EasyManua.ls Logo

Doosan DL160 User Manual

Doosan DL160
236 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
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

Table of Contents

Questions and Answers:

Doosan DL160 Specifications

General IconGeneral
Engine ModelCummins QSB4.5
Operating Weight10, 300 kg (22, 711 lbs)
Rated Power99 kW (133 hp)
Lift Capacity3, 000 kg (6, 614 lbs)
Maximum Lift Height4, 000 mm (13.1 ft)
Fork Length1, 220 mm (48 in)
Transmission TypeAutomatic
Gross Power104 kW (140 hp)
Load Capacity3, 000 kg (6, 614 lbs)
Load Center500 mm (19.7 in)
Lifting Height4, 000 mm (13.1 ft)
Turning Radius2, 500 mm (98.4 in)
Travel Speed (full load)28 km/h (17.4 mph)
Travel Speed (no load)30 km/h (18.6 mph)
Engine Power99 kW (133 hp)
Fuel TypeDiesel
Tire TypePneumatic
Overall Length3, 800 mm (149.6 in)
Overall Width1, 450 mm (57.1 in)
Mast Height (lowered)2, 200 mm (86.6 in)
Mast Height (raised)5, 000 mm (196.9 in)
Weight10, 300 kg (22, 711 lbs)

Summary

DL160 Operation and Maintenance Manual

Presentation

Overview of the machine's general features, including its intended use, engine, electrical, and mechanical systems.

CE MARKING, EMC DIRECTIVE

Information on CE marking compliance and the EU EMC Directive for electromagnetic compatibility.

COMMUNICATION EQUIPMENT INSTALLATION

Guidelines for installing communication equipment and ensuring electromagnetic interference protection.

PRODUCT PLATES

Details on identifying machine and component numbers for ordering parts and service.

Safety

Essential safety information, including operator responsibilities, alert symbols, and hazard definitions.

GENERAL SAFETY ESSENTIALS

Covers accessory applications and the location and maintenance of safety labels on the machine.

Warnings for Operation, Inspection and Maintenance

General safety precautions for operating and maintaining the machine.

Warnings When Opening Engine Hood

Safety warning regarding opening the engine hood.

Warnings for Handling Accumulator

Critical warnings about the explosion hazard associated with hydraulic accumulators.

Warnings for High Temperature Hydraulic Oil

Safety precautions for handling hot hydraulic oil to prevent injury.

Warnings for Battery Maintenance

Hazards related to battery fumes, acid, and safe maintenance practices.

Warnings to Use Safety Lock

Emphasizes the importance of using the safety lock during servicing operations.

Warning Tag

Instructions on using warning tags during inspection or maintenance.

UNAUTHORIZED MODIFICATIONS

Consequences of modifications and general hazard information for safe operation.

Inside Operator's Compartment

Safety precautions for entering, exiting, and operating within the machine's cabin.

Clothing and Personal Protective Items

Recommendations for appropriate attire and protective gear, including masks and ear protection.

Recommendations for Limiting Vibrations

Measures to reduce operator exposure to vibrations and prevent asbestos dust inhalation.

Fuel, Oil and Hydraulic Fluid Fire Hazards

Guidelines for preventing fires related to fuels, oils, and hydraulic fluids.

Precautions When Handling Fluids at High Temperature

Safety measures for handling hot fluids and avoiding injuries from work equipment.

Fire Extinguisher and First Aid Kit

Recommendations for fire safety equipment and protection against falling objects.

Maintain Standard Safety Equipment in Good Condition

Ensuring safety equipment is functional and providing attachment precautions.

Engine Ventilation

Safety considerations for engine exhaust gases and accumulator handling.

BEFORE STARTING ENGINE

Essential work site precautions and checks before starting the engine.

Checks Before Starting Engine

Daily inspection procedures to be performed before starting the engine.

Before Operating Machine

Crucial checks and preparations required before operating the machine.

MACHINE OPERATION

Guidelines for safe machine operation, including seat belt usage and operator posture.

Travel Precautions

Safety advice for machine travel, including on slopes and rough terrain.

Avoid High Voltage Cables

Safety measures when working near high voltage lines and before digging.

Use Care on Loose Support

Precautions for working on unstable ground and digging hazards.

Observe General Safety Rules

Adherence to general safety rules and local regulations.

Take Time to Provide Good Visibility

Tips for ensuring good visibility and avoiding pinch points, especially when reversing.

Parking Machine

Procedures for safely parking the machine, including cold weather operation.

Shutdown Control Functions

Steps for properly shutting down the machine and warnings about riding on attachments.

MAINTENANCE

General information on maintenance, including warning tags and cleaning procedures.

Fire Prevention and Explosion Prevention

Guidelines for using proper tools and preventing fires during maintenance.

Burn Prevention

Precautions when handling hot components, coolant, and hydraulic oil.

Welding Repairs

Safety procedures for welding and precautions for attachment handling.

