Doosan DL550-3 Wheel Loader Service Repair Manual Instant Download

1
Shop Manual DL550-3 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.
950106-00434E June 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Wheel Loader Safety .......................
..................................................
... SP002397 Specifications Specification for
DL550-3 ..........................................
........................... SP002593 General
Maintenance General Maintenance
Instructions......................................
.................. SP002454 Standard
Torques...........................................
......................................
SP002404 Engine Engine...........................
..................................................
...................... SP002399 Engine Coolant
Heater (Option) ..................................
......................... SP002328 Drivetrain Tra
nsmission and Torque Converter (ZF 4WG-310)
............................ SP000786 Transmission
and Torque Converter (ZF 5WG) ...................
................ SP002401 Axle ZF - Multitrac (MT
- L 3115 II / 3125 II)............................
............. SP002657 Transmission Error Codes
(ZF) .............................................
............... SP002423 Driveshaft..............
..................................................
.............................. SP002424 Brake Ser
vice Brake .......................................
................................................
SP002426 Supply Valve.............................
..................................................
.......... SP002427 Charging Block
..................................................
...................................
SP002428 Parking Brake ...........................
..................................................
.......... SP002429 Brake Pedal Valve
..................................................
.............................. SP002430 Accumulato
r.................................................
......................................... SP002431
Table of Contents Page I
3
Steering Power Steering System ...................
..................................................
... SP002465 Steering Unit .......................
..................................................
................ SP002425 Steering
Pump..............................................
........................................
SP002480 Flow Amplifier ..........................
..................................................
........... SP002434 Jerk Softener and
Accumulator ......................................
...................... SP002658 Emergency
Steering .........................................
....................................
SP002436 Frame Articulation Center
..................................................
.............................. SP002542 Counterwei
ght...............................................
........................................
SP002437 Tank Oil Tank ..........................
..................................................
.................... SP002725 Fuel
Tank..............................................
................................................
SP002439 Hydraulics Main Pump....................
..................................................
...................... SP002486 Main Control
Valve ............................................
................................... SP002441 3rd
Control Valve (Option)............................
........................................
SP002442 Load Isolation System ...................
..................................................
..... SP002443 Cooling System.....................
..................................................
.............. SP002444 Pilot System..............
..................................................
.......................... SP002445 Hydraulic
Schematic (DL550-3)...............................
............................. SP002659 Electrical
System Air Conditioner...........................
..................................................
......... SP002447 Electrical System
..................................................
................................ SP002448
Electrical Schematic (DL450-3 / DL550-3)
...........................................
SP002449
Table of Contents Page II
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Safety
6
Wheel Loader
Safety
SP002397
Edition 3
SP002397 Page 1
Wheel Loader Safety
7
Table of Contents Wheel Loader Safety Safety
Instructions .....................................
........... 5 Applicable Models
................................................
5 Safety Messages ................................
.................. 6 Safety Decals
..................................................
..... 7 General...................................
.............................. 7 Transportation
..................................................
.. 18 Operation...................................
......................... 20 Maintenance
..................................................
..... 38 Environment and Circumstances............
............ 53
SP002397 Page 3
Wheel Loader Safety
8
SAFETY INSTRUCTIONS
WARNING
AVOID DEATH OR SERIOUS INJURY Instructions are necessary before operating or servicing machine. Read and understand the Operation and 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.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DL200-3 10001 and Up
DL220-3 10001 and Up
DL250-3 10001 and Up
DL300-3 10001 and Up
DL350-3 10001 and Up
DL420-3 10001 and Up
DL450-3 10001 and Up
DL550-3 10001 and Up
SP002397 Page 5
Wheel Loader Safety
9
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.
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.

SP002397
Wheel Loader Safety Page 6
10
SAFETY DECALS Location of safety labels (decals)
can vary from unit to unit. Refer to appropriate
Operation and Maintenance Manual, and parts
manual for your unit. Always replace damaged or
faded decals.
GENERAL
Safe Operation is Operator's Responsibility Only
trained and authorized personnel should operate
and maintain the machine. Follow all safety
rules, regulations and instructions when
operating or performing maintenance on machine.

