Description

Doosan 1760XL, DSL802 Skid Steer Loader Operation and Maintenance Manual (SB2308E00)

Doosan 1760XL, DSL802 Skid Steer Loader Index:

1.0. OWNER/OPERATOR SAFETY OVERVIEW
1.1. Safety Message for Owners and Operators ………………………………………………………………………………1
1.1.1. Owner/Employer Responsibility ……………………………………………………………………………………1
1.1.2. Operator Responsibility ………………………………………………………………………………………………..2
1.2. Maintaining a Safe Workplace………………………………………………………………………………………………….3
1.3. Matching the Machine to the Job …………………………………………………………………………………………….4
1.3.1. Warning Signal Options………………………………………………………………………………………………..4
1.3.2. Modifications ………………………………………………………………………………………………………………4
1.4. Maintenance Practices …………………………………………………………………………………………………………..5
1.5. Operator Safety Training …………………………………………………………………………………………………………5
1.5.1. Formal Training …………………………………………………………………………………………………………..5
1.5.2. Inspection Training ……………………………………………………………………………………………………..6
1.5.3. Training Program Development ……………………………………………………………………………………6
1.5.4. Practical Training…………………………………………………………………………………………………………7
1.5.5. Recognition ………………………………………………………………………………………………………………..7
1.6. Information Resources for Operation, Maintenance, and Safety ………………………………………………….7
2.0. SAFETY INFORMATION
2.1. Safe Operating Practices…………………………………………………………………………………………………………9
2.2. Rated Operating Load Plate ………………………………………………………………………………………………….11
2.3. Safety Warning Label Locations and Descriptions ……………………………………………………………………12
2.3.1. Label Locations …………………………………………………………………………………………………………12
2.3.2. Label Descriptions……………………………………………………………………………………………………..13
2.4. General Safety and Hazard Information ………………………………………………………………………………….17

cont. 2.0 SAFETY INFORMATION
2.4.1. Unauthorized Modification …………………………………………………………………………………………17
2.4.2. Clothing and Personal Protective Items……………………………………………………………………….17
2.4.3. Mounting and Dismounting …………………………………………………………………………………………18
2.4.4. Fire Prevention and Hazardous Fluids and Vapors ……………………………………………………….19
2.5. Operating Safety ………………………………………………………………………………………………………………….20
2.5.1. Work Site Safety ……………………………………………………………………………………………………….20
2.5.2. Operator’s Cab …………………………………………………………………………………………………………21
2.5.3. Safe Operating Practices …………………………………………………………………………………………..21
2.5.4. Ventilation for Enclosed Areas ……………………………………………………………………………………22
2.5.5. Flammable and Explosive Atmospheres ……………………………………………………………………….22
2.5.6. Precautions for Mirrors, Windows, and Lights ………………………………………………………………23
2.5.7. Ensuring Visibility ……………………………………………………………………………………………………..23
2.5.8. Traveling in Reverse, Safe Working Zone ……………………………………………………………………24
2.5.9. Avoiding High-Voltage Cables……………………………………………………………………………………..24
2.5.10. Operating on Snow ……………………………………………………………………………………………………25
2.5.11. Working on Loose Ground or Uneven Surfaces …………………………………………………………….25
2.5.12. Preventing Crushing or Cutting ……………………………………………………………………………………26
2.5.13. Parking ……………………………………………………………………………………………………………………26
2.5.14. Precautions for Attachments ……………………………………………………………………………………….27
2.5.15. Precautions for Loading and Emptying the Bucket …………………………………………………………27
2.5.16. Precautions for Stopping the engine …………………………………………………………………………….28
2.6. Maintenance Safety ………………………………………………………………………………………………………………29
2.6.1. Periodic Maintenance ………………………………………………………………………………………………..29
2.6.2. Precautions for High Temperature Operations ………………………………………………………………30
2.6.3. Maintaining and Inspecting Hydraulic Equipment …………………………………………………………..31
S-8
cont. 2.0 SAFETY INFORMATION
2.6.4. Precautions for High Pressure Oil………………………………………………………………………………..32
2.6.5. Battery Hazard Precautions ……………………………………………………………………………………….33
2.6.6. Waste Material Precautions ……………………………………………………………………………………….34
2.6.7. Rotating Fans and Belts …………………………………………………………………………………………….34
2.6.8. Tire Maintenance……………………………………………………………………………………………………….35
3.0. SERIAL NUMBER LOCATIONS
3.1. Vehicle Serial Number …………………………………………………………………………………………………………..36
3.2. Engine Serial Number …………………………………………………………………………………………………………..36
4.0. MACHINE COMPONENTS
4.1. Identification of Machine Parts ………………………………………………………………………………………………37
5.0. CONTROLS AND INSTRUMENTS
5.1. Instrument Panel ………………………………………………………………………………………………………………….39
5.2. Controls …………………………………………………………………………………………………………………………….41
5.2.1. Drive Control Lever ………………………………………………………………………………………………….41
5.2.2. Pedals ……………………………………………………………………………………………………………………44
5.2.3. Boom Pedal …………………………………………………………………………………………………………….44
5.2.4. Attachment Pedal ……………………………………………………………………………………………………..45
5.2.5. Bucket Pedal …………………………………………………………………………………………………………..45
5.2.6. Engine Control & Auxiliary hydraulic attachment bleed off …………………………………………….46
5.2.7. Seat Bar ………………………………………………………………………………………………………………….47

