Doosan DL550-5 Operation & Maintenance Manual
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Doosan DL550-5 Operation & Maintenance Manual

Wheel loader, serial number 10001 and up
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Table of Contents

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WHEEL LOADER
Manual
DL550-5
Serial Number 10001 and Up
950106-01245NA-1
July 2014

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Summary of Contents for Doosan DL550-5

  • Page 1 950106-01245NA-1 July 2014 WHEEL LOADER Operation & Maintenance Manual DL550-5 Serial Number 10001 and Up...
  • Page 3 Operation & Maintenance 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 950106-01245NA-1 world. July 2014 Copyright DOOSAN 2014...

  • Page 5: Table Of Contents

    Left Side Electric Steering Control Unit (Optional)......2-69 Various Cabin Locations ..............2-72 Heater and Air Conditioner Operation..........2-76 Stereo/CD Player (Optional) ............2-82 Seat Adjustment W/Air Suspension (Standard) ....... 2-83 Seat Adjustment W/Air Suspension and Heater ......2-86 DL550-5 Table of Contents...

  • Page 6: Table Of Contents

    Maintenance Handling Access............4-7 Handling Oil, Fuel, DEF (AdBlue) Coolant........4-10 Electrical System Maintenance............4-14 Recommend Fuel, Coolant, and Lubricant ........4-15 Preventive Maintenance ..............4-22 Table of Recommended Lubricants ..........4-24 Transmission Oil ................4-27 Axle Oils................... 4-28 Table of Contents DL550-5...

  • Page 7: Table Of Contents

    Severe Conditions Maintenance ............ 4-111 Tires ....................4-112 Transmission Recalibration............4-115 Transportation ................5-1 Transporting Machine ................ 5-1 Lifting Machine................... 5-5 Troubleshooting ................6-1 Braking....................6-1 Electrical System ................6-2 Engine....................6-2 Hydraulic System ................6-5 Steering....................6-7 Travel System ..................6-8 DL550-5 Table of Contents...

  • Page 8: Table Of Contents

    Specification ................7-1 General Specifications ............... 7-1 Working Range and Dimensions ............7-2 Working Capacities ................7-4 Approximate Weight of Workload Materials........7-5 Index ...................8-1 Table of Contents DL550-5...

  • Page 9: Foreword

    If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.

  • Page 10: Safety Messages

    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. Foreword DL550-5...

  • Page 11: Aem Safety Manual (North America Only)

    The AEM Safety Manual delivered with the machine gives general safety information. The AEM Safety Manual must be read and understood before beginning operation or maintenance and is not intended to replace the Operation & Maintenance Manual delivered with the machine. Figure 1 DL550-5 Foreword...

  • Page 12: Product Information

    Roll-over Protective Structure (ROPS) and can result in death or serious injury. Contact your DOOSAN distributor for further information. Engine and Emission Control System Maintenance Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating.

  • Page 13: Product Identification

    The engine type designation and number. Front Axle The manufacturer's name and address and front drive axle CIN. Transmission The manufacturer's name and address and transmission CIN. Rear Axle The manufacturer's name and address and rear drive axle CIN. DL550-5 Foreword...