• Do not operate machine if you are under the
  influence of drugs or alcohol. An operator who is
  taking prescription drugs must get medical
  advice to determine if he or she can safely
  operate the machine.
• When working with other personnel on a work site,
  be sure that all personnel know the nature of
  work and understand all hand signals that are to
  be used.
• Be sure that all guards and shields are installed
  in their proper location. Have guards and
  shields repaired or replaced immediately if
  damaged.
• Be sure that you understand the use and
  maintenance of all safety features such as pilot
  cutoff switch and seat belt. Use them at all
  times.
• Never remove, modify or disable any safety
  features. Always keep them in good operating
  condition.
• Always check for and know the location of
  underground and overhead utility lines before
  working.
• Failure to use and maintain safety features
  according to instructions in this manual, Safety
  Manual and Shop Manual can result in death or
  serious injury.

Know Your Machine Know how to operate your
machine. Know the purpose of all controls,
gauges, signals, indicators and monitor displays.
Know the rated load capacity, speed range,
braking and steering characteristics, turning
radius and operating clearances. Keep in mind
that rain, snow, ice, loose gravel, soft ground,
slopes etc., can change operating capabilities
of your machine.
SP002397 Page 7
Wheel Loader Safety
11
Proper Work Tools and Attachments Only use work
tools and attachments that are recommended by
DOOSAN for use on DOOSAN machines. When
installing and using optional attachments, read
instruction manual for attachment, and general
information related to attachments in this
manual. Because DOOSAN cannot anticipate,
identify or test all attachments that owners
may want to install on their machines, contact
DOOSAN for written authorization and approval of
attachments, and their compatibility with
optional kits. Attachments and attachment
control systems that are compatible with the
machine are required for safe and reliable
machine operation. Do not exceed maximum
operating weight (machine weight plus
attachment) that is listed on ROPS certification
plate. Make sure that all guards and shields are
in place on machine and on work tool. Depending
on type or combination of work equipment, there
is a potential that work equipment could
interfere with the cabin or other parts of
machine. Before using unfamiliar work equipment,
check if there is any potential of interference,
and operate with caution. While you are
performing any maintenance, testing, or
adjustments to attachments, stay clear of the
following areas cutting edges, pinch points,
and crushing surfaces. Never use attachment as a
work platform or manlift. Contact your DOOSAN
distributor about auxiliary hydraulic kits for
attachments installation. If you are in doubt
about the compatibility of a particular
attachment with the machine, consult your DOOSAN
distributor.
Pressurized Fluids Pressurized air or fluids can
cause debris and/or fluids to be blown out. This
could result in death or serious
injury. Immediately after operations are stopped,
coolant, engine oil, and hydraulic oil are at
their highest temperatures and the radiator and
hydraulic tank are still under pressure. Always
wait for temperature to cool down. Follow
specified procedures when attempting to remove
caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool
down, and follow specified procedures when
performing these operations. Failure to do so
can result in death or serious injury. When
pressurized air and/or pressurized water is used
for cleaning, wear protective clothing,
protective shoes, and eye protection. Eye
protection includes goggles or a protective face
shield. Pressure can be trapped in a hydraulic
system and must be relieved before maintenance
is started. Releasing trapped pressure can cause
sudden machine movement or attachment movement.
Use caution if you disconnect hydraulic lines or
fittings.
FG018457
Figure 1
SP002397
Wheel Loader Safety Page 8
12
Engine
13
Table of Contents
Engine Safety Instructions .......................
......................... 5 Applicable
Models............................................
..... 5 DC13 Engine ..............................
.......................... 6 Inspection
..................................................
........... 7 Cleaning the Engine
..................................................
...... 7 Special Tools ...........................
............................. 7 Engine
Identification ...................................
........ 18 Engine Data Plate.....................
..................................... 18 Mounting
the Engine in a Universal Stand...................
.. 19 Engine Specification ......................
..................... 20 Motor...................
................................................
21 Removal and Installation of Motor
................................. 21 Installing
Engine ...........................................
................. 21 Tightening
Torques...........................................
.. 23 Normal Tightening Torque ...................
