor displays for normal operation before starting the engine Listen for unusual noises and remain alert for other potentially hazardous cond...

Page 37: ...achine is used without repairing the problems it may lead to unexpected injury or failure Clear all personnel from directly around machine and from the area Clear all obstacles from the machine s path Beware of hazards Be sure that all windows are clean Secure the doors and the windows in the open position or in the shut position Adjust the rear view mirrors for best visibility close to the machin...

Page 38: ...t anyone operate machine unless they ve been fully and completely trained in safety and in operation of the machine Seat Belts Must Be Used at All Times Whenever engine is running operator must be seated at the control station with seat belt properly engaged Movement Alarms If wheel loader is equipped with an audible travel movement alarm test alarm on a daily basis Audible alarm should sound as s...

Page 39: ...ugh ground travel at low speed and avoid sudden changes in direction Always keep to the permissible water depth Refer to Allowable Water Depth on page 3 18 When traveling over bridges or structures on private land check first that the bridge or structure can withstand the weight of the machine When traveling on public roads check with the local authorities and follow their instructions Sloping Ter...

Page 40: ...that safety margin NOTE Before starting any type of operation near power lines either above ground or buried cable type you should always contact power utility directly and work out a safety plan with them Before Starting to Dig Contact Authorities Below ground hazards also include natural gas lines water mains tunnels and buried foundations Know what s underneath work site before starting to dig ...

Page 41: ... inadequate supports when work is being done Block wheels fore and aft to prevent any movement Digging Beneath Overhangs Digging beneath an overhang is dangerous Overhang could collapse on top of operator and cause serious injury or death Go on to another digging area before steep overhangs are formed Know height and reach limits of wheel loader and plan ahead while working Park wheel loader away ...

Page 42: ...also be guidelines standards or restrictions on equipment that may be used to perform certain kinds of work Check and follow all local requirements which may also be related to below ground hazards and power lines Never Use Ether Starting Aids An electric grid type manifold heater is used for cold starting Glowing heater element can cause ether or other starting fluid to detonate causing injury Ob...

Page 43: ... hitting the work equipment always do the following When working in tunnels on bridges under electric wires or when parking the machine or carrying out other operations in places with limited height be extremely careful not to hit the bucket or other parts To prevent collisions operate the machine at a safe speed when working in confined spaces indoors or in crowded areas Do not pass the bucket ov...

Page 44: ... becomes unstable In cold weather do not touch metal surfaces with your bare hands If you touch a metal surface in extremely cold weather your skin may freeze to the metal surface Parking Machine Avoid making sudden stops or parking the machine wherever it happens to be at the end of the work day Plan ahead so that the wheel loader will be on firm level ground away from traffic and away from high ...

Page 45: ...ll lock down security equipment that may have been installed on machine Never Let Anyone Ride on Attachment Never let anyone ride on any work attachment such as the bucket crusher grapple or clamshell grab bucket There is a danger of the person falling and suffering serious injury IMPORTANT When hydraulic system maintenance or service work must be performed be aware that accumulators in system sto...

Page 46: ...urself When washing the machine do the following Wear shoes with nonslip soles to prevent yourself from slipping and falling on wet places Wear safety glasses and protective clothing when washing the machine with high pressure steam Take action to prevent touching high pressure water and cutting your skin or having mud fly into your eyes Do not spray water directly on electrical components sensors...

Page 47: ...d explosion Fire Prevention and Explosion Prevention All fuels most lubricants and some coolant mixtures are flammable Leaking fuel or fuel that is spilled onto hot surfaces or onto electrical components can cause a fire Store all fuels and all lubricants in properly marked containers and away from all unauthorized persons Store oily rags and other flammable material in a protective container Do n...

Page 48: ...ali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Allow cooling system components to cool before you drain the cooling system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Remove the hydraulic tank filter plug only after the engine has been stopped Make sure that the hydraulic tank fi...

Page 49: ...hat 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 If heat is applied directly to rubber hoses or piping under pressure they may suddenly break so cover them with a fireproof covering Wear protective clothing...

Page 50: ...arried out with the inspection cover open but not locked there is danger that it may suddenly close and cause injury if there is a gust of wind Crushing Prevention and Cutting Prevention You should always have at least two people working together if the engine must be run during service One person needs to remain in the operator s seat ready to work the controls or stop the machine and shut off th...

Page 51: ... operation Park wheel loader on firm level ground and lower all equipment before shutting down and switching OFF controls When engine lube oil gearbox lubricant or other fluids require change wait for fluid temperatures to decrease to a moderate level before removing drain plugs NOTE Oil will drain more quickly and completely if it is warm Do not drain fluids at temperatures exceeding 95 C 203 F h...

Page 52: ... oil has enough force to pierce the skin and cause serious injury Always use a piece of wood or cardboard to check for suspected hydraulic leaks Never use your hands or expose your fingers Do not bend high pressure lines Do not strike high pressure lines Do not install lines tubes or hoses that are bent or damaged Make sure that all clamps guards and heat shields are installed correctly to prevent...

Page 53: ...tical Parts Must Be Replaced Periodically Replace following fire related components as soon as they begin to show any sign of wear or at regular periodic intervals whether or not deterioration is visible Fuel system flexible hoses the tank overflow drain hose and the fuel fill cap Hydraulic system hoses especially the pump outlet lines and front and rear pump branch hoses Keep mounting brackets an...

Page 54: ...s oil fuel solvent filters and batteries Check Tire Pressure and Condition Maintain tire pressure but do not overinflate Inspect tires and wheels daily When inflating tires follow procedures in Maintenance Section which include using an extension to allow you to avoid standing in front of or over a tire Do not change a tire unless you have both experience and proper equipment NOTE Refer to Recomme...

Page 55: ... structure verify that it can handle the load High pressure loads between the boom structure and support may cause the support to slip causing the boom to collapse leading to injuries or death Take the installation location of support and supporting surface into consideration A supporting structure must be used when disconnecting front hoses or removing any other mechanical component related to th...

Page 56: ...r vegetable oil Call a doctor or poison prevention center immediately When cleaning the top surface of the battery wipe it with a clean damp cloth Never use gasoline thinner or any other organic solvent or detergent Tighten the battery caps securely Explosive battery gas can be set off by sparks from accidental contact or static discharge Turn OFF all switches and engine when working on batteries ...

Page 57: ... or vehicle do not allow the two machines to touch Wear safety glasses or goggles while required battery connections are made 24 volt battery units consisting of two series connected twelve volt batteries have a cable connecting one positive terminal on one of the 12 volt batteries to a negative terminal on the other battery Booster or charger cable connections must be made between the nonseries c...

Page 58: ...ne the signals to use and follow these signals correctly 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 It is dangerous to carry out towing on slopes so select a place where the slope is gradual If there is no place where the sl...

Page 59: ...aration for transport The hauling vehicle trailer and load must all be in compliance with local regulations governing the intended shipping route Partial disassembly or teardown of wheel loader may be necessary to meet travel restrictions or particular conditions at the work site Refer to Transportation on page 5 1 of this Operation and Maintenance Manual for information on loading unloading and t...

Page 60: ...OP000753 Safety 1 48 ...

Page 61: ...0 Seat Belt on page 2 46 11 Door Side Latch on page 2 47 12 Arm Rest on page 2 48 13 Fuse Box Relay Engine Emergency Stop Switch on page 2 49 Each group is explained with a point location drawing or photo and a brief description of each control switch gauge or valve Indicator lights work besides the gauges on the instrument panel The operator should monitor machine pressure on the instrument panel...

Page 62: ...NT LOCATIONS DL160 The following figure identifies the location of major machine components HAAA4070 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 47 46 Figure 1 ...

Page 63: ...eturn Filter 20 Control Valve 21 Air breather 22 Steering Wheel 23 Operator s Controls 24 Air Conditioner Filter Located on R h Side 25 Rotating Beacon 26 Seat 27 Muffler 28 Radiator 29 Fan 30 Engine Oil Level Gauge Located on R h Side 30 Engine Oil Filler Cap Located on R h Side 31 Battery 32 Fuel Tank 33 Fuel Filler Cap Located On R h Side 34 Rear Pivot 35 Rear Axle 36 Engine Oil Filter 37 Trans...

Page 64: ...s controls in operator s cabin 1 3 4 FG006189 2 Figure 2 Reference Number Description 1 Steering Console and Pedal See page 2 5 2 Various Cabin Locations See page 2 33 3 Right Side Switch Panel See page 2 22 4 Seat Adjustment See page 2 44 Reference Number Description ...

Page 65: ...nce Number Description 1 Starter Switch 2 Horn Button 3 Combination Switch 4 Accelerator Pedal 5 Steering Wheel Adjustment Lever 6 Brake Pedals 7 Steering Wheel 8 Kick down Switch 9 Transmission Lever 10 Front Instrument Panel See page 2 13 11 Hour Meter 12 Hazard Warning Light Switch Reference Number Description ...