6.0. OPERATING INSTRUCTIONS
6.1. Inspection Before Boarding ………………………………………………………………………………………………….48
6.2. Boarding the Loader …………………………………………………………………………………………………………….48
6.3. Starting………………………………………………………………………………………………………………………………..49
6.4. Traveling and Steering …………………………………………………………………………………………………………51
6.5. Operation …………………………………………………………………………………………………………………………..52
6.6. Traveling on a Slope, Parking ………………………………………………………………………………………………55
6.7. Towing Procedures ………………………………………………………………………………………………………………56
6.8. Lifting ………………………………………………………………………………………………………………………………..57
6.9. Transportation ……………………………………………………………………………………………………………………..58
6.10. Bucket and Attachments ……………………………………………………………………………………………………….59
6.11. Boom Lock Operation………………………………………………………………………………………………………….. 62
7.0. PERIODIC MAINTENANCE
7.1. Safety Warnings……………………………………………………………………………………………………………………64
7.2. Access to Items Requiring Service …………………………………………………………………………………………65
7.2.1. Rear door and engine hood ……………………………………………………………………………………….65
7.2.2. Canopy Tilting …………………………………………………………………………………………………………..66
7.3. Daily Pre/Post Start Checks ………………………………………………………………………………………………….67
7.3.1. Pre-Start Checks ……………………………………………………………………………………………………….67
7.3.2. After Starting-Before Operation……………………………………………………………………………………68
7.4. Service Schedule ………………………………………………………………………………………………………………..69
7.5. Lubrication Points ………………………………………………………………………………………………………………..71
7.6. Operator Restraint Lubrication and Maintenance ……………………………………………………………………..75
7.6.1. Lubrication ………………………………………………………………………………………………………………76
7.6.2. Function ………………………………………………………………………………………………………………….76
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cont. 7.0 PERIODIC MAINTENANCE
7.7. Engine Lubrication ………………………………………………………………………………………………………………76
7.7.1. General ……………………………………………………………………………………………………………………77
7.7.2. Draining Engine Oil ……………………………………………………………………………………………………77
7.7.3. Remove/Replace Engine Oil Filter ………………………………………………………………………………77
7.8. Engine Cooling System …………………………………………………………………………………………………………78
7.9. Fan Belt ………………………………………………………………………………………………………………………………79
7.9.1. Belt Tension………………………………………………………………………………………………………………79
7.9.2. Adjustment………………………………………………………………………………………………………………..79
7.10. Two Stage Air Filter ………………………………………………………………………………………………………………80
7.10.1. Removal-Primary Element …………………………………………………………………………………………80
7.10.2. Removal-Secondary Element ……………………………………………………………………………………..81
7.10.3. Installation ………………………………………………………………………………………………………………..81
7.11. Spark Arrestor ……………………………………………………………………………………………………………………..81
7.11.1. General ……………………………………………………………………………………………………………………81
7.11.2. Maintenance …………………………………………………………………………………………………………….82
7.12. Battery ………………………………………………………………………………………………………………………………..82
7.12.1. Remove and Install ……………………………………………………………………………………………………82
7.12.2. Jump Starting the Loader …………………………………………………………………………………………..83
7.13. Priming The Fuel System ……………………………………………………………………………………………………..84
7.13.1. Bleeding the Fuel System …………………………………………………………………………………………..84
7.13.2. Draining the Water From the Fuel Fillter ……………………………………………………………………….85
7.13.3. Fuel Tank Drain …………………………………………………………………………………………………………85
7.14. Hydraulic System Maintenance ………………………………………………………………………………………………86
7.14.1. Oil Level Indicator ……………………………………………………………………………………………………..86
7.14.2. Filter Replacement ……………………………………………………………………………………………………87
7.14.3. Hydraulic Fluid Replacement ……………………………………………………………………………………..87

cont. 7.0 PERIODIC MAINTENANCE
7.15. Chain Case Drain and Refill ………………………………………………………………………………………………….88
7.16. Parking Brake Adjustment ……………………………………………………………………………………………………..89
7.17. Tire Maintenance ………………………………………………………………………………………………………………….90
7.17.1. General Information……………………………………………………………………………………………………90
7.17.2. Inflation Pressures……………………………………………………………………………………………………..91
7.17.3. Installation and Removal …………………………………………………………………………………………….91
8.0. DIMENSIONAL & PERFORMANCE SPECIFICATION
8.1. Dimensional Specifications ……………………………………………………………………………………………………92
8.2. Operational Specification (Per SAE J732 Feb 80) ……………………………………………………………………94
8.2.1. Performance …………………………………………………………………………………………………………….94
8.2.2. Power Unit………………………………………………………………………………………………………………..94
8.2.3. Final Drive Components …………………………………………………………………………………………….95
8.2.4. Hydrostatic Transmission Pump ………………………………………………………………………………….95
8.2.5. Hydraulic System ……………………………………………………………………………………………………..96
8.2.6. Electrical Components ………………………………………………………………………………………………97
8.2.7. Instrument Features ………………………………………………………………………………………………….98
8.2.8. Seat …………………………………………………………………………………………………………………………98
8.2.9. Fluid Capacities & Specifications ………………………………………………………………………………..99
•ENVIRONMENT PROTECTION SECTION ……………………………………………………………………………………..102
•WORLDWIDE NETWORK