  • Page 14: Federal Emission Control Systems

    The warranty period shall begin on the date the engine is delivered to the first ultimate purchaser who, in good faith, purchases the engine for purposes other than imminent resale. Foreword DL550-5...
  • Page 15 Any replacement part, as defined in Section 1900 (b), Title 13 of the California Code of Regulations, may be used in the performance of any maintenance or repairs and must be provided without charge to the owner. DL550-5 Foreword...
  • Page 16 NOx sensor, engine out NOx sensor, tail pipe DOC (when applicable) 10. SCR System: DEF (AdBlue) tank DEF (AdBlue) tank level, temperature and quality sensors DEF (AdBlue) hose DEF (AdBlue) injector DEF (AdBlue) injector pressure and temperature sensors Foreword DL550-5...
  • Page 17 Scania industrial diesel engine. Scania may deny a warranty claim if the engine or part failed because abuse, neglect, improper maintenance or unapproved modifications. Receipts covering the performance of regular maintenance must retained event questions arise concerning maintenance. DL550-5 Foreword...
  • Page 18 Scania installation instructions and emissions certificate for this engine type. Damage resulting from accidents, acts of nature or other events beyond the control of Scania. Foreword DL550-5 0-10...
  • Page 19 If you do not receive the warranty service to which you believe you are entitled under the Warranty provisions, or if you need additional support or information concerning the Warranty, contact your DOOSAN or SCANIA engine distributor. Catalytic Converter WARNING...
  • Page 20 • When engine is running, the exhaust system parts can reach such high temperatures there is a risk of personal injury. Make sure that exhaust system temperature has cooled before starting to work. Foreword DL550-5 0-12...
  • Page 21 Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, Scania CV AB will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts and labor. DL550-5 Foreword 0-13...
  • Page 22 Scania CV AB dealer as soon as a problem exists. The warranty repairs must be completed by the dealer as expeditiously as possible. • If you have any questions regarding your warranty rights and responsibilities, you should contact Scania USA, Inc at 1-210-403-0007. Foreword DL550-5 0-14...

  • Page 23: Safety

    Safety DL550-5 Safety...

  • Page 24: Safety Decals

    Safety Decals With Text Safety decals with text consist of a signal word, pictorial and a text message panel. In some cases, a pictorial panel may not be part of the safety decal. Safety DL550-5...
  • Page 25 The safety information panel uses pictorials and/or prohibition signs to identify the actions necessary to avoid the hazard. Avoidance Panel Horizontal Configuration Hazard Avoidance Panel Panel FG018723 Figure 1 DL550-5 Safety...
  • Page 26 Information and Location for Safety Decals 11(LIS) (Brake) (Steering) (Pilot) WL1400801 Figure 2 Safety DL550-5...
  • Page 27 • TO LEAVE THE WHEEL LOADER: Lower the attachment to the ground and make sure all controls are in neutral. Engage the parking brake. Set pilot cutoff switch to OFF position. Stop the engine and remove the key. DL550-5 Safety...
  • Page 28 Do not weld on or drill holes in the protective structure. • Replacing ROPS, if damaged or modified. Refer to See “Roll-over Protective Structure (ROPS)/ Falling Object Protective Structure (FOPS)” on page 2-23 for more information. 950205-04645 WL1400814 Safety DL550-5...
  • Page 29 • If battery acid contact occurs: Flush your skin with water immediately and apply baking soda or lime to neutralize the acid. Flush your eyes with water for 10 ~ 15 minutes. Get medical attention immediately. DL550-5 Safety...
  • Page 30 11. Pressurized Gas and Fluid (950205-03782) WARNING AVOID DEATH OR SERIOUS INJURY • Heat or impact can cause the accumulator to explode. • Keep away from flame. EX1301187 • Do not weld on or drill into accumulator. Safety DL550-5...
  • Page 31 ROLL AWAY CAN CAUSE DEATH OR SERIOUS INJURY • Before disengaging park brake, block wheels to 950205-01691B prevent machine movement. WL1400815 Additional Decal 15. Electric Welding Attention (950212-02440) IMPORTANT Electrical welding on the frame can damage the engine's electronic control unit (ECU). 950212-02440 EX1402396 DL550-5 Safety...
  • Page 32 WL1400810 engage parking brake. Check the transmission oil level using the dipstick or gauge. If necessary, add transmission oil (Spec. SAE 15W40) Correct oil level (Oil temp. 80°C (176°F)):  Hot zone (dipstick type)/Red line (gauge type) Safety DL550-5 1-10...
  • Page 33 See the Operation & Maintenance Manual for more information. ISO 22241 DIN 70070 950205-01489A WL1300370 21. DEF (AdBlue) Filter (950205-02449) IMPORTANT DEF (AdBlue ) Filter ® Operation & Maintenance Manual information on the DEF filter. 950205-02449 WL1300373 DL550-5 Safety 1-11...
  • Page 34 23. Pressure Check (950205-04646A) Part Name Remarks 2, 3 Steering Unit Brake Pilot Supply Valve ACC. Charging Valve 7,10 Brake Pilot Filter 950205-04646A Main Control Valve WL1400816 Flow Amplifier Oil Sampling (HYD) Main Pump Fan Motor T/M Parking Safety DL550-5 1-12...
  • Page 35 Mirror heater ON/OFF Fuel Heater Fuel heater ON/OFF Rotating Beacon Rotating beacon ON/OFF Emergency For emergency steering test: Steering Test Press and hold switch to test steering operation See Operation and Maintenance Manual for more information 950205-XXXXX WL1400811 DL550-5 Safety 1-13...