Page 66: ...ssure warning light should remain ON after the other four have turned OFF NOTE Preheat Indicator Light The operation of the preheat cycle depends on coolant temperature When the engine coolant is cold enough the preheat indicator light will remain ON until the engine preheat cycle is completed The preheat cycle takes about twenty seconds to complete and the indicator light will turn OFF When the l...

Page 67: ...s right outside directional lights and directional indicator light on instrument panel NOTE When turn is completed the lever automatically returns to the NEUTRAL position Should it not it can be manually returned by hand NOTE Turn signals will function with starter switch in OFF position C Window Washer Switch When the outside area of the lever is pressed it activates the washer pump and sprays fl...

Page 68: ...ocks into position and light turns ON the high beams G Neutral Position Normal low beams H Pull Up Momentarily turns ON both the low beams and high beams Returns to NEUTRAL position when released NOTE High and low beams will only function with the headlight switch in the position 4 Accelerator Pedal Controls the travel speed of loader and working speed of load handling system Figure 8 F G H HAAA43...

Page 69: ...Left Pedals Pressing brake pedal will apply the brakes to the loader The brake pedal modes can be switched from INCHING to NO INCHING or vice versa by using the transmission cutoff switch See page 2 29 1 FG003887 Figure 10 1 2 FG003888 RELEASE LOCK Figure 11 FG002183 Figure 12 CAUTION When descending down an incline slow down the machine by using both the brake pedal and the engine as a brake by s...

Page 70: ...will shift transmission into 1st gear This will allow the driver to perform a quick digging movement NOTE Kick down is RELEASED when transmission is placed in NEUTRAL position or the switch is pressed again Kick down function range Automatic 2nd 3rd 4th Manual 2nd A second kick down switch Figure 15 is located on the right button in the tip of the pilot control valve lever joystick FG003939 Figure...

Page 71: ...ears direction of travel error codes and kick down activation See page 2 13 A transmission neutral lever lock is in base of transmission lever This neutral lever lock prevents the transmission lever from being moved out of NEUTRAL N NEUTRAL LOCK position Prevents lever from being moved out of NEUTRAL D DRIVE position Allows lever to be moved from NEUTRAL to FORWARD and REVERSE 10 Front Instrument ...

Page 72: ...ed the directional indicator lights in front and back of the machine light up and flash warning others in the area At the same time the directional indicator lights on the instrument panel will turn ON to warn the operator The hazard warning lights operate independent of the starter switch O In this position this switch turns OFF hazard warning lights I In this position this switch turns ON all tu...

Page 73: ...Oil Temperature Gauge 7 Hour Meter Reference Number Description Reference Number Description 8 Left Turn and Hazard Warning Light 9 High Beam Indicator Light 10 Work Light Indicator Light 11 Preheat Indicator Light 12 Mirror Heating Indicator Light 13 Not Used 14 Right Turn and Hazard Warning Light 15 Battery Warning Light 16 Parking Brake Indicator Light 17 Brake Fluid Pressure Warning Light 18 A...

Page 74: ...r range indicator bars will indicate which gear is selected by displaying the corresponding number of bars The forward and reverse indicator bars will be OFF when the transmission is in MANUAL MODE When transmission is in AUTOMATIC MODE all the gear range indicator bars and both travel direction indicators will be ON IMPORTANT All of gauge and warning lights except for the turn lights high beam li...

Page 75: ...l as soon as possible When the pointer comes close to the E red zone approximately 11 7l 3 U S gal of fuel remains 5 Engine Coolant Temperature Gauge This gauge displays temperature of engine coolant 10 0 50 40 20 30 FG004182 Figure 25 15 20 10 5 0 30 25 FG004183 Figure 26 FG003948 Figure 27 FG003949 Figure 28 CAUTION When the pointer indicates red zone it means the engine is overheated Stop the o...

Page 76: ...eft Turn and Hazard Warning Light This light blinks when left 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 FG003950 Figure 29 CAUTION When the pointer indicates red zone it means the transmission is overheated Stop th...

Page 77: ...ll turn ON when the front and or rear work lights are activated 11 Preheat Indicator Light This indicator light will turn ON when the engine preheat function is operating Do not start engine as long as this light is ON 12 Mirror Heating Indicator Light This indicator light will turn ON when the mirror heater is operated Figure 32 HAOD394L Figure 33 2658A Figure 34 HAOA639L FG004184 Figure 35 ...

Page 78: ... to ON position this red warning light should turn ON When engine is running this red light should turn OFF If light remains ON when engine is running alternator is defective 16 Parking Brake Indicator Light This indicator light will turn ON when the parking brake is APPLIED If vehicle is moved while parking brake is applied a warning alarm will sound FG004174 Figure 36 Figure 37 HAOA610L Figure 3...

Page 79: ...rn indicator light OFF turn starter switch OFF and then back ON 19 Engine Warning Light This light will turn ON when a nonfatal system error occurs with the engine or its peripherals If this light turns ON check the engine as described under the engine diagnostic switch and repair the cause of the fault to prevent engine from having fatal errors Figure 39 HA0O2024 WARNING Never operate or travel m...

Page 80: ... Steering Indicator Light Optional This indicator light will turn ON when the emergency steering system is activated due to a hydraulic failure Immediately stop any operation stop machine APPLY parking brake and shut down engine NOTE The light will also turn ON when the system is being tested AQO0050L Figure 42 Flash Pause Fault Code 423 example AQO0010L Figure 43 Figure 44 AJO0450L DANGER Emergen...

Page 81: ...rating Controls 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 ...

Page 82: ...Economy Mode Switch 7 Alternative Idle Switch 8 Headlight Switch 9 Front Work Light Switch 10 Rear Work Light Switch 11 Rear Wiper Switch 12 Pilot Cutoff Switch 13 Parking Brake Switch 14 Transmission Cutoff Switch 15 Mirror Heating Switch 16 Engine Diagnostic Switch 17 Idle Speed Control Switch 18 Fuel Heater Switch Optional 19 Emergency Steering Test Switch Optional 20 Rotating Beacon Light Swit...

Page 83: ...KED position Pilot control valve lever joystick operating pattern and description of operation 1 Horn Switch See page 2 24 2 Kick down Switch See page 2 24 NOTE Operating condition of 2nd gear function Start a engine Transmission lever is neutral Parking brake switch is off release NOTE Release condition of 2nd gear function When the transmission lever will be push forward or pull reverse When the...

Page 84: ... 4th Manual 2nd NOTE Kick down is RELEASED when transmission is placed in NEUTRAL position or the switch is pressed again A second kick down switch Figure 49 is on the end of the transmission lever 3 Horn Button Two Places Pressing the left button at the tip of the pilot control valve lever joystick Figure 51 or the button at the end of the combination switch Figure 52 will sound the horn NOTE Sta...

Page 85: ...accelerate the machine 4 Up and downshifts are made automatically between 1st 2nd 3rd 4th gears forward and between 1st 2nd 3rd in reverse 5 It is unnecessary to use kick down function for 1st gear Auto 2 4 mode Travel mode 1 1 3 is same as Auto 1 4 2 Up and downshifts are made automatically between 2nd 3rd 4th gears forward and between 2nd 3rd in reverse 3 Kick down switch must be used for shifti...

Page 86: ... alternate low idle switch is closed and 0 volts are detected by the ECM on the alternate low idle signal line This is convenient to use when operator wants to decrease warm up time in the winter and improve machine acceleration O OFF position I ON position 8 Headlight Switch O In this position this switch turns OFF clearance tail instrument panel switch and headlights NOTE If the switch is not in...

Page 87: ...per mounted on rear windshield of operator s cabin I In this position windshield washer fluid sprays onto the rear windshield while running the rear wiper When released the switch returns to the O OFF position II In this position this switch turns ON windshield wiper mounted on rear windshield of operator s cabin Figure 58 HAOQ071L O I CAUTION Do not turn ON the work light when traveling on public...

Page 88: ...he indicator light on the front instrument panel comes ON This brake can also be used as an emergency brake Figure 61 HBOI110L O I CAUTION When driving or parking the pilot cutoff switch must be changed to O OFF position Figure 62 HA0O2019 P O I WARNING Set the parking brake switch in the I APPLIED position before leaving the loader Make sure to APPLY the parking brake switch before trying to star...

Page 89: ...pressing the left brake pedal This mode is suitable for a load handling operation When the accelerator pedal is pressed in this setting more power is concentrated on the load handling system to quicken the boom lifting speed NOTE 1 Transmission CUTOFF function dose not operate at 3rd and 4th gear for protection of transmission 2 Despite transmission CUTOFF switch the right brake pedal has braking ...

Page 90: ...ult code is displayed contact your authorized dealer for repair To know the fault code information refer to the engine control system of shop manual 17 Idle Speed Control Switch The idle speed control allows the idle speed to be adjusted 25 rpm increments by pressing the idle speed control switch The switch will only work from 700 to 1200 rpm 18 Fuel Heater Switch Optional This switch is used to o...