.......................... 23 Cylinder............
..................................................
. 32 Cylinder Head ...............................
................................. 32 Valve
Mechanism ........................................
.................. 45 Cylinder Block..............
..................................................
48 Cylinder Liner................................
................................. 63 Flywheel
Housing ..........................................
................ 67 Front Cover...................
.................................................
70 Oil Mist Separator ............................
.............................. 72 Camshaft
..................................................
..................... 78 Crankshaft
..................................................
................... 86 Flywheel Housing
..................................................
........ 89 Piston................................
.............................................
90 Belt Circuit ..................................
................................... 95 Gear
Wheel Transmission ...............................
............ 103 Lubrication System
...........................................
108 Centrifugal Oil Cleaner ......................
.......................... 108
SP002399 Page 3
Engine
14
Oil Cooler .......................................
............................. 116 Oil Filter
..................................................
..................... 118 Oil Pump................
..................................................
.... 119 Oil Sump.................................
..................................... 120 Oil
Pressure Sensor ..................................
.................. 121 Turbocharger...............
................................................
122 Solenoid Valve for Wastegate Valve
........................... 126 Wastegate Valve
..................................................
....... 127 Cooling System .......................
......................... 128 Thermostat
..................................................
................ 129 Coolant Pump.................
.............................................
131 Coolant Temperature Sensor ...................
................... 132 Accumulator
..................................................
.............. 132 Calculating the Fuel
Consumption Factor ................... 133 Fuel
System............................................
.......... 136 General Information on the XPI
Fuel System.............. 136 Overflow Valve
..................................................
.......... 156 Feed Pump..........................
........................................
156 Injector Scania XPI...........................
........................... 158 Fuel Filter
..................................................
.................. 161 Fuel Heater................
..................................................
164 Exhaust Temperature Sensor Before Catalytic
Converter 164 Electrical System
..............................................
165 E44, Control Unit Ems S8 .....................
...................... 165 Alternator............
..................................................
....... 180 Starter Motor ........................
.......................................
184 Installing ...................................
................................... 185 EMS,
Engine Management System S8 ......................
. 186 DEF Tank ...................................
...................... 191 General................
..................................................
...... 191 Reductant .............................
.......................................
191 System Overview, Mechanics ...................
.................. 192 System Overview,
Electric..........................................
. 193
SP002399
Engine Page 4
15
Reductant Unit ...................................
.......................... 194 Placement and
Fitting ..........................................
........ 195 Installation.........................
...........................................
195 Connection of Reductant Unit
...................................... 196 Fuel
System Troubleshooting...........................
197 M - Metal Shavings in the Engine
................................ 199 L -
Low-pressure Check................................
............... 201 L - Descriptions,
Low-pressure Check ......................... 202
H - High-pressure Check ..........................
................... 204 H - Descriptions,
High-pressure Check........................ 206
SP002399 Page 5
Engine
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ENGINE IDENTIFICATION
Engine Data Plate Applies to engines with
cylinder block generation 2.
Reference Number Description
A Smoke Value
B Engine Type
C Engine Serial Number
A
B
C
FG020225
Figure 3
FG020227
Figure 4
Engine data on plate, on 9 and 13 liter engines
with XPI
2 123 44XX
1 Typ/Type DC 13 06
Variant Motor/Engine No
Reference Number Description
1 Engine Type and Engine Serial Number
2 Engine Serial Number, Stamped
3 Smoke Data
4 Valve Clearance
3
4