Crushing Prevention and Cutting Prevention

Safety measures for preventing crushing injuries and securing inspection covers.

Do Not Work on Hot Engines or Hot Cooling or Hydraulic Systems

Warnings about stored energy in hydraulic lines and working on hot systems.

Precautions with High-pressure Line, Tubes and Hoses

Safety guidelines for inspecting and replacing hydraulic components.

Safety Critical Parts Must Be Replaced Periodically

Crucial advice on immediate medical attention for oil injection injuries and replacing critical parts.

Dispose of All Petroleum Based Oils and Fluids Properly

Environmental guidelines for disposing of oils and preventing injuries from boom/bucket operations.

BATTERY

Hazards associated with batteries, including explosion risks and electrolyte handling.

Boost Starting or Charging Engine Batteries

Safety procedures for jump-starting and charging batteries, including disconnection guidelines.

TOWING

Essential safety measures and procedures for towing the machine.

SHIPPING AND TRANSPORTATION

Regulations and procedures for safely transporting the machine.

Operating Controls

Comprehensive guide to all controls, switches, and indicators on the machine.

COMPONENT LOCATIONS

Diagrams identifying the location of major machine components.

OPERATOR'S AREA

Overview of controls and features within the operator's cabin.

STEERING CONSOLE AND PEDALS

Detailed description of the steering wheel, brake pedals, and related controls.

Starter Switch

Explanation of the three-position starter switch for engine operation.

Horn Button (Two Places)

Location and operation of the horn buttons.

Combination Switch

Functionality of the directional signals, hazard lights, and washer switch.

Accelerator Pedal

Function of the accelerator pedal for controlling machine speed.

Steering Wheel Adjustment Lever

How to adjust the steering wheel for tilt and telescopic position.

Brake Pedal (Right and Left Pedals)

Operation of brake pedals and their modes, with caution for inclines.

Steering Wheel

Controls machine direction by steering front wheels.

Kick-down Switch (Two places)

Function of the kick-down switch for quick digging movements.

Transmission Lever

Operation of the transmission lever for forward, neutral, and reverse gears.

Front Instrument Panel

Details of gauges and warning lights on the instrument panel.

Transmission Display

Explanation of the transmission display indicating gears, direction, and error codes.

Speedometer

Displays the vehicle's current travel speed.

Tachometer

Indicates engine speed in revolutions per minute.

Fuel Gauge

Shows the amount of fuel remaining in the tank.

Engine Coolant Temperature Gauge

Displays the temperature of the engine coolant.

Transmission Oil Temperature Gauge

Indicates the temperature of the transmission oil.

Hour Meter

Records the total operating time of the engine.

Left Turn and Hazard Warning Light

Indicates left turn signals and hazard warning light status.

High Beam Indicator Light

Indicates when the headlights are set to high beam.

Work Light Indicator Light

Indicates when front and/or rear work lights are activated.

Preheat Indicator Light

Indicates when the engine preheat function is operating.

Mirror Heating Indicator Light

Indicates when the mirror heater is operated.

Right Turn and Hazard Warning Light

Indicates right turn signals and hazard warning light status.

Battery Warning Light

Indicates potential issues with the battery charging system.

Parking Brake Indicator Light

Indicates when the parking brake is applied.

Brake Fluid Pressure Warning Light

Warns of low pressure in the brake fluid circuit.

Air Cleaner Clogged Warning Light

Indicates when the air filter is restricted and requires service.

Engine Warning Light

Alerts to non-fatal system errors within the engine or its peripherals.

Engine Stop Light

Indicates a fatal system error requiring immediate shutdown.

Emergency Steering Indicator Light (Optional)

Alerts to activation of the emergency steering system due to hydraulic failure.

Water in Fuel Warning Light

Indicates when the water separator for the fuel system is full.

RIGHT SIDE SWITCH PANEL

Identification of various switches located on the right side panel.

Pilot Control Valve Lever (Joystick)

Operation and patterns for the pilot control valve lever (joystick).

Kick-down Switch (Two Places)

Function and operation of the kick-down switch.

Cigar Lighter

Usage and power specifications for the 12-volt cigar lighter.

Automatic Shift Mode Switch

Controls for automatic and manual transmission shifting modes.

Economy Mode Switch

Allows switching between standard and economy engine performance modes.

Alternative Idle Switch

Feature to select alternate idle speeds for warm-up and acceleration.

Headlight Switch

Controls for operating clearance, tail, instrument panel, and headlights.

Front Work Light Switch

Operation of the front-mounted work lights.

Rear Work Light Switch

Operation of the rear-mounted work lights.

Rear Wiper Switch

Controls for the rear windshield wiper and washer fluid.

Pilot Cutoff Switch

Enables or disables the pilot control valve lever (joystick).

Parking Brake switch

Engages or releases the parking brake and its indicator light.

