Doosan DL160 User manual

Copyright Doosan 2008K1040196E Operation and Maintenance Manual
DOOSAN reserves the right to improve our products in a continuing process to provide the best possible
product to the market place. These improvements can be implemented at any time with no obligation to
change materials on previously sold products. It is recommended that consumers periodically contact their
distributors for recent documentation on purchased equipment.
This documentation may include attachments and optional equipment that is not available in your
machine's package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
Operation and Maintenance Manual
K1040196E
Serial Number 5001 and Up
May 2008
DL160

K1040196E
I-I
Presentation
1Presentation
PRESENTATION
FG01308
7
Figure 1

K1040196EPresentation
I-II
Intended Use
The machine is intended to be used under normal conditions for
the applications described in the Operator's Manual. If it is used
for other purposes or in potentially dangerous environments, for
example explosive atmosphere or areas with dust containing
asbestos, etc., special safety regulations must be followed and
the machine must be equipped for such use. Contact the
manufacturer/dealer for further information.
The machine is designed for a maximum machine weight
(includes equipment and attachments) of 8,730 kg (19,246 lb)
for DL200. If the maximum weight is exceeded, no warranties on
the part of the manufacturer will apply. However, always pay
attention to national regulations for traveling on public roads.
Engine
DL160 has a cummins QSB4.5 4.5 liter engine. The engine has
intercooling and is fitted with a common rail system. The
common rail system is positioned at an angle above the pistons
and are controlled via the camshaft and a electronic control
module (ECM).
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 information via
there. The Control Unit (for the machine) receives signals from
sensors on the machine and these are passed to the Gauge
Panel. The ECU controls the engine.
Power Transmission
The transmission is electrohydraulically controlled, where all
gears are in constant mesh. The gear ranges are achieved by
applying different combinations of clutches. Between the engine
and transmission gears there is a hydraulic torque converter,
which controls the output torque. The front and rear axles have
planetary gears in the wheel hubs and this reduces the strain on
the respective drive shafts.
Brake System
The machine is provided with a dual circuit, all hydraulic, brake
system with one circuit for each axle. Each circuit meets the
requirements for secondary brake capability.

K1040196E
I-III
Presentation
Parking Brake
The parking brake is a wet disk brake built into the front axle. The
brake is applied by spring force and is released hydraulically.
Steering System
The machine uses a load sensing, hydrodynamic steering
system. It has a steering arc of 40°.
Cabin
The cabin has a heating and ventilation system with defrosting
for front and rear windows. Air-conditioning is standard. The
cabin has two emergency exits, the door and right side window.
FOPS and ROPS
The cabin is approved as a protective cabin according to FOPS
and ROPS standards. FOPS is an abbreviation of Falling Object
Protective Structure (roof protection) and ROPS is an
abbreviation of Roll Over Protective Structure (roll over
protection).
Never carry out any unauthorized alterations to the cabin, e.g.
lowering the roof 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 use a triple vane pump which contains
three pumping sections. The first pumping section supplies oil
for the front attachment. The second pumping section supplies
oil for the steering cylinders. Surplus oil which is not necessary
for the steering function is directed into control valve to join the
first pump is oil by the priority valve. Pilot pump oil is used for
brake and pilot line operation.
Equipment
The machine can be provided with different types of optional
equipment, depending on the requirements of different markets.
Examples of such equipment are emergency steering, pallet fork
and rear full fender.

K1040196EPresentation
I-IV
CE MARKING, EMC DIRECTIVE
CE Marking
(Declaration of Conformity)
(Only applies to machines marketed within the EU/EEA.)
This machine is CE marked. This means that when delivered the
machine meets the applicable "Essential Health and Safety
Requirements," which are given in the Machinery Safety
Directive, 98/37EC.
Any person carrying out changes that affect the safety of the
machine, is also responsible for the same.
As proof that the requirements are met, the machine is supplied
with an EU Declaration of Conformity, issued by DOOSAN CE
for each separate machine. This EU declaration also covers
attachments manufactured by DOOSAN CE. The
documentation is a valuable document, which must be kept safe
and retained for at least ten years. The document should always
accompany the machine when it is sold.
If the machine is used for other purposes or with other
attachments than described in this manual, safety 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 interference, which may constitute
safety risks.
The EU EMC directive on "Electromagnetic Compatibility," 89/
336/EEC, provides a general description of what demands can
be made on the machine out of a safety point of view, where
permitted limits have been determined and given according to
international standards.
A machine or device which meets the requirements must be CE
marked. Our machines have been tested particularly for
electromagnetic interference. The CE marking of the machine
and the declaration of conformity also cover the EMC directive.
If other electronic equipment is fitted to this machine, the
equipment must be CE marked and tested on the machine with
regard to electromagnetic interference.
FG001781
Figure 2