FG020228
Figure 5
SP002399
Engine Page 18
17

• Mounting the Engine in a Universal Stand
• Preparations before commencing work
• Remove engine from the machine.

2
3
4
1
FG020231
Figure 6
Reference Number Description
1 Engine Control Unit
2 Fuel Filter
Reference Number Description
3 High-pressure Pump and Feed Pump
4 Starter Motor
1. Mount the engine in the universal stand.
Reference Number Description
1 Bolt M10x30 (8 off)
2 Nut M16 (4 off)
3 Bolt M16x50 (4 off)
2
3 99 331
1
FG020232
Figure 7
SP002399 Page 19
Engine
18
ENGINE SPECIFICATION
ITEMS ITEMS SPECIFICATION
Engine Type 4-Cycle Water Cooled, Waste Gate Turbocharge, Air to Air Intercooled Direct Injection
Engine Emission US EPA Tier 4i (EU Stage IIIB)
Engine Maker and Model SCANIA / DC 13
Engine Injection System Extra high-pressure fuel injection system, XPI
Engine Rated Net Power 283 kW (390 HP) _at_ 1,800 rpm (SAE J1995)
Valve Clearance Intake Valve 0.45 mm
Valve Clearance Exhaust valve 0.70 mm
Number of cylinders and Configuration Number of cylinders and Configuration 6, Straight
Rotating Direction (from Flywheel) Counterclockwise
Oil Pressure (bar, kg/cm²) Normal with the engine at operating temperature, operating speed 3 - 6
Oil Pressure (bar, kg/cm²) Min. permitted at idling speed 0.7
Crankcase pressure with closed crankcase ventilation -55 - 20
Using Lubrication Oil ACEA-E3, E4, E5 or E7 (for fuel with ultra low sulfur)
Oil Filter Paper filter form Scania
Interval between oil changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 130 mm
Piston Stroke 140 mm
Displacement 12.7 dm3
Compression Ratio 17.31
Number of teeth on the flywheel 158
Low Idle Speed 600 - 750 rpm
High Idle 2,180 rpm
Weight, without Coolant and Oil 1050 kg
Cooling System Volume, excluding radiator 16 dm3
Cooling System Coolant Temperature 90 - 95
Cooling System Number of Thermostats 1
Cooling System Thermostat, Opening Temperature 80/87
Electrical System Type 1-pin, 24V, DC
Electrical System Starter Motor (Standard Equipment) 1-pin, 24V, 6 kW
Electrical System Alternator (Standard Equipment) 1-pin, 28V, 100 A
SP002399
Engine Page 20
19
MOTOR Removal and Installation of Motor
NOTE
Replace coolant hoses if there is clear damage to
the coolant hoses which were removed.

1. Drain the oil and coolant.
2. Remove air filter and inlet pipe between the
   turbocharger and air filter. Cover the
   turbocharger inlet pipe.
3. Undo the connections for coolant, charge air
   pipes between engine and charge air cooler, and
   bleed pipe for the expansion tank.
4. Undo the cable harness with clamping.

NOTE
The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
FG020236
Figure 8

1. Fasten the lifting chain 98 094 to the rear
   lifting eyes 99 637.
2. Fasten the lever block 587 308 to the front
   lifting eye.

NOTE
The lifting eyes 99 637 are designed to manage a
maximum inclination angle of 30 when lifting an
engine.
max 30
7. Undo the engine insulator bolts and lift
away/out the engine.
max 20 FG020237
Figure 9
Installing Engine 1. Fasten the lifting chain 98
094 to the rear lifting eyes.
NOTE
The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used. The
lifting eyes 99 637 are designed to manage a
maximum inclination angle of 30 when lifting an
engine.

max 30
NOTE
max 20

1. Fasten the lever block 587 308 to the front
   lifting eye.
2. Lift the engine, position it on the engine
   insulators and screw it into place.

FG020237
Figure 10
SP002399 Page 21
Engine
20

1. Attach the cable harness with clamping.
2. Install the connections for coolant, charge air
   pipes between engine and charge air cooler, and
   bleed pipe for the expansion tank.
3. Install the air filter and inlet pipe between the
   turbocharger and air filter.
4. Fill with oil and coolant as directed in booklet
   0003-01.
5. Test run the engine to check that no leakage
   occurs. Top up with coolant if necessary.

SP002399
Engine Page 22
21
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TIGHTENING TORQUES
Normal Tightening Torque The specifications in
the tables below show the normal tightening
torque for screws, nuts and unions. The values
are to be used unless other values are specified
in the inspection information. Always check
whether there are special tightening torques
given in the descriptions for the respective
areas in the inspection information before using
the general values for normal and special
tightening torques respectively. The following
conditions apply

• A tolerance of 15 applies to all values
  unless otherwise specified.
• All contact surfaces are to be clean and free of
  paint.
• Bolts and nuts are normally not lubricated
  regardless of surface treatment. All exceptions
  are specified in the inspection information.

Union Assemblies The specified values apply with
a tolerance of 5 . The values apply to
tightening with a counterhold. Thread Inserts The
specified tightening torques also apply to bolted
joints with a thread insert (Heli-Coil). Thread
inserts often provide greater strength compared
to a directly screwed thread. This generates a
stronger bolted joint in aluminium or the like.
For this reason, thread inserts are used in
certain joints in Scania's production.
NOTE
When a damaged thread is repaired with a thread
insert, the normal screw and prescribed
tightening torque are to be maintained. Install
the thread insert as instructed in the
inspection information.
SP002399 Page 23
Engine
23
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