Transmission Cutoff Switch

Changes brake pedal mode between 'INCHING' and 'NO INCHING'.

Mirror Heating Switch

Activates the mirror heater to remove frost and ice.

Engine Diagnostic Switch

Allows operator to view fault codes recorded by the engine warning light.

Idle Speed Control Switch

Adjusts idle speed in increments of 25 rpm.

Fuel Heater Switch (Optional)

Operates the fuel heater, which heats fuel when temperatures are low.

Emergency Steering Test Switch and Automatic Test (Optional)

Tests the emergency steering system functionality.

Rotating Beacon Light Switch (Optional)

Controls the operation of the rotating beacon light.

Power Socket for 12 Volt

Provides a 12V DC power source for small electronic devices.

VARIOUS CABIN LOCATIONS

Diagram showing the locations of various cabin features.

Cabin Light

Illuminates the cabin for night work.

Stereo / CD Player (Optional)

Information regarding the operation of the optional audio system.

SEAT ADJUSTMENT

Procedures for adjusting the operator's seat for optimal comfort and control.

SEAT BELT

Instructions for proper use, adjustment, and maintenance of the seat belt.

DOOR SIDE LATCH

Description of cabin door securing mechanisms and emergency exits.

ARM REST

Adjustment features for the operator's armrest.

FUSE BOX/RELAY/ENGINE EMERGENCY STOP SWITCH

Details on fuse boxes, relays, and the engine emergency stop switch.

HEATER AND AIR CONDITIONER OPERATION

Instructions for operating the cabin's climate control system.

Operation Panel

Controls for fan speed, temperature, air direction, and ventilation modes.

ENGINE START AND STOP

Procedures for starting and stopping the engine, including break-in recommendations.

MACHINE TRAVEL

Safety guidelines and procedures for moving the machine.

MACHINE SHUT DOWN

Steps for properly shutting down the machine.

BOOM RAISE KICK-OUT

Adjusting the boom's automatic height limit.

ADJUSTMENT OF BUCKET POSITION SWITCH

Procedure for adjusting the bucket position switch.

ALLOWABLE WATER DEPTH

Warnings regarding operation in water and salt water.

Inspection, Maintenance and Adjustment

Guide to maintenance procedures, including preventive maintenance and service intervals.

SAFETY WHEN SERVICING

Critical safety rules to follow during machine servicing.

Service Position

Correct machine positioning and safety checks before commencing service work.

Before Service Read

Essential reading and tool preparation before starting service work.

Fire Prevention Measures

Recommendations for fire extinguishers and steps to take in case of fire.

Working on Painted Surfaces

Safety procedures for paint removal before welding or grinding.

Floor Rubber

Safety measures for handling floor rubber, especially after heat exposure.

Rubber and Plastics

Handling precautions for rubber and plastics, and waste disposal information.

PREVENTIVE MAINTENANCE

Periodic checks, lubrication, and filter replacements for optimal machine condition.

Engine Serial Number

Safety precautions to be followed before performing any maintenance checks.

TABLE OF RECOMMENDED LUBRICANTS

Detailed list of recommended lubricants for various machine components.

LUBRICATION AND SERVICE CHART

Procedures and importance of greasing machine bearings and symbol key.

MAINTENANCE INTERVALS

Schedule of maintenance tasks based on operating hours or time intervals.

BOLT TORQUE CHART

Specifications for tightening torque of various metric bolts.

ELECTRICAL SYSTEM

Procedures for checking battery condition and electrical system safety.

ENGINE COOLING SYSTEM

Importance of cooling system maintenance, antifreeze types, and concentration tables.

HANDLING OF ACCUMULATOR

Critical safety warnings and procedures for handling hydraulic accumulators.

HYDRAULIC PRESSURE CHECKS

Procedures for checking and adjusting hydraulic system pressures.

Fan Motor Pressure and Fan rpm

Specifications and checking procedures for fan motor pressure and speed.

LONG TERM STORAGE

Procedures for cleaning, hydraulic system, lubrication, battery, and cooling system care for storage.

PARKING BRAKE ADJUSTMENT

Steps for adjusting front and rear axle service brakes and parking brake release.

TIRES

Guidelines for inflating tires, checking wheel nut tightness, and identifying tire damage.

Recommended Air Pressure

Recommended tire pressures for working and driving conditions.

Transportation

Procedures and safety precautions for loading and unloading the machine.

SUMMARY OF SAFETY PRECAUTIONS FOR LIFTING

Key factors to evaluate for ensuring safe lifting operations.

Troubleshooting

Common problems and solutions for the engine, hydraulic, travel, steering, braking, and electrical systems.

Specification

Technical specifications for the DL160 machine.

WORKING RANGE AND DIMENSIONS

Illustrations and measurements of the machine's exterior dimensions and working range.

WORKING CAPACITIES

Details on bucket capacity, tipping load, and approximate weights of workload materials.

Related product manuals