K1040196E
I-V
Presentation
COMMUNICATION EQUIPMENT
INSTALLATION
Protection Against Electromagnetic
Interference
This machine has been tested in accordance with EU directive
89/336/EEC governing electromagnetic interference. 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 applicable to the
machine.

K1040196EPresentation
I-VI
PRODUCT PLATES
With the aid of the product plates, shown below, it is possible to
identify the machine and its components. The Product
Identification Number, PIN, indicates the model designation,
engine code and serial number of the machine. The Component
Identification Number, CIN, indicates the serial number of the
component. Make a note of the identification numbers.
When ordering spare parts, and in all telephone enquiries or
correspondence the PIN and CIN must always be quoted.
6
8
1, 2
435
7
FG008048
Figure 1
Reference
Number Description
1 Primary Marking The machine PIN (stamped into right side).
2 Product Plate The manufacturer's name and address, machine PIN.
3Additional 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 weight, cabin serial number, ROPS/
FOPS number and ROPS/FOPS certificate number.
5 Engine The engine type designation and number.
6 Front Axle The manufacturer's name and address and front drive axle CIN.
7 Transmission The manufacturer's name and address and transmission CIN.
8 Rear Axle The manufacturer's name and address and rear drive axle CIN.

K1040196E
I
Table of Contents
Table of Contents
Safety..........................................................................................1-1
To the Operator of a Wheel Loader ................................................... 1-1
General Safety Essentials.................................................................. 1-4
Location of Safety Labels................................................................... 1-4
Unauthorized Modifications.............................................................. 1-13
General Hazard Information............................................................. 1-13
Before Starting Engine..................................................................... 1-22
Machine Operation........................................................................... 1-26
Maintenance .................................................................................... 1-34
Battery.............................................................................................. 1-44
Towing ............................................................................................. 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
Arm Rest.......................................................................................... 2-48
Fuse Box/Relay/Engine Emergency Stop Switch ............................ 2-49

K1040196ETable of Contents
II
Operation....................................................................................3-1
Instrument Panel Control Functions................................................... 3-1
New Machine Break-in Procedures ................................................... 3-1
Engine Start and Stop........................................................................ 3-2
Machine Travel ................................................................................ 3-10
Machine Shut Down......................................................................... 3-13
Boom Raise Kick-out ....................................................................... 3-15
Bucket Angle Indicator ..................................................................... 3-15
Adjustment of Bucket Position Switch.............................................. 3-16
Towing Machine............................................................................... 3-16
If Engine Stalls While Traveling ....................................................... 3-17
Allowable Water Depth .................................................................... 3-18
Inspection, Maintenance 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 Service .......................................................... 4-59
2,000 Hour / Yearly Service............................................................. 4-61
12,000 Hour / Six Year Service........................................................ 4-67
Severe Conditions Maintenance ...................................................... 4-68
Bolt Torque Chart............................................................................. 4-69
Electrical System ............................................................................. 4-70
Engine Cooling System.................................................................... 4-72

K1040196E
III
Table of Contents
Handling of Accumulator.................................................................. 4-74
Hydraulic Pressure Checks.............................................................. 4-75
Long Term Storage.......................................................................... 4-81
Parking Brake Adjustment ............................................................... 4-82
Tires................................................................................................. 4-83
Transportation ...........................................................................5-1
Loading and Unloading...................................................................... 5-1
Summary of Safety Precautions for Lifting......................................... 5-2
Troubleshooting ........................................................................6-1
Engine................................................................................................ 6-1
Hydraulic System............................................................................... 6-3
Travel System.................................................................................... 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

K1040196ETable of Contents
IV

OP000753
1-1
Safety
OP000753
1Safety
TO THE OPERATOR OF A
WHEEL LOADER
Please respect the importance of taking responsibility for your
own safety, and that of other people who may be affected by
your actions.
The safety information on the following pages is organized into
the following sections:
1. “General Safety Essentials” on page 1-4
2. “Location of Safety Labels” on page 1-4
3. “Unauthorized Modifications” on 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 and
understand entire Operation and Maintenance Manual.
Any operation, maintenance, traveling or shipping methods
that do not follow safety guidelines printed in this Manual
could cause serious injury or death.