Page 91: ... indicator light should turn ON NOTE If unit does not steer do not operate unit until problem is corrected C Release switch Switch will automatically return to O OFF position Automatic Test This is a system check that tests the hydraulic oil pressure in the emergency steering system lines With starter switch turn to I ON position an emergency warning light on the front gauge panel will turn ON for...

Page 92: ...be used for charging a cellular phone or powering a small 12V DC electrical device Open the cap when using it NOTE This socket is designed for small electrical capacity devices Do not use this socket for large electrical capacity devices Thus damage can be avoided 22 Cup Holder Place to put beverages 12 V HAAE1990 Figure 71 ...

Page 93: ...1 2 3 5 8 6 7 FG006505 Figure 72 Reference Number Description 1 Cabin Light 2 Stereo CD Player Optional 3 Heater and Air Conditioner Control Panel 4 Speakers 5 Storage Compartment 6 Windshield Washer Tank 7 Electrical Box 8 Fuse Box Reference Number Description ...

Page 94: ...ned ON and OFF irrespective of the position of the starter switch 2 Stereo CD Player Optional For operation of stereo see Stereo CD Player Optional on page 2 42 3 Heater and Air Conditioner Control Panel For operation of heater and air conditioner see Heater and Air Conditioner Operation on page 2 37 FG004192 Figure 73 V O E U M S U P N H O F F O SOUND TUNE L AM FM 1 4 3 2 5 6 SCAN PROGRAM AST FG0...

Page 95: ...ides behind of the operator s seat Keep the operation manual and other documents in this compartment 6 Windshield Washer Tank Contains windshield washer fluid It is located behind the operator s seat 3 Figure 77 7 Electrical Box Contains relays and electric components It is located on left side of cabin Figure 76 HBOM350L 3 2 1 FG003889 Figure 77 FG003956 Figure 78 ...

Page 96: ...0754 Operating Controls 2 36 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 ...

Page 97: ...ned into one unit to the right side of the operator s seat If necessary the operator can control interior cabin temperature using the operation panel 3 3 2 2 1 5 4 FG006506 Figure 80 Reference Number Description 1 Operation Panel 2 Front Nozzle Air Conditioner 3 Front Nozzle Defroster 4 Foot Nozzle 5 Rear Nozzle Reference Number Description ...

Page 98: ... Conditioner Switch A OFF Switch Turns OFF the heater and air conditioner unit B A C Switch Turns ON the air conditioner when one of the blower switches is activated FG003966 1 4 5 2 3 Figure 81 Reference Number Description 1 Fan and Air Conditioner Switch 2 Blower Fan Switches 3 Temperature Control Switch 4 Selector Switch for Wind Direction 5 Ventilation Selector Switch Reference Number Descript...

Page 99: ...tch The temperature control consists of 24 stages An LED is turned ON for every three stages Whenever pushing it it changes in stages Pushing it continuously it changes continuously A COOL Switch Lowers the temperature B WARM Switch Raises the temperature LED COLOR STATUS Green LED Air conditioner Full green maximum operation of air conditioner Red LED Heater Full red maximum operation of heater 4...

Page 100: ...t air flow for defrosting front window of operator s cabin 5 Ventilation Selector Switch A A Switch Draws fresh air into operator s compartment B B Switch Recirculates air within the operator s compartment Used to rapidly reduce condensation on windows FG006508 Figure 86 FG006509 Figure 87 Figure 88 HAOC981L A B ...

Page 101: ...or temperature Operate the air conditioner from twenty thirty minutes a week to circulate the refrigerant in the system NOTE The blower switch must be on LO speed NOTE The filter must be cleaned out every 500 hours and replaced with a new one every 1 000 hours NOTE In the event that the unit is being operated in a dusty environment the cleaning and replacement must be performed more frequently If ...

Page 102: ...o V O E U M S U P N H O F F O SOUND TUNE L AM FM 1 4 3 2 5 6 SCAN PROGRAM AST FG000108 2 3 7 9 8 5 6 10 4 1 Figure 89 Reference Number Description 1 Power Volume Control 2 Sound Mode Selector 3 Band Selection 4 Tuning Up Down 5 Scan Function Auto Store 6 Preset Station 7 Tape Ejection 8 Fast Forward Rewind 9 Tape Loading Slot 10 LCD Reference Number Description ...

Page 103: ...OP000754 2 43 Operating Controls CD Player Optional AST DIR FG000109 Figure 90 ...

Page 104: ...tment range is 60 mm 2 36 in for both front and rear 4 Weight Adjustment Knob Turning knob 4 Figure 92 to right makes suspension harder Turning knob to left makes suspension softer Adjust according to operator s weight by checking weight indicator dial Adjustment range is from 50 120 kg 110 265 lb 5 Backrest Adjustment Lever Pulling up right lever 5 Figure 92 allows seat backrest to be moved forwa...

Page 105: ...ect and maintain the suspension and adjustment mechanisms of the seat regularly 3 Check that the machine is properly maintained Tire pressure brakes steering linkages etc 4 Steer brake accelerate shift gears move the attachments and load the attachments smoothly 5 Adjust the machine speed and travel path to reduce the vibration level Slow down if it is necessary when passing rough terrain Drive ar...

Page 106: ...osition 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 Never fasten a seat belt across abdomen Under no circumstances should operator be standing in cabin when operating wheel loader Do not adjust seat position while vehicle is moving because a loss of con...

Page 107: ... is emergency exit from the cabin can be opened in two positions Position 1 ventilation position Open the window and secured it with the lock bar A Figure 98 Position 2 full opened position Open the window and push it to backward 3 To release doors from both sides of the cabin Pull the handles Figure 99 in the direction of arrows The handles are located on both sides of the operator s seat 1 FG003...

Page 108: ...ntrols 2 48 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 1 2 FG003898 Figure 100 ...

Page 109: ...use is blown turn OFF the starter switch and shut off the power supply Remedy the cause if needed and replace the fuse with a new one FUSE BOX 1 FUSE BOX 2 FG003972 Figure 102 Fuse Box One No Name Capacity 1 Rear Wiper Window Washer 10A 2 Parking Brake Pilot Cut Off 10A 3 Rotating Beacon Optional 10A 4 CCTV Optional 10A 5 Spare 10A 6 Cigar Lighter 10A 7 Turn Signal Light Hazard Light Indicate Ligh...

Page 110: ... Optional 10A 4 Electric Steering Optional 10A 5 Emergency Steer Optional 10A 6 Horn Front Wiper 10A 7 Position Light Left 10A 8 Position Light Right 10A 9 Fuel Heater Optional 30A 10 Work Light Rear 20A 11 Mirror Heater 15A 12 Work Light Front 15A 13 Stereo Clock 12V Socket 15A 14 Memory Backup Pilot Buzzer 15A ...

Page 111: ...ng the fuse check the function of the relay Circuit Breaker A circuit breaker is next to the relay by the batteries at back of unit under engine compartment hood When a short circuit or an overload occurs the circuit breaker automatically cuts off current thus preventing electrical wires from burning FG003973 Figure 103 FG003974 Figure 104 FG003975 Figure 105 ...

Page 112: ...not shut down when using the starter switch it can be stopped by moving the engine emergency stop switch to the I Emergency Stop position O In this position the engine emergency stop system is OFF I In this position Emergency Stop is selected the engine will shut down NOTE When released the switch will return to O OFF position FG003978 Figure 106 HAOB100L A Figure 107 WARNING When changing the fus...

Page 113: ... BREAK IN PROCEDURES All wheel loaders are inspected and adjusted before leaving the factory However it is required that the operator follow these steps during initial break in period Failure to follow these steps may result in damage to equipment or reduced performance 1 Make sure to check all fluid levels before starting and every 8 10 operating hours 2 Do all Daily maintenance and service check...

Page 114: ...This will ensure that the parking brake is APPLIED 2 Move all control levers to NEUTRAL position 3 Make sure transmission neutral lock is in the N NEUTRAL LOCK position Figure 1 HA0O2019 P O I FG003979 Figure 2 IMPORTANT If transmission lever is not in NEUTRAL position engine will not start FG003980 Figure 3 ...

Page 115: ...perly do not start unit Follow test procedure given with test switch 6 Rotate starter key to START position Starter motor should crank immediately and engine should start within a few seconds 7 Release starter key when engine starts Key will return to I ON position Figure 4 HBOI111L O I FG000084 O I Figure 5 FG000085 O I Figure 6 FG003899 O I Figure 7 IMPORTANT If engine does not start after appro...

Page 116: ...ngine is burning engine oil Check cause 11 Check for usual engine vibration and noises If any are heard or felt investigate cause NOTE If engine coolant temperature gauge shows red while running take the following action Discontinue work and allow engine to run at LOW IDLE Open engine compartment cover for good ventilation Once engine temperature gauge returns to the green zone shut down engine Af...

