Part of the Doosan Repair Manuals.
Looking for the Doosan DX160LC-3 shop manual PDF? All 891 pages of this factory shop manual (OEM #950106-01172E) cover your DX160LC-3 excavator from the swing bearing down to the track assembly. Inside: a complete hydraulic schematic with troubleshooting, testing, and adjustment procedures, full electrical schematics for the starting, charging, preheating, and monitoring circuits, and page after page of standard torque tables. You also get step-by-step teardown and reassembly for the main pump, swing motor, travel device, cylinders, and main control valve. Torque the main pump drive coupling bolts to 21-23 kg•m, and the travel motor frame and sprocket mounts to 25.7 ±4.0 kg•m. No more chasing pilot-pressure problems with borrowed numbers. Bookmarked with a full text layer; jump straight to any section or search any spec by keyword, right beside the machine.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 5-72 | Track Excavator Maintenance Safety |
| Specifications | 73-102 | Specifications for DX160LC-3, General Dimensions, Working Range, General Specifications, Engine Performance Curves, Performance Tests |
| General Maintenance | 103-140 | General Maintenance Instructions, Standard Torques |
| Upper Structure | 141-242 | Cabin, Counterweight, Fuel Tank, Fuel Transfer Pump, Swing Bearing, Swing Reduction Gear |
| Lower Structure and Chassis | 243-276 | Track Assembly |
| Engine and Drivetrain | 277-306 | Engine Coolant Heater, Drive Coupling (Main Pump) |
| Hydraulic System Troubleshooting, Testing and Adjustment | 307-342 | Operation of Working Components, Pilot Pressure, Power Mode Valve, Pressure Up Valve, Pump Input Power Control, Swing System Troubleshooting |
| Accumulator | 343-350 | Accumulator General Description, Precharge Pressure, Specifications |
| Center Joint (Swivel) | 351-364 | Center Joint Inspection, Testing, Disassembly, Reassembly |
| Cylinders | 365-404 | Cylinder Theory of Operation, Disassembly, Reassembly, Special Tools, Maintenance Standards |
| Swing Motor | 405-440 | Swing Motor Specifications, Construction, Principles of Working, Troubleshooting, Disassembly, Reassembly |
| Travel Device | 441-500 | Travel Device Basic Structure, Operation Principle, Disassembly, Reassembly, Performance Test |
| Main Pump | 501-538 | Main Pump General Description, Pump Regulator Operation, Disassembly, Reassembly, Performance Characteristics |
| Gear Pump | 539-550 | Single Gear Pump Disassembly, Driveshaft and Seal Handling, Reassembly |
| Main Control Valve | 551-602 | Theory of Operation, Composite Operation, Antidrift Valve, Main Relief Valve, Overload Relief Valve, Negacon Relief Valve, Adjusting Relief Valve |
| Remote Control Valve (Work Lever / Joystick) | 603-624 | Theory of Operation, Parts List, Specifications and Torques, Disassembly, Reassembly, Start-Up Procedures |
| Travel Control Valve (with Damper) | 625-652 | Pressure Reducing Valve, Damper Mechanism Theory, Causes of Faults and Measures, Wear Limits and Tolerances, Removal and Installation |
| Solenoid Valve Assembly | 653-664 | 5-Solenoid Valve Parts List, Functions of the Assembly, Solenoid Valve Diagram, Check Points and Solutions for Problems |
| Breaker EPPR Valve (Option) | 665-676 | Structure and Parts List, Functions and Operation, Maintenance, Disassembly, Assembly |
| Dozer Valve | 677-690 | Structure Diagram, Performance Specification, Hydraulic Pressure Circuit Diagram, Parts List, Disassembly and Assembly |
| Hydraulic Schematic (DX160LC-3) | 691-699 | Main Pump and Pilot Filter, Solenoid and Accumulator Circuits, Joystick and Pedal Valves, Main Control Valve, Boom Arm and Bucket Cylinders, Swing and Travel Devices, Center Joint, Oil Cooler and Full Flow Filter, Dozer and Smart Boom Circuits |
| Electrical System | 700-857 | Electrical Supply System, Engine Starting Circuit, Engine Preheating System, Charging System, Monitoring System, EPOS Electronic Hydraulic Control, Engine Control System, Engine Overheat Protection, Fault Code Tables |
| Electrical Schematic | 858-865 | Battery and Charging Circuits, Starting and Auto Shutoff Unit, Engine Control and Air Flow Meter, EPOS and Auxiliary Mode Wiring, A/C and Blower Circuits, Lighting and Beacon, Alarm Buzzer and Relays, AMP and Bosch Connector Pinouts |
| Attachments | 866-891 | Boom and Arm, Bucket |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Fuel pump thermal limiter open temperature | 150 ±5°C (302 ±41°F) | p. 190 |
| Fuel pump thermal limiter reactivation temperature | 143°C (289°F) | p. 190 |
| Drive coupling (main pump) bolt torque, Ta | 21 - 23 kg•m | p. 305 |
| Drive coupling (main pump) bolt torque, Tb | 10 - 12 kg•m | p. 305 |
| Travel device frame and sprocket mount bolt torque, M16 | 25.7 ±4.0 kg•m | p. 459 |
| Pilot pressure at pump | 40 ±5 kg/cm2 (569 ±71 psi) | p. 324 |
| Pilot pressure at joystick | 23.5 ±1.5 kg/cm2 (334 ±21 psi) | p. 324 |
| Air cleaner replacement period (monitor default) | 2,000 hr | p. 736 |
| Return filter replacement period (monitor default) | 1,000 hr | p. 736 |
| Pilot filter replacement period (monitor default) | 1,000 hr | p. 736 |
| Engine oil filter replacement period (monitor default) | 500 hr | p. 736 |
| Oil Pressure Sensor (150 kPa) | 0.921 ±0.07 V | p. 779 |
| Oil Pressure Sensor (500 kPa) | 2.395 ±0.06 V | p. 779 |
| Crankshaft Sensor Resistance | 860 Ω ±10% (at 20°C) | p. 781 |
| Cab air filter cleaning interval | 500 hours | p. 819 |
