Doosan DL550-5 Wheel Loader Service Repair Manual Instant Download

1
Shop Manual
DL550-5 Wheel Loader
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-01246E January 2015
Original Instructions
Copyright DOOSAN 2015
2
Table of Contents
1 Safety
1 Wheel Loader Safety
2 Specifications
1 Specifications
3 General Maintenance
1 General Maintenance Instructions
2 Standard Torques
4 Engine
1 Engine
5 Drivetrain

1. Transmission and Torque Converter (4WG)
2. Transmission and Torque Converter (5WG) (Option)

1. Front Axle
2. Rear Axle
3. Driveshaft

6 Steering
1 Power Steering System

1. Steering Unit
2. Steering Pump
3. Flow Amplifier
4. Jerk Softener Accumulator

7 Brake
1 Service Brake

• Brake Pilot Supply Valve
• Charging Block
• Parking Brake
• Brake Pedal Valve
• Accumulator
• Brake Filter
• Table of Contents
• Page I

3
8 Cooling System
1 Cooling System

1. Fan Brake Pump
2. Fan Motor
3. Fan Control Valve
4. Radiator Assembly

9 Hydraulic System
1 Main Pump

1. Main Control Valve
2. Pilot System
3. Hydraulic System
4. Hydraulic System Troubleshooting

10 Frame
1 Articulation Center

1. Cabin
2. Counterweight
3. Oil Tank
4. Fuel Tank
5. Cylinders

11 Electrical System
1 Electrical System
2 Air Conditioner
12 Options

1. Emergency Steering
2. Load Isolation System

1. 3rd Control Valve
2. Auto Grease System

13 Schematic
1 Hydraulic Schematic/Electrical Schematic
Table of Contents Page II
4
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com
5
Wheel Loader
Safety
Edition 1
Wheel Loader Safety 1-1-1
DL550-5
6
Table of Contents Wheel Loader Safety Safety
Instructions .....................................
.....1-1-5 Safety Messages .......................
.....................1-1-5 General................
...........................................1-1-7 O
peration..........................................
............1-1-18 Maintenance ...................
..............................1-1-31 Transportatio
n ..............................................1-
1-46 Environment and Circumstances................
..1-1-48
Wheel Loader Safety 1-1-3
DL550-5
7
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation Maintenance
Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check
for correct function after adjustments repairs
or service. Untrained operators and failure to
follow instructions can cause death or serious
injury.
SAFETY MESSAGES Safety messages and safety decals
included in this manual and on the machine
provide instructions how to operate, service and
maintain the machine. Safety messages and safety
decals indicate potential hazards and describe
safety precautions required to avoid hazards.
Operator and maintenance personnel should read
and understand these safety messages and decals
before beginning operation or maintenance.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and
Safety Instructions. This is a Safety Alert
Symbol. Wherever it appears in this manual or on
safety decals on the machine, you must be alert
to the potential for personal injury or
accidents. Always observe safety precautions and
follow recommended procedures. Signal Words The
signal words "DANGER", "WARNING", "CAUTION" are
used throughout safety messages and safety decals
in this manual or on the machine. They indicate
an existence of, and the relative seriousness
of, a hazard. All three indicate that a safety
risk is involved. Observe the precautions
indicated whenever a Safety Alert Symbol is
present, no matter which signal word appears
next to it.
Wheel Loader Safety 1-1-5
DL550-5
8
DANGER
DANGER - This signal word is used on safety
messages and safety labels and indicates an
imminently hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety
messages and safety labels and indicates a
potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION - This signal word is used on safety
messages and safety labels and indicates a
potentially hazardous situation which, if not
avoided, could result in minor or moderate
injury. Other Signal Words In addition to safety
signal words, the following signal words are
used to indicate proper and effective use of
machine.
IMPORTANT
This signal word identifies procedures which must
be followed to avoid damage to machine.
NOTE
The word "NOTE" identifies information for
effective use.