Page 117: ...ontrol levers to NEUTRAL position 3 Make sure transmission neutral lock is in the N NEUTRAL LOCK position 4 Set pilot cutoff switch to O LOCKED position This will LOCK pilot control valve lever joystick HA0O2019 P O I Figure 8 FG003979 Figure 9 IMPORTANT If transmission lever is not in NEUTRAL position engine will not start FG003980 Figure 10 Figure 11 HBOI111L O I ...

Page 118: ...r 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 O OFF position 9 Perform Hydraulic System Warm up Cold Weather on page 3 9 FG000084 O I Figure 12 CHECK 1 FG013059 Figure 13 FG000085 O I Figure 14 FG003899 O I Figure 15...

Page 119: ...ERY TERMINAL 3 Follow normal engine starting procedures 4 After engine has started remove negative jumper cable and then positive cable 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 hydrog...

Page 120: ...Set parking brake switch to the I APPLIED position This will ensure that the parking brake is APPLIED 4 Set bucket on ground 5 Put pilot cutoff switch to O LOCK position This will LOCK pilot control valve lever joystick 6 Allow engine to idle for one two minutes to cool down FG003979 Figure 17 FG003980 Figure 18 Figure 19 HA0O2019 P O I Figure 20 HBOI111L O I ...

Page 121: ...the oil through the system Do this for five minutes NOTE Do not allow cylinders to pass hydraulic oil over relief valve for more than twenty seconds at a time 5 Cycle boom and bucket about five times without a load to circulate oil through system Hydraulic System Warm up Cold Weather 1 Follow Steps 1 through 3 in Hydraulic System Warm up 2 Do not operate machine at full speed until system has full...

Page 122: ...e 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 Never place transmission in NEUTRAL when going down a hill Over speeding transmission can damage transmission gears Never change...

Page 123: ...ng travel as a result of accidentally touching pilot control valve lever joystick 4 Press brake pedal 5 Set transmission neutral lock is in the D DRIVE position 6 Set parking brake switch to the O RELEASE position This will RELEASE the parking brake Figure 24 HBOI111L O I FG002183 Figure 25 FG003980 Figure 26 Figure 27 HAOP043L P O I ...

Page 124: ...ORWARD position 9 Release the brake pedal while slowly pressing the accelerator pedal FG003979 Figure 28 FG003980 Figure 29 WARNING When traveling at high speed or on a steep hill do not make sharp changes in direction This could cause vehicle to overturn When traveling or changing direction always look carefully to be certain that no one is in path of vehicle ...

Page 125: ...k is in the N NEUTRAL LOCK position 4 Set parking brake switch to the I APPLIED position This will ensure that the parking brake is APPLIED Figure 30 FG002183 FG003979 Figure 31 FG003980 Figure 32 CAUTION LOCK transmission lever Whenever machine is parked LOCK transmission lever in NEUTRAL to prevent accidental machine movement Figure 33 HA0O2019 P O I ...

Page 126: ...rger 8 Rotate starter key to O OFF position Remove key 9 If machine is parked on a slope install wheel chocks in front of and behind vehicle wheels Figure 34 HBOI111L O I FG003900 O I Figure 35 Figure 36 2876A WARNING Always secure machine with wheel chocks when parked on a slope Leaving machine in gear will provide no braking effect because transmission clutch is hydraulically operated When engin...

Page 127: ...r in Raise or Hold Raise position until boom has reached maximum height Then remove your hand from lever Lever will automatically return to NEUTRAL position This prevents hydraulic pump from working against relief valve maximum pressure BUCKET ANGLE INDICATOR Upper right side of bucket includes a bracket that indicates angle of bottom of bucket Top of bracket is parallel with bottom of bucket If b...

Page 128: ... end of arm 3 is aligned with center of magnetic switch 4 5 Tighten bolts 1 Figure 40 6 Start engine Raise boom dump bucket then move bucket lever into crowd detent position Now lower boom and check to see that bucket has stopped at required position A small readjustment of bracket 2 Figure 40 may be necessary TOWING MACHINE When necessary to tow another vehicle the tow rope must be tied to the to...

Page 129: ...he towed vehicle Check the tow rope or tow bar for damage and make sure it has sufficient strength for the work When necessary to descend a grade another towing vehicle must be used in the rear to retard When towing make sure you are doing the following Start slowly A sudden start can lead to a broken tow rope The tow line must be along the center line of both your loader and the vehicle to be tow...

Page 130: ... housing As a rule of thumb the allowable water depth is about 400 mm This means that the loader should not be used in a river Observe the following conditions 1 Check the water depth in advance when crossing across a river 2 Use the same precautions before crossing across a swampy area 3 Do not enter rivers whose river bed is steep or has a rapid flow CAUTION Avoid use of the loader in salt water...

Page 131: ...The intervals recommended between checks oil changes and lubrication apply provided that the machine is used under normal environmental and operating conditions See Lubrication and Service Chart on page 4 17 Arrival and Delivery Inspection Before the machine leaves the factory it is tested and adjusted The dealer must also if the warranty is to apply carry out Arrival and Delivery Inspections acco...

Page 132: ...he 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 Condition Test A Condition Test is carried out at authorized dealer workshops and provides information about the general condition of the machine ...

Page 133: ... Point Fuel 6 Draining Coolant 7 Pre Fuel Filter 8 Filling Point Transmission 9 Draining Hydraulic Oil 10 Pilot Filter 11 Oil Dipstick 12 Oil Filter Engine 13 Draining Engine Oil 14 Filling Point Engine 15 Main Fuel Filter 16 Battery 17 Return Oil Filter 18 Filling Point Coolant 19 Filing Point Washer Fluid 20 Filling Point Hydraulic Oil 21 Ventilation Filters Cabin 22 Alternator Belt 23 Suction S...

Page 134: ...s lifting devices or working methods are used other than those described in this publication Further safety rules and information and warning texts are given within the respective section NOTE Lifting with a jack must only be carried out by trained personnel WARNING If work has to be carried out on the machine before it has cooled down care must be observed with regard to risk of burns from hot li...

Page 135: ...3061 4 Figure 3 Reference Number Description 1 The bucket attachment must be resting on the ground 2 Apply the parking brake 3 Shut down engine and take out the ignition key Does not apply when checking oil level in transmission 4 Carefully release the pressure in pressure lines and pressure vessels to avoid risks 5 Attach a black and yellow Warning Tag to the steering wheel 6 Connect the frame jo...

Page 136: ...es when required Do not wear loose fitting clothing or jewelry Keep service surfaces and handholds clean from oil dirt and ice Use the stepping areas provided with antislip protection to avoid the risk of slipping Worn painted over or loose protections must be replaced Remember that high pressure water jets when washing and spilled oil can cause the protections to loosen Do not direct the water je...

Page 137: ...angerous to one s health the machine must be especially equipped for this purpose Special local safety regulations apply within such areas and also when servicing the machine Shut down engine before opening engine covers etc Make sure that no tools or other objects which may cause damage have been forgotten in or on the machine Check that the equipment you are using for lifting or supporting parts...

Page 138: ...ifting arms to the ground 3 Shut down engine by turning the ignition key to the 0 OFF position 4 Leave the cabin 5 Turn off the battery disconnect switch 6 Start putting out the fire and notify the fire brigade department if necessary It is forbidden to smoke or have an open flame near a machine when filling with fuel or when the fuel system has been opened and in contact with the surrounding air ...

Page 139: ...ter motor between alternator and starter motor to the preheating element on the engine Electrical cables must not lie directly against oil or fuel lines The following applies for welding and grinding work A fire extinguisher must be kept near at hand The ventilation must be good when working indoors Approved respirator must be used The work surface must be cleaned Do not weld or grind on component...

Page 140: ...which take a long time to heal It usually means that damaged tissue must be surgically removed Several hours may pass after contact with the acid before any symptoms appear and therefore one is not given any immediate warning The acid may remain on the machine parts for several years after a fire If swelling redness or a stinging feeling appears and one suspects that the cause may be contact with ...

Page 141: ...he environment must be taken care of in an environmentally safe way Check List After Fire When handling a machine which has been damaged by fire or been exposed to intense heat the following protective measures must under all circumstances be followed Use thick gloves made of rubber and wear goggles which are certain to protect your eyes Never touch burnt components with your bare hands as there i...

Page 142: ...ions Machines working in extremely hot or dusty conditions will require more frequent service checks Total hours of machine operation are determined by hour meter that is on the front instrument panel Product Identification Number P I N Location The PIN is stamped on the product identification plate Figure 9 on the right side of front frame above wheel cover NOTE Please make note of these numbers ...