  • Page 36: General

    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.
  • Page 37 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.
  • Page 38 Additional protection for operator's cabin may be required such as a Falling Object Protective Structure (FOPS) or window guards. Contact your DOOSAN distributor for information on available protective HAOA110L guards. Figure 4 To prevent personnel from being struck by flying objects, keep personnel out of work area.
  • Page 39 Always have at least two people working together if the engine must be running during service. One person needs to remain in the operator's seat, ready to work the controls to stop the machine or stop engine, if necessary. DL550-5 Safety 1-17...
  • Page 40 Dust that is generated from repairing or grinding nonmetallic hoods or nonmetallic fenders can be toxic, flammable and explosive. Repair these components in a well ventilated area away from flames or sparks and wear FG018458 a dust mask when grinding painted parts. Figure 11 Safety DL550-5 1-18...
  • Page 41 Improper jumper cable connections can cause an explosion that can result in death or serious injury. Do not charge a frozen battery. This can cause an explosion. After market radios or other electric operated equipment in cabin must have a fuse in the electrical circuit. DL550-5 Safety 1-19...
  • Page 42 Do not use ether or starting fluids on any engine that has glow plugs, or an electric grid type manifold heater. These starting aids can cause an explosion and result in death or serious injury. Use procedures in this manual for connecting battery and for jump-starting. FG018458 Figure 13 Safety DL550-5 1-20...
  • Page 43 When using a fire extinguisher, always aim extinguisher at base of fire. • If an optional fire extinguishing system is in place, be familiar with its operating procedures. NOTE: Depending on job conditions, other procedures could be necessary if a fire occurs. DL550-5 Safety 1-21...
  • Page 44 Never touch injector terminal or inside of engine controller. NOTE: If it is necessary to touch injector terminal or inside WL1300010 engine controller, contact your DOOSAN distributor. Figure 16 Safety DL550-5 1-22...
  • Page 45 Never modify the operator's cabin by welding, grinding, drilling holes or adding attachments unless instructed by DOOSAN in writing. Changes to the cabin can cause loss of operator protection from roll-over and falling objects, and result in death or serious injury.
  • Page 46 Never modify the operator cabin by welding, grinding, drilling holes or adding attachments unless instructed in writing by DOOSAN. Changes to the cabin can cause loss of operator protection from rollover and falling objects, and can result in death or serious injury.

  • Page 47: Operation

    Know width and length of your machine and work equipment to maintain proper clearance when you operate machine or work WARNING No Entry equipment near fences or near boundary obstacles. FG013735 Figure 19 DL550-5 Safety 1-25...
  • Page 48 Use points marked by arrows in diagram when getting on or off machine. Do not carry tools or supplies when you mount or dismount the machine. Safety DL550-5 1-26...
  • Page 49 When standing up from operator's seat, always place pilot cutoff switch in "O" (OFF) position. If you accidentally move work equipment levers when they are not locked, the machine could suddenly move and cause damage, death or serious injury. DL550-5 Safety 1-27...

  • Page 50: Seat Belt

    If original color of webbing in these areas is extremely faded and/or webbing is packed with dirt, webbing strength may be reduced. NOTE: Contact your DOOSAN distributor for seat belt system replacement parts. WARNING AVOID DEATH OR SERIOUS INJURY...
  • Page 51 Inspect equipment and repair immediately if there are problems with visual aids. If machine cannot be fixed immediately, DO NOT use the machine. Contact your DOOSAN distributor and arrange for repairs. DL550-5 Safety...
  • Page 52 • Connect positive (+) cable first when installing cables and disconnect negative (-) cable first when removing them. Safety DL550-5 1-30...