1. Turn battery disconnect switch to "ON" position.
2. Close battery compartment door.

DL550-5
Wheel Loader Safety 1-1-6
9
Engine
10
SAFETY INSTRUCTIONS WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are
necessary before operating or servicing machine.
Read and understand the Operation Maintenance
Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check
for correct function after adjustments repairs
or service. Untrained operators and failure to
follow instructions can cause death or serious
injury.
Engine 4-1-7
DL550-5
11
OVERVIEW
FRONT
WL1400008
Figure 1
DL550-5
Engine 4-1-8
12
Special Tightening Torque The specifications
recommend values for special tightening torques
for certain threaded joints where there are
strict requirements on the distribution of
prestressing force. The distribution of the
tightening torque is 15 and the clamping force
then spread about 30.
Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts. Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread. (Metric Threads, Course Pitch) Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts. Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread. (Metric Threads, Course Pitch) Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts. Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread. (Metric Threads, Course Pitch) Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts. Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread. (Metric Threads, Course Pitch)
Thread Strength Class Strength Class FG020238
Thread 8.8/8 10.9/10 FG020238
Thread Tightening Torque (Nm) Tightening Torque (Nm) FG020238
M4 2.9 3.6 FG020238
M5 6 7.5 FG020238
M6 9.5 12 FG020238
M8 24 30 FG020238
M10 47 59 FG020238
M12 84 105 FG020238
M14 135 170 FG020238
M16 210 270 FG020238
M18 290 360 FG020238
M20 420 530 FG020238
M22 580 730 FG020238
M24 730 910 FG020238
Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread (Metric Thread, Fine Interval) Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread (Metric Thread, Fine Interval) Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread (Metric Thread, Fine Interval) Hexagonal Screws, Hexagon Socket Screws, Six-point Socket Screws, Hexagon Nuts Applies also with Captive Washer and Hexagon Screws with Thread Cleaning Thread (Metric Thread, Fine Interval)
Thread Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm) FG020238
Thread 8.8/8 10.9/10 FG020238
Thread Tightening Torque (Nm) Tightening Torque (Nm) FG020238
M8x1 26 32 FG020238
M10x1.25k 50 62 FG020238
M12x1.25k 92 115 FG020238
M14x1.5k 150 180 FG020238
M16x1.5k 230 290 FG020238
M18x1.5k 330 410 FG020238
M20x1.5k 470 590 FG020238
M22x1.5k 640 800 FG020238
M24x1.5k 830 1040 FG020238
DL550-5
Engine 4-1-28
13
Flange Screws with Hexagonal Head and Hexagonal Flange Nuts (Metric Threads, Course Pitch) Flange Screws with Hexagonal Head and Hexagonal Flange Nuts (Metric Threads, Course Pitch) Flange Screws with Hexagonal Head and Hexagonal Flange Nuts (Metric Threads, Course Pitch) Flange Screws with Hexagonal Head and Hexagonal Flange Nuts (Metric Threads, Course Pitch)
Thread Thread Tightening Torque ( 15 Nm) Thread Tightening Torque ( 15 Nm)
Thread 8.8/8 10.9/10
Thread Tightening Torque (Nm) Tightening Torque (Nm)
M5 6.7 8.1
M6 10.2 13
M8 26 32
M10 50 63
M12 92 115
M14 149 187
Tightening Torques for Hose Clamps Specifications
in the tables show tightening torque when
tightening by hand. Tightening torque for new
unfitted hose clamp is max 1 Nm.
A Width (mm) Tightening Torque (15 Nm)
7.5 - 9 1.5
12 5
D
A EX1301803
Figure 10
A Width (mm) Tightening Torque (15 Nm)
25 20
A Figure 11
EX1301804
A Width (mm) Tightening Torque (15 Nm)
20 10
25 20
A
EX1301805
Figure 12
Engine 4-1-29
DL550-5
14
Tightening Torques for Engines
IMPORTANT
Tightening torques for threaded joints in
engines. If the tightening torque is not
available in the table for each engine, refer to
the special and normal tightening torques tables.
Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly Engine Assembly
Cylinder Block Cylinder Block Cylinder Block Cylinder Block Cylinder Block Cylinder Block
Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm Piston cooling nozzle 23 Nm
Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap Main Bearing Cap
NOTE The screws can only be reused 3 times. Mark the NOTE The screws can only be reused 3 times. Mark the
screws each time before installing. screws each time before installing. 1 2 3 4

EX1301810
Torx screw (M19) 110 Nm 90 Torx screw (M19) 110 Nm 90
Hexagon screw (M19) 110 Nm 90 Hexagon screw (M19) 110 Nm 90
EX1301811 EX1301811 EX1301811 EX1301811
Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap Connecting Rod Cap
NOTE The screws can only be reused 3 times. Mark the
screws each time before installing. 1 2 3 4

EX1301810
DL550-5
Engine 4-1-30
15
Torx screw 50 Nm 90 Check torque 170 Nm EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070 EX1302070
Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing Flywheel Housing
Lead-in union 40 Nm 6
Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package Cylinder Head and Valve Package
Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head Cylinder Head
NOTE The screws can only be reused 3 times. Mark the
screws each time before fitting. 1 2 3 4