Page 143: ...recautions 1 Before performing any maintenance checks move pilot cutoff switch to LOCKED position Place a Warning Tag on controls so that no one begins to operate machine while maintenance checks are being performed 2 Clean up all fuel spills Fuel spills are hazardous especially around engine 3 Inspect all fuel lines for leakage Replace any lines fittings O rings or filters that show signs of wear...

Page 144: ...LTEX RANDO HD CZ 46 SIGMA DX 1 10W40 MULTIFAK EP 2 CHEVRON AW 32 BELOW 0 C AW 46 ABOVE 0 C DELO 400 15W40 DELO GREASE EP 2 DELO GEAR OIL or RPM UNIV GEAR 80W90 TEXACO RANDO HDZ 46 URSA SUPER PREMIUM 15W40 MULTIFAK ALL PURPOSE EP 2 MULTI GEAR EP SAE 80W90 ESSO UNIVIS N 46 ESSOLUBE XT 5 15W40 RONEX MP SPARTAN EP220 or EXXON GX 80W90 MOBIL MOBIL DTE 13M MOBIL DELVAC MX 15W40 RONEX MP LUBE SHC LS 15W9...

Page 145: ...ended Concentration Manufacturers Meeting ASTM D3306 50 Antifreeze 50 Distilled Water Dexcool ELC by Chevron Texaco 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 exc...

Page 146: ...grade oils If CF or CG oils must be used make the oil drain intervals half of the API CI 4 values 3 Engine oil drain intervals need to be reduced by 50 when fuel sulfur content exceeds 0 5 5000 ppm Component Capacity Engine QSB 4 5 Engine Oil Pan with Filter 11 liters 2 9 U S gal NOTE The filter holds an additional 1 liter 1 qt of oil Cooling System 8 5 liters 2 2 U S gal Fuel Tank 185 liters 48 9...

Page 147: ...ing into the bearing Therefore grease the bearing until new clean grease is forced out through the outer seal Between 10 and 15 strokes with a normal handheld grease gun is required to grease one of the bearings for the lifting arms Wipe off grease fittings and grease gun before greasing so that dirt and sand is not introduced through the grease fittings Symbol key These standard symbols are used ...

Page 148: ...OP000756 Inspection Maintenance and Adjustment 4 18 Lubrication and Service Chart FG013088 7 18 1 1 1 10 5 15 9 19 19 13 14 8 11 21 21 16 2000h 1000h 500h 250h 50h 10h 1500h 6 3 12 4 2 Figure 12 ...

Page 149: ...dge 1 F 15 Transmission Filter Cartridge 1 F 16 Full Flow Filter Element 1 F 17 Oil Suction Strainer Strainer 1 C 18 Brake and Pilot Filter Element 1 19 Air Cleaner Element Outer 1 C Element Inner 1 20 Air Intake Precleaner Case 1 C 21 Air Conditioner Filter Outer Cartridge 1 C Inner 1 C V Maintenance and Refill C Cleaning F First Time Exchange Only F100 Every 10 Hours for First 100 Hours W10 Ever...

Page 150: ...4 28 Start Engine Check Starting Ability and Observe Exhaust Color at Start up and at Normal Operating Temperature Listen for Any Abnormal Sounds 4 28 Check Operation of All Controls 4 28 Inspect Cooling Fan Blade 4 29 Check Engine Drive Belt Wear 4 29 Check Air Intake System 4 30 50 Hour Weekly Service Perform All Daily 10 Hour Service Checks 4 31 Grease Front Attachment Pins 4 31 Grease Upper an...

Page 151: ...uter Air Cleaner Element 4 51 Drain and Replace Transmission Oil and Filter 4 52 Clean Fuel Tank and Strainer 4 54 Replace Air Conditioner Inner Filter 4 55 Check Air Conditioner Refrigerant 4 55 Check and Adjust Engine 4 56 Replace Hydraulic Full Flow Filter 4 57 1 500 Hour 9 Month Service Perform All Daily 10 50 250 and 500 Hour Service Checks 4 59 Replace Axle Differential and Planetaries Oil 4...

Page 152: ...se Front Attachment Pins on page 4 31 Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear 1 Inflate tires to proper operating pressure for working conditions See Tires on page 4 83 Check Engine Oil Level NOTE When checking level using a dipstick always remove and wipe it clean before making final level check 1 Check level of engine oil every day before starting engine ...

Page 153: ...ce transmission lever in NEUTRAL Apply parking brake Shut down engine 4 Block tires Once tires are blocked start engine and have a person remain in the cabin 5 Allow engine to idle until transmission temperature is to 80 C 176 F 6 Remove transmission dipstick Figure 16 Wipe dipstick clean and then insert it back into transmission 7 Remove dipstick and check oil level mark Oil level must be between...

Page 154: ... base of the filter fits over a circular base in the bottom of the tank The retaining rod 3 screws into the top of the filter 2 but the spring 4 slides over the top of the rod Be certain that this spring does not fall into the tank during reassembly 1 If filter assembly was removed insert assembly into the tank and check to make sure it is securely in place 2 Check O ring for damages and replace i...

Page 155: ...cylinders and hydraulic motors are not showing any signs of leakage If any is noted determine the source of the leak and repair Fill Fuel Tank 1 At end of each work day fill fuel tank Add fuel through fuel fill cap Figure 21 When working at a temperature of 0 C 32 F or higher use ASTM No 2 D or its equivalent At temperatures below 0 C 32 F use ASTM No 1 D or its equivalent 2 Securely tighten cap a...

Page 156: ...ith propylene glycol 1 Check sight gauge 1 Figure 25 that is attached to the radiator Coolant level must be visible in red centered circle shown on gauge To add coolant remove fill cap 2 Figure 25 of the radiator and add coolant to proper level by checking sight gauge 1 Figure 25 If temperature is below freezing see Antifreeze Concentration Tables on page 4 73 for antifreeze protection Use the tab...

Page 157: ...developed 2 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 Inspect Seat Belt for Proper Operation Inspect the Structure for Cracks and Faulty Welds 1 During the daily walk around inspection and when gre...

Page 158: ...isten for Any Abnormal Sounds Check Operation of All Controls 1 With engine at rated speed operate all of the controls 2 Follow cold weather hydraulic system warm up procedures 3 Note any slow operations or unusual movements Determine the cause and repair fault before operating IMPORTANT Cold weather operation requires that the operator fully warm up the hydraulic oil before beginning machine oper...

Page 159: ... length cracks that intersect with transverse cracks are not acceptable Replace the belt if it is frayed or has pieces of material missing 2 Before installing new belts make sure all pulley grooves are clean and not worn Replace pulley if damaged or if the grooves are worn 3 All pulley support bearings shafts and brackets must be in working order 4 When replacing belts and pulleys pulley alignment...

Page 160: ... 250 hours If the tension falls below the required minimum the belt will be able to slip damaging the belts and pulley grooves NOTE When operating in abrasive conditions check tension every 100 hours Check Air Intake System 1 Park the machine on a level surface apply the parking brake lower the attachment to the ground and shut down engine 2 Check the engine intake hose and hose clamps for damage ...

Page 161: ...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 If bucket is being used in water grease fittings immediately after machine is removed from water A Bucket hinge pins 2 locations 1 each side Figure 33 D C E F H1 H3 A I FG013066 B G H2 J K Figure 32 Figure 33 ...

Page 162: ...32 B Bucket link connecting pin 1 location Figure 34 C Lever link connecting pin 1 location Figure 35 D Lift cylinder rod ends 2 locations 1 each side Figure 36 E Arm to lever connecting pin 1 location Figure 37 Figure 34 Figure 35 Figure 36 Figure 37 ...

Page 163: ...er rod end 1 location Figure 38 G Lift cylinder heads 2 locations 1 each side Figure 39 H Remote grease fittings Figure 38 Figure 39 Figure 40 Reference Number DL160 1 Figure 40 50 Hour Right Arm 2 Figure 40 50 Hour Bucket Cylinder Head End 3 Figure 40 50 Hour Left Arm ...

Page 164: ... two remote grease points 1 and 3 Figure 40 2 Bucket cylinder head end Greased from one remote grease point Figure 42 I Steering cylinder rod ends 2 locations 1 each side Use remote grease fittings mounted on frame Figure 43 J Steering cylinder head ends 2 locations 1 each side Figure 44 Figure 41 Figure 42 Figure 43 Figure 44 ...

Page 165: ...igure 45 Grease Upper and Lower Center Pins 1 Center pins upper Figure 46 and lower Figure 47 Two locations on right side of machine Replace Engine Oil and Filter After First 50 Hours NOTE Replace engine oil and filter after first 50 hours on a new machine and every 500 hours thereafter See page 4 48 Figure 45 FG001641 Figure 46 FG001642 Figure 47 ...

Page 166: ...rocedure printed under 250 hour maintenance interval Check Air Conditioner and Alternator Belt Tension on page 4 39 Clean Exterior of Radiator Oil Cooler and Air Conditioner Condenser 1 Dust and dirt accumulation on fins of radiator 1 CAC cooler 4 oil cooler 2 and additional transmission cooler 3 greatly reduce their cooling efficiency Use compressed air water and steam to clean fins on radiator o...