OP000753Safety
1-2
Learn Signal Words Used With Safety Alert
Symbol
The words "CAUTION," "WARNING," and "DANGER" used
throughout this manual and on decals on the machine indicate
degree of risk of hazards or unsafe practices. All three degrees
of risk indicate that safety is involved. Observe precautions
indicated whenever you see the Safety Alert "Triangle," no
matter which signal word appears next to the "Exclamation
Point" symbol.
SAFETY ALERT SYMBOL
Be Prepared – Get to Know All Operating and Safety
Instructions.
This is the Safety Alert Symbol. Wherever it appears – in
this manual or on safety signs on the machine – you must
be alert to potential for personal injury or accidents. Always
observe safety precautions and follow recommended
procedures.
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 potential of a hazardous situation that, if not
avoided, could result in serious injury or death. It may also
be used to alert against a highly unsafe practice.
DANGER!
This word is used on safety messages and safety labels and
indicates an imminent hazard of a situation that, if not
avoided, is very likely to cause death or extremely serious
injury. It may also be used to alert against equipment that
may explode or detonate if handled or treated carelessly.

OP000753
1-3
Safety
Safety precautions are described in SAFETY from page 1-4 on.
DOOSAN cannot predict every circumstance that might involve
a potential hazard in operation and maintenance. Therefore the
safety messages in this manual and on the machine may not
include all possible safety precautions. If any procedures or
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.

OP000753Safety
1-4
GENERAL SAFETY ESSENTIALS
Accessory Applications
The wheel loader has been designed primarily for moving earth
with a bucket. For use as a grapple or for other object handling,
contact DOOSAN. Lifting-work applications are permitted in
approved lift configuration, to rated capacity only, with no
side-loading (unless prohibited by local regulation). Do not use
machine for activities for which it was not intended. Do not use
bucket for lifting work, unless lift slings are used in approved
configuration.
LOCATION OF SAFETY LABELS
The operator should know and pay attention to the information
and warning plates/decals which are positioned on 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 not
visible. When you clean the warning signs, use a cloth, water
and soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the safety signs. Solvents, gasoline, or other
harsh chemicals could loosen the adhesive that secures the
warning sign. Loose adhesive will allow the warning sign to fall
off.
Replace any safety sign that is damaged, or missing. If a safety
sign is attached to a part that is replaced, install a safety sign on
the replacement part.

OP000753
1-5
Safety
FG013042
13
10
12
6 4 11 5 9
83710
46
2
Figure 1

OP000753Safety
1-6
1. Warnings for Operation, Inspection and
Maintenance (4190-2545A, 190-00092)
2. Warnings for Cooling Fan
(2190-3315, 190-00557)
NOTE: Please stop the engine before any cleaning, checking
or repairing with cooling fan swing.
Entanglement in the fan can cause serious injury.
CAUTION!
•Read manual and labels before
operation and maintenance. Follow
instructions and warnings in manual
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
authorized service shop. Do not attempt to make an overhaul.
ACO1360L
WARNING!
Keep your hands away from the fan during
operation. Entanglement in the fan can cause
serious injury.
AMO0390L

OP000753
1-7
Safety
3. Warnings 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

OP000753Safety
1-8
5. Warnings for Handling Accumulator
(190-00703, 190-00099)
Accumulator
Wheel loader pilot control system is equipped with an
accumulator. Accumulator will store a pressure charge that may
enable hydraulic controls to be activated for a brief period of
time after engine has been shut down. Activation of any controls
may enable 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 charge.
IMPORTANT
Refer to Shop Manual for service procedures. Do not
release any pilot lines until pressure within accumulator
has been released.