EX1301810
Cylinder head bolt, tightened in four stages 3 6 1 2 5 4 FG020253
First stage 60 Nm 3 6 1 2 5 4 FG020253
Second stage 150 Nm 3 6 1 2 5 4 FG020253
Third stage 250 Nm 3 6 1 2 5 4 FG020253
Fourth stage 90 3 6 1 2 5 4 FG020253
Engine 4-1-31
DL550-5
16
Rocker Cover Rocker Cover
Rocker cover, upper 18 Nm Rocker cover, lower 18 Nm
Rocker cover, upper 18 Nm Rocker cover, lower 18 Nm
Valve Mechanism Valve Mechanism
Adjusting screw nut on rocker arm 35 Nm EX1301822
Adjusting screw nut on rocker arm 35 Nm
DL550-5
Engine 4-1-32
17
Screw for rocker arm shaft bearing retainer 90 Nm 60
Roller Tappet Shaft Roller Tappet Shaft
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm 3 1 2 WL1400012
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm
Banjo screw for roller tappet shaft (engines produced earlier) 33 Nm Slotted screw for roller tappet shaft (engines produced later) 40 Nm
Engine 4-1-33
DL550-5
18
Crank Mechanism Crank Mechanism
Flywheel Flywheel
M18 flange screw 180 Nm 120
Torsion Damper Torsion Damper
Torsion damper hub 90 Nm 30 Torsion damper hub 90 Nm 30
Timing Gear Timing Gear
Intermediate gear 50 Nm 60 Camshaft gear 20 Nm 40 EX1301830
Lubrication System Lubrication System
Ladder Frame Ladder Frame
Ladder frame to cylinder block, 8.8 screw 26 Nm Ladder frame to cylinder block, 10.9 screw 32 Nm Ladder frame against cylinder block, 8.8 screw with spacer 26 Nm 29 25 21 17 13 9 5 1 3 7 11 15 19 23 27 33 31 37 35 41 39 40 42 36 38 32 28 24 20 16 12 8 4 2 6 10 14 18 22 26 30 34 EX1301831
Oil Sump Oil Sump
9 5 1 3 7 13 11 17 15 16 18 12 8 4 6 10 14 2 EX1301832
DL550-5
Engine 4-1-34
19
Oil Sump, Plastic Oil Sump, Plastic
Oil sump, spring screw 20 Nm Oil sump, spring screw 20 Nm
Oil Plug Oil Plug
Thread insert for oil plug 320 Nm Magnetic oil plug, oiled seal 80 Nm Magnetic oil plug, dry seal 115 Nm
Thread insert for oil plug 320 Nm Magnetic oil plug, oiled seal 80 Nm Magnetic oil plug, dry seal 115 Nm
Thread insert for oil plug 320 Nm Magnetic oil plug, oiled seal 80 Nm Magnetic oil plug, dry seal 115 Nm
Oil plug for filler connection in oil sump 60 Nm Oil pump, 10.9 screw 32 Nm Oil pump, 8.8 screw 26 Nm Hose connection for cooling system 85 Nm Oil fill pipe, retaining screw 20 Nm Oil plug for filler connection in oil sump 60 Nm Oil pump, 10.9 screw 32 Nm Oil pump, 8.8 screw 26 Nm Hose connection for cooling system 85 Nm Oil fill pipe, retaining screw 20 Nm
Engine 4-1-35
DL550-5
20
Oil Filter Oil Filter
Element type filter, cover 25 Nm Oil filter unit without loose filter Hand tighten
Oil Cooler Oil Cooler
Oil cooler core 26 Nm
Centrifugal Oil Cleaner Centrifugal Oil Cleaner
Nut for outer cover 15 Nm
Oil Mist Separator Oil Mist Separator
Nut (M18 x 1.5) 35 5 Nm Nut (M18 x 1.5) 35 5 Nm
Exhaust System Exhaust System
Exhaust Manifold Exhaust Manifold
Cylinder head hexagon screw 40 Nm 60 Cylinder head Torx screw 60 Nm 60 Turbocharger 50 Nm Cylinder head hexagon screw 40 Nm 60 Cylinder head Torx screw 60 Nm 60 Turbocharger 50 Nm
DL550-5
Engine 4-1-36
21
Exhaust pipe from Turbocharger Exhaust pipe from Turbocharger
Turbocharger (V-clamp) 20 Nm EX1301840
Turbocharger Oil Pipe Turbocharger Oil Pipe
Turbocharger lubrication pipe 40 1.2 Nm (3 ) Nut for turbocharger lubrication pipe 35 5 Nm Turbocharger lubrication pipe 40 1.2 Nm (3 ) Nut for turbocharger lubrication pipe 35 5 Nm
Turbocharger Coolant Pipe Turbocharger Coolant Pipe
Water inlet, turbocharger 40 Nm Water inlet, variable geometry turbocharger electric motor 10 Nm Water inlet, turbocharger 40 Nm Water inlet, variable geometry turbocharger electric motor 10 Nm
Variable Geometry Turbocharger, Electric Motor Variable Geometry Turbocharger, Electric Motor
To be tightened crosswise in two stages (Screw 12.9) 3 Nm, 11 Nm To be tightened crosswise in two stages (Screw 12.9) 3 Nm, 11 Nm
Silencer Silencer
Exhaust pipe to and from silencer (V-clamp) 20 Nm EX1301840
Reductant Doser Reductant Doser
Nut (M6) 10 Nm
Engine 4-1-37
DL550-5
22
Suggest If the above button click is invalid.
Please download this document first, and then
click the above link to download the complete
manual. Thank you so much for reading
23
Charge Air Cooler Charge Air Cooler
Pipe connection (V-clamp) 8 Nm EX1301840
Fuel System Fuel System
Injectors Injectors
Nut for cable connection 2 Nm
Tighten the Injector in Four Stages Tighten the Injector in Four Stages
First stage, injector holder 20 Nm Second stage, connection 20 Nm
First stage, injector holder 20 Nm Second stage, connection 20 Nm
DL550-5
Engine 4-1-38
24
https//www.ebooklibonline.com Hello dear
friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com