Page 167: ...nd inspect it for damage 3 Use compressed air to clean filter If element is very dirty use a mild soap and water solution to clean it NOTE Clean air conditioning filter every 50 hours and replace a new one every 500 hours of service NOTE If water was used to clean filter be sure it is completely dry before installation NOTE In the event that the unit it being operated in a dusty environment the cl...

Page 168: ...round Lower boom and position bucket on ground Shut down engine 2 Position a container under hydraulic tank drain plug Open tank breather cap See Figure 20 on page 4 25 Loosen drain valve at bottom of tank Figure 51 Allow all water and sediment to drain out Tighten drain valve NOTE Dispose of drained fluids according to local regulations Figure 50 WARNING Be certain that hydraulic oil has cooled b...

Page 169: ... at prescribed intervals the air cleaner is serviced regularly and that the exhaust system and lubricating oil lines do not leak In case jarring noises can be heard or if the turbocharger vibrates it must be reconditioned or replaced immediately Only authorized dealer workshops should carry out work on the turbocharger Check Air Conditioner and Alternator Belt Tension Loosen the tension adjusting ...

Page 170: ... hours of operation to comply with new machine break in requirements NOTE After first change oil and filter must be changed every 1 000 hours Follow procedure under 1 000 hour maintenance interval See page 4 52 Replace Axle Differential and Planetaries Oil After First 250 Hours NOTE The differential and planetaries oil must be drained and refilled after first 250 hours of operation There after eve...

Page 171: ...r every 1 000 hours 6 months service 2 Remove and clean rubber evacuator valve 1 Figure 57 from bottom of air cleaner housing cover 2 Figure 57 Inspect seal lips for wear or damage Replace valve if necessary NOTE Install evacuator valve with lips parallel to the cover 3 Remove the access cover 2 Figure 57 by loosening the latches 3 4 Remove the outer filter 4 Figure 57 from the housing Do not remo...

Page 172: ...and inner filters Do not clean inner filter Water Trap Take care of fuel spillage by using a vessel or a plastic hose Drain the water trap every 250 hours Draining water from the fuel has to be done by hand A nonreturn valve in the filter head prevents the fuel from running back to the tank As no fuel can run back the pressure will remain and as a consequence no water will be drained unless new fu...

Page 173: ...pilot filter Perform the following steps 1 Vent hydraulic oil tank 2 Unscrew element cover 5 Figure 63 Cover is filled with oil Dispose of oil 3 Remove O ring 3 Figure 63 and filter 4 4 Use a nonflammable nontoxic solvent to clean out cover 5 Figure 63 5 Insert a new filter 4 Figure 63 into cover 5 Install a new O ring 3 6 Screw cover 5 Figure 63 onto filter head 1 FG008104 Figure 62 Figure 63 ...

Page 174: ... clean fuel This will help reduce fuel system priming 5 Start engine After engine has run for a couple of minutes shut down engine and look for signs of leaks If engine does not start fuel system may need priming Prime fuel system using the following procedure A Loosen plug on top of fuel filter head B Unscrew and pump the hand operated primer pump near fuel injection pump Pump primer until fuel i...

Page 175: ...in fuel filter must have the following characteristics engine mounted Remove Disconnect the wiring harness from the fuel heater if equipped Loosen and remove the fuel filter Make sure the seal ring does not stick to the filter head Remove the ring with an O ring pick if necessary NOTE Both fuel filters must be removed at the same time Install new filter Apply a small amount of oil around filter ga...

Page 176: ...filter gasket with fuel NOTE Fill fuel filter with clean fuel This will help reduce fuel system priming Clean Exterior of Radiator Oil Cooler and Air Conditioner Condenser 1 Dust and dirt accumulation on fins of radiator oil cooler and additional transmission cooler greatly reduce their cooling efficiency Use compressed air water and steam to clean fins on radiator oil cooler and transmission cool...

Page 177: ...er on the lower right side of cabin on the outside to gain access filter 2 Remove filter 2 Figure 72 and inspect it for damage 3 Use compressed air to clean filter If element is very dirty use a mild soap and water solution to clean it NOTE Clean air conditioning filter every 500 hours and replace with a new one every 1 000 hours of service NOTE If water was used to clean filter be sure it is comp...

Page 178: ...n type Remove and discard filter 3 Install new filter Apply a small amount of oil around filter gasket Screw filter on head until gasket contacts head by hand turn filter 3 4 1 turn more with filter wrench NOTE See Fluid Capacities on page 4 16 for capacity and Table of Recommended Lubricants on page 4 14 of this manual for recommended oil for the operating conditions 4 Fill engine with correct oi...

Page 179: ...on Maintenance and Adjustment 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 ...

Page 180: ...r can be cleaned according to instructions which your authorized dealer will give you However after the filter has been cleaned five times or if it is damaged it must be replaced NOTE Make a mark on the decal at the end of the secondary filter every time the primary filter is replaced or cleaned In connection with replacing the filter the cover for the air cleaner should also be cleaned It works a...

Page 181: ... secondary filter unless it is to be replaced Replace Outer Air Cleaner Element 1 Open the side access cover at the rear of the cabin 2 Remove the evacuator valve 1 Figure 78 and air cleaner cover 2 Figure 78 NOTE Inspect evacuator valve seal lips for wear or damage Replace valve if necessary Install evacuator valve with lips parallel to the cover CAUTION Never clean the inside of air filter housi...

Page 182: ...o perform this operation 2 Start machine and drive it until transmission fluid has warmed to 80 C 176 F Park machine on firm level ground Lower bucket to ground 3 Place transmission lever in NEUTRAL Apply parking brake Shut down engine Block tires NOTE See Fluid Capacities on page 4 16 for capacity and Table of Recommended Lubricants on page 4 14 of this manual for recommended oil for the operatin...

Page 183: ...a person remain in the cabin 16 With engine idling have second person check transmission fluid level again Add fluid until level reaches high mark on dipstick 17 Idle engine until transmission fluid temperature reaches 80 C 176 F Check fluid level with engine idling Level must reach high mark on dipstick NOTE If oil level is above top high mark on dipstick drain oil until level is at high mark NOT...

Page 184: ... 2 Drain fuel tank 3 Remove cover and strainer located on bottom of tank 4 Use a nonflammable nontoxic parts cleaner to clean strainer and any sediment inside tank 5 Install strainer and cover 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...

Page 185: ...ioner Refrigerant 1 Apply the parking brake and lower attachment to the ground 2 Remove the cover 3 Press the HI flow control switch to set maximum air flow 4 Set the temperature control switch fully to the cool position and fully open the cabin doors 5 Slightly accelerate the engine to about the middle speed range compressor speed 1500 1800 rpm 6 Compare the flow of bubbles in the sight glass wit...

Page 186: ... the following items Engine Compression Pressure Injection Pressure Injection Timing Amount of Refrigerant Appearance of the Sight Glass Solutions Normal Almost clear Any bubbles disappear if the engine speed is increased to 1500 rpm High No bubbles are seen Contact your local DOOSAN loader dealer for inspection and recharging refrigerant Low A flow of bubbles is visible ...

Page 187: ...over on hydraulic oil tank 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 ...

Page 188: ... underside of cover 2 Figure 89 8 Set a new filter element 6 Figure 89 and valve 5 down into hydraulic oil tank Press element down onto its base until top of element is approximately 4 mm 0 157 below edge of hydraulic oil tank 9 Install a new O ring 4 Figure 89 on cover 2 Set spring 3 into place on element 6 10 Set cover 2 Figure 89 into place over element 6 Install bolts 1 through cover 2 and tig...

Page 189: ... on the differential housing To drain and replace oil in an axle perform the following steps 1 Drive machine onto a level surface Position wheels on axle being drained so that axle end level plugs 1 Figure 90 are in the lowest position Apply parking brake Block wheels 2 Clean areas around drain plugs on both ends of axle Remove plugs NOTE See Fluid Capacities on page 4 16 for capacity and Table of...

Page 190: ...tighten level plugs at all three locations 7 Repeat procedure for other axle Axle Brake Disk Wear Measurement NOTE A wear measurement on the multidisk brake must be made at least once a year especially in case of a change in braking behavior like e g Braking noise Braking power reduced Deceleration changed Brake fluid level changed Braking pressure changed Insert feeler gauge into oil level check ...

Page 191: ... housing Do not use compressed air to blow out housing 4 Install new inner filter and secure it into position with wing nut Do not clean and reuse inner filter 5 Install new outer filter and secure it into position with wing nut 6 Install air cleaner cover NOTE Make sure that all gaskets on wing nuts and cover are properly installed and seated Check Steering Brake Drive Shaft Engine and Fuel Syste...

Page 192: ...gy feel when pressing brake pedal is a sign that air is present in brake hydraulic system To bleed air out of brake hydraulic system perform the following steps Figure 94 1 Start engine and place transmission in NEUTRAL 2 Remove rubber cap from bleeder screw on wheel 3 Place one end of a plastic hose 2 over bleeder screw 1 Place other end of hose in a container 3 filled with brake fluid 4 Station ...

Page 193: ...s on page 4 16 for capacity 2 Place a container under the radiator and open the drain valve Figure 96 NOTE Dispose of drained fluids according to local regulations Figure 95 FG013813 WARNING Allow the engine to cool before releasing the radiator cap Make sure to loosen the cap slowly to release any remaining pressure Radiator cleaning is performed while the engine is running Take extreme caution w...

Page 194: ... 4 16 for capacity 2 Position a catch tank beneath hydraulic oil tank drain plug Open hydraulic oil tank breather cap See Figure 18 on page 4 24 Remove drain plug from bottom of hydraulic oil tank Figure 98 Allow all hydraulic oil to drain out NOTE See See Fluid Capacities on page 4 16 for capacity CAUTION Be certain that hydraulic oil has cooled before draining it Hot oil could splash and cause b...

Page 195: ...draulic oil tank A Disconnect hose 1 Figure 101 from strainer cover 2 B Remove bolts 1 Figure 102 that retain strainer cover 2 C Remove strainer cover 2 Figure 102 and strainer 3 from hydraulic oil tank D Remove strainer 3 Figure 102 from strainer cover 2 E Clean strainer 3 Figure 102 in a nonflammable nontoxic solvent F Mount strainer 3 Figure 102 on strainer cover 2 G Insert strainer 3 Figure 10...

Page 196: ...ator Test the brake accumulator for proper precharge of Nitrogen gas 1 Park the machine on a level surface apply the parking brake lower the attachment to the ground 2 Run the engine at low idle for five minutes to fill the brake accumulator with oil 3 Shut down engine 4 Turn the starter switch to ON position 5 Count the number of times you can depress the right hand brake pedal before the brake w...

Page 197: ...d more than 2 years before being discarded or installed on a machine In service lifetime of hoses fitted on a machine can never exceed 6 years but replace hoses described in Replace Pipes and Hoses on page 4 62 every year Always replace hoses having exceeded the allowed in service lifetime irrespective of the external appearance wear Always store hoses in a dark place at a maximum of 65 relative h...

Page 198: ...r and oil cooler fins to remove dirt and dust 3 Clean fuel system intake strainer and fuel filter more frequently 4 Inspect starter motor and alternator and clean as often as necessary Rocky Terrain 1 Check wheels tires rims and valve stems for damage or excessive wear 2 Inspect for loose or damaged fittings and bolts 3 On a more frequent basis inspect bucket and boom for damage or excessive wear ...

Page 199: ... 30 60 12 mm x std 8 57 62 11 89 86 14 52 105 12 mm x 1 5 9 00 65 12 59 91 14 94 108 14 mm x std 13 55 98 18 95 137 23 10 167 14 mm x 1 5 14 94 108 21 02 152 24 89 180 16 mm x std 20 88 151 29 46 213 35 54 257 16 mm x 1 5 22 54 163 31 53 228 38 03 275 18 mm x std 28 90 209 40 52 293 48 41 350 18 mm x 1 5 32 50 235 45 92 332 55 04 398 20 mm x std 40 94 296 57 95 419 69 01 499 20 mm x 1 5 46 05 333 ...

Page 200: ...e 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 Battery electrolyte is diluted sulfuric acid Take extreme caution when handling the batteries The electrolyte can cause severe chemical burns If any electrolyte gets on your clothing or skin wash it ...

Page 201: ...rmal BLACK Insufficient charging check alternator TRANSPARENT Insufficient battery electrolyte replace with new battery NOTE Colors may vary from one battery manufacturer to another Always refer to instructions on battery The batteries should always be replaced in pairs Using an old battery with a new one will shorten the life span of the new battery ...

Page 202: ...t Engine overheating is often caused by bent or clogged radiator fins The spaces between the fins can be cleaned by use of air or water under pressure When straightening bent fins use care not to damage the tubes or break the bond between the fins and the tubes Heavy duty diesel engines require a balanced mixture of water and antifreeze Drain and replace the mixture every year or 2 000 hours of op...

Page 203: ...he blue green color makes it very difficult to tell the difference of what type of antifreeze is in a cooling system The colors are only a dye added to the clear antifreeze Do not rely on color Keep careful machine records of what brand and type of antifreeze is used in the unit If you are unsure of what type of antifreeze is in the system drain and flush the system NOTE Do not mix ethylene glycol...

Page 204: ...pilot system hoses until accumulator pressure has been released from the circuit To release pressure turn the starter switch to I ON position and operate pilot control valve lever and brake pedal Even though the engine is shut down hydraulic actuated components may move while releasing pilot pressure Keep all personnel away from machine while performing this operation Set pilot cutoff switch to O ...

Page 205: ...r main pump must open at 195 205 kg cm2 2770 2900 psi 4 To adjust pressure use screw on relief valve cartridge Figure 109 loosen lock nut and turn screw clockwise to raise relief pressure Turn screw counterclockwise to lower relief pressure 5 Tighten lock nut after pressure has been adjusted Figure 107 Port Number Description Specification 1 Steering Pump Pressure 175 5 Bar 2 Main Pump Pressure 20...

Page 206: ...o raise relief pressure Turn adjusting screw counterclockwise to lower relief pressure 3 Relief pressure should be set at 120 kg cm2 1 710 psi cut in and 140 kg cm2 1 990 psi cut out 4 Tighten lock nut after adjustment has been made Transmission Clutch Pressure 1 Attach gauge to Port 3 Figure 107 2 It is not impossible to adjust pressure Transmission Pressure 16 18 kg cm2 228 256 psi Figure 110 Fi...

Page 207: ... to raise relief pressure Turn screw counterclockwise to lower relief pressure 4 Install plug and washer after pressure has been adjusted Pilot Control Valve Lever Joystick Activation Pressure 1 Loosen lock nut on adjusting screw of pilot relief cartridge Figure 116 Turn adjusting screw clockwise to raise relief pressure Turn adjusting screw counterclockwise to lower relief pressure 2 Relief press...

Page 208: ...6 Inspection Maintenance and Adjustment 4 78 Service Brake Outlet Pressure 1 Attach gauge to brake pressure test port 1 Figure 117 of front axle 2 Outlet pressure should be 34 40 kg cm2 484 569 psi Figure 117 ...

Page 209: ...has a fail safe characteristic this means max relief valve setting is adjusted automatically if the voltage supply is interrupted e g broken wire This results in a max fan speed and therefore in a max cooling performance Fan Motor Pressure Standard 160 5 bar Speed Control 136 5 bar Without Speed Control Fan rpm 500 1 800 Speed Control 1 800 Without Speed Control 7 8 4 3 2 9 1 6 5 FG001746 Figure 1...

Page 210: ...ressure gauge to the pressure port 6 on the inlet hose 3 Check the maximum pressure by fully depressing the accelerator pedal and reading the pressure gauge Maximum fan motor pressure 160 2 kg cm2 The fan speed is approximately 1800 rpm at this time FG013090 3 5 2 1 4 Figure 119 Reference Number Description 1 Fan Motor 2 Fan Guard 3 Inlet Line 4 Outlet Line 5 Relief Valve Reference Number Descript...

Page 211: ...ht oil to all exposed cylinder rods Apply a coating of light oil to all control linkages and all control valve spools Check condition of oil coating each month and add to coating where necessary Battery Disconnect cables from battery or remove battery from machine If battery is removed fully charge battery and store it Cooling System Care If cooling system does not need antifreeze and is filled wi...

Page 212: ...g bolt 3 Figure 120 clockwise four turns 0 25 mm rotation to set the clearance to 1 mm 0 4 in 5 Install lock bracket 1 Figure 120 and bolt 2 Repeat steps 1 5 for other side Front Axle Parking Brake Emergency Release 1 Locate parking brake release bolt on the lower section on both sides of the housing 2 Loosen lock nut 4 Figure 120 from adjusting bolt 5 3 Tighten adjusting bolt 5 Figure 120 until i...

Page 213: ...the tire tread as shown in the figure Tire installed on a split rim may explode causing injury or in the worst case death Use a long air hose with a self attaching air chuck which allows you to stand outside the danger area Tires on stored wheels spare wheels must be kept laying down on their side and only be inflated sufficiently to keep the rim parts in position Wheel Nut Tightening Check After ...

Page 214: ...a wheel and tire must be removed from machine and replaced or if a tire must be replaced on wheel allow this task to be performed only by experienced service personnel A tire rim could be propelled off wheel and cause serious bodily injury or death See Figure 121 WARNING Improper servicing or changing tires and rims can cause explosion resulting in serious injury or death Do not service or change ...

Page 215: ...the correct one for the load to be handled and transported over a particular distance If L5 tires are used for loading and carrying operations due attention must be paid to the transporting distances Radial tires are to be preferred for loading and carrying operation as the buildup of heat is less in this type of tire Tires Working Pressure Driving Pressure Remarks Front Rear Front Rear Radial Ply...

Page 216: ...OP000756 Inspection Maintenance and Adjustment 4 86 ...

Page 217: ...load the machine onto to the specified part of the trailer NOTE Have someone in clear view and in a safe position provide directions while loading 5 Lower the bucket and lock each control lever using the pilot cutoff switch 6 Apply the parking brake and set the articulation stopper in the LOCKED position 7 Tape over the exhaust stack outlet to prevent turbo Windmilling damage 8 Place blocks in fro...

Page 218: ...and work site crew Condition of ground support Wheel loader configuration and attachments Weight lifting height and lifting radius Safe rigging of load Proper handling of suspended load Tag lines on opposite sides of load can be very helpful in keeping a suspended load secure if they are anchored safely to control points on ground Figure 3 ...

Page 219: ...l system Clean system and add new fuel Air in fuel system Purge air from system Engine stop control failed Replace stop control Engine stop relay failed Replace relay Engine starts runs only at low speed or shuts down Engine oil viscosity incorrect Change oil Clogged or dirty fuel injectors Clean injectors Fuel filters plugged Replace filters Engine stop motor cable out of adjustment Readjust Engi...

Page 220: ...de oil for weather conditions change oil Clogged oil filter Change filter and oil Defective alarm switch Contact your DOOSAN dealer Oil leakage from pipe or joint Clogged suction strainer Excessive engine wear Defective oil pump Coolant temp warning light turns ON Low engine coolant level Add coolant Loose slipping broken fan belt Adjust or replace belt Clogged radiator fins Clean Scale or mineral...

Page 221: ...Remedy Problem Possible Cause Remedy None of the controls function loud noise from pumps Hydraulic pump failed Contact your DOOSAN dealer Low hydraulic oil level Add hydraulic oil as required Suction line plugged or damaged Clean or replace as required None of the controls function no noise from pumps Pilot pump failure Contact your DOOSAN dealer Cutoff solenoid valve failed Replace solenoid Relie...

Page 222: ... 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 boom have little power or do not operate Overload relief valve is not operating properly Repair valve or replace Damaged hydraulic hose Replace hose Loose hydraulic fittings Tighten fittings Internal damage to control valve housing Replace control va...

Page 223: ...age to torque converter Repair or replace Engine malfunction See Engine Troubleshooting Table Brake valve Disassemble and clean Unusual transmission noise Low transmission fluid or low quality fluid Add fluid or change fluid Worn transmission parts Replace parts Broken gears or bearings Replace parts Transmission fails to operate Damaged transmission clutch disks Replace disks Damaged wires in tra...

Page 224: ...ng pump failure Repair or replace Leaking steering cylinder Repair cylinder Rust on steering column bearing and spline Lubricate Tire air pressure is low Inflate to proper pressure High initial resistance to movement of steering wheel Air in load sensing line inside priority valve Bleed system to remove air Sediment blocking orifice of load sensing line inside priority valve Clean and repair Sedim...

Page 225: ...r bleeding brakes brakes are not fully released Damaged brake disks Replace disks Damaged brake disk return spring Replace return springs Problem Possible Cause Remedy Battery has no power and will not accept a charge Damaged battery plates Replace battery Alternator not charging properly Repair or replace alternator Bad ground Clean and tighten Loose electrical connector Clean and tighten Alterna...

Page 226: ...OP000040 Troubleshooting 6 8 ...

Page 227: ...s 81 7 kw 1800 rpm Rated Horse Power 110 ps 81 kw 2000 rpm Max Torque 47 kg m 461 N m 1500 rpm Transmission Full Automatic Power Shift Full Automatic Power Shift Speeds 4 Forward 3 Reverse Brake Systems Service Brakes Full Hydraulic Separate Dual Line Wet Discs Parking Brake Spring Applied Oil Released on Front Axle Wet Disc Performance Travel Speed 6 6 4 1 11 7 7 3 21 4 13 4 34 5 21 6 km h MPH St...

Page 228: ...7 Specification 7 2 WORKING RANGE AND DIMENSIONS Figure 1 illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket F B D C G I H A E b a HBOM630I Figure 1 ...

Page 229: ... C 3 139 mm 10 4 3 139 mm 10 4 Bucket Width D 2 450 mm 8 0 2 450 mm 8 0 Wheel Base E 2 700 mm 8 10 2 700 mm 8 10 Centerline of Tires F 1 870 mm 6 2 1 870 mm 6 2 Ground Clearance G 400 mm 1 3 400 mm 1 3 Dump Height to tooth H 2 745 mm 9 0 2 685 mm 8 10 Dump Distance to Bucket Edge I 1 020 mm 3 4 1 073 mm 3 5 Bucket Angle Raised a 51 51 Bucket Angle Lowered Carry b 42 50 42 50 Tire Size 17 5R25 L2 1...

Page 230: ... yard of many types of workload materials APPROXIMATE WEIGHT OF WORKLOAD MATERIALS MATERIAL LOW WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS Charcoal 401 kg m3 695 lb yd3 Coke blast furnace size 433 kg m3 729 lb yd3 Coke foundry size 449 kg m3 756 lb yd3 Coal bituminous slack pil...

Page 231: ...61 kg m3 1 620 lb yd3 Gypsum crushed to 3 inch size 1 522 kg m3 2 565 lb yd3 Gravel DRY packed fragments 1 810 kg m3 3 051 lb yd3 Gravel WET packed fragments 1 922 kg m3 3 240 lb yd3 Limestone graded above 2 1 282 kg m3 2 160 lb yd3 Limestone graded 1 1 2 or 2 1 362 kg m3 2 295 lb yd3 Limestone crushed 1 522 kg m3 2 565 lb yd3 Limestone fine 1 602 kg m3 2 705 lb yd3 Phosphate rock 1 282 kg m3 2 16...

Page 232: ...WEIGHT OR DENSITY 1 100 KG M3 1 850 LB YD3 OR LESS MEDIUM WEIGHT OR DENSITY 1 600 KG M3 2 700 LB YD3 OR LESS HIGH WEIGHT OR DENSITY 2 000 KG M3 3 370 LB YD3 OR LESS IMPORTANT Weights are approximations of estimated average volume and mass Exposure to rain snow or ground water settling or compaction due to overhead weight and chemical or industrial processing or changes due to thermal or chemical t...

Page 233: ...ut 3 15 Brake Charge Pressure 4 76 Brake Pedal 2 9 Brakes Accumulator 4 66 Bleeding 4 62 Brake Fluid Warning 2 19 Brake Fluid Warning Light 2 19 Brake Pedal 2 9 Troubleshooting 6 7 Bucket Angle Indicator 3 15 Capacity 7 4 Position Switch 3 16 Teeth and Side Cutters 4 27 C Cab Light 2 34 Center Pins 4 35 Cigar Lighter 2 25 Circuit Breaker 2 51 Clean Exterior of Radiator Oil Cooler and Air Condition...

Page 234: ...evel 4 24 Fan Motor Pressure 4 80 Full Flow Filter Replace 4 36 4 57 Hydraulic Oil Replace 4 64 Hydraulic Pressures 4 75 Leaks in the Hydraulic System 4 25 Long Term Storage 4 81 Service Brake Outlet Pressure 4 78 System Pilot Filter Replace 4 43 System Warm up 3 9 System Warm up Cold Weather 3 9 Troubleshooting 6 3 I Indicator Lights Air Filter Indicator Light 2 19 Battery Warning Light 2 18 Brak...

Page 235: ...Belt 2 46 Seat Belt Inspection 4 27 Shipping and Transportation 1 47 Shutdown Engine Stop 3 8 Machine 3 13 Shutdown Control Functions 1 33 Sloping Terrain 1 27 Speakers 2 35 Speedometer 2 15 Starter Switch 2 6 Start up Cold Weather Engine Start 3 5 Engine Start 3 2 Hydraulic System Warm up 3 9 Hydraulic System Warm up Cold Weather 3 9 Steering Troubleshooting 6 6 Wheel 2 10 Switch Panel 2 22 Switc...

Page 236: ...ravel System Troubleshooting 6 5 Troubleshooting 6 1 U Unauthorized Modifications 1 13 Unloading and Loading 5 1 V Vibration 2 45 Vibration Level 1 15 Visibility 1 31 W Water in Fuel Warning Light 2 21 Weight of Workload Materials 7 4 Wheel Nut Torque 4 84 Window Washer Liquid 4 27 Work Area 1 30 Work Light Indicator Light 2 17 2 21 Working Capacities 7 4 Working Range and Dimensions 7 2 ...

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Doosan DL160, Operation And Maintenance Manual

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