  • Page 53: Starting Engine

    Do not operate steering suddenly. Work equipment can hit FG019362 ground and this can damage machine or structures in area. Figure 21 When traveling on rough ground, travel at low speed, and avoid sudden changes in direction. DL550-5 Safety 1-31...
  • Page 54 10° or more to right or left, or 30° or more from front to rear. Know permitted ground pressure. Ground pressure of the machine may change depending on attachment and load. Keep height and length of attachment in mind. Safety DL550-5 1-32...
  • Page 55 This could cause wheel loader to tip or rollover, which could cause death or serious injury to operator. Working around deep pits, trenching or along high walls may require support blocks, especially after heavy rains or during spring thaws. DL550-5 Safety 1-33...
  • Page 56 Keep the machine under control. Do not overload the machine beyond capacity. • Do not turn on slopes or travel across slopes. Always go down to a flat place to change position of the machine, then travel backup the slope again. WL1400121 Figure 24 Safety DL550-5 1-34...
  • Page 57 An unexpected fall of front structure can cause death or Figure 26 serious injury. While operating a machine, do not let people enter the work area. A sudden collapse of front structure caused from a hydraulic hose failure can result in death or serious injury. DL550-5 Safety 1-35...
  • Page 58 Figure 28 AVOID DEATH OR SERIOUS INJURY Pressurized oil has enough force to pierce skin and cause death or serious injury. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury. Safety DL550-5 1-36...

  • Page 59: Parking Machine

    Machine movement will occur if any controls are moved. This can result in death or serious injury. Always move hydraulic lockout control to "LOCK" position before stopping the engine or immediately after engine stops running. DL550-5 Safety 1-37...

  • Page 60: Maintenance

    Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can result in death or serious injury. • Never service DOOSAN equipment without instructions. • Always lower lift arm and attachment to ground before doing any maintenance. •...
  • Page 61 Maintenance procedures which are not in this manual must be performed ONLY BY QUALIFIED SERVICE PERSONNEL. Always use genuine DOOSAN replacement parts. • Only authorized personnel should service and repair the machine. Do not allow unauthorized personnel access to the machine or into work area.
  • Page 62 "O" (OFF) position, complies with the Occupational Safety and Health Administration's (OSHA) lockout requirements. "DO NOT OPERATE" warning tags, are available from your DOOSAN distributor. • Always attach "DO NOT OPERATE" warning tag to work EX1301177...
  • Page 63 Hitting hard metal pins, bucket teeth, cutting edges or bearings with a hammer, can cause metal pieces to break or fly off resulting in serious injury. Always wear safety goggles and leather gloves. Keep personnel and bystanders away. DL550-5 Safety 1-41...
  • Page 64 Check electrical wires daily for wires that are loose or frayed. Tighten all loose, and repair or replace all frayed, electrical wires before operating machine. Remove all flammable materials and debris from the engine compartment, exhaust system components and hydraulic lines. Safety DL550-5 1-42...

  • Page 65: Burn Prevention

    Do not smoke while you are checking battery electrolyte level. Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact skin, eyes or other body parts. Always wear safety goggles and face protection when working with batteries. DL550-5 Safety 1-43...
  • Page 66 (a solution or suspension of calcium hydroxide, i.e. slaked lime in water). After the work has been completed, the gloves must be washed in limewater and then discarded. Safety DL550-5 1-44...
  • Page 67 Hydrofluoric Acid Burn Jelly or something similar. Seek medical advice. Symptom may not appear until several hours afterwards. Discard gloves, rags etc. which are suspected of having touched burned rubber that contains fluorides. DL550-5 Safety 1-45...
  • Page 68 • Wear protective clothing. • Make sure there is good ventilation. • Remove all flammable objects and make sure a fire extinguisher is available for immediate use. Safety DL550-5 1-46...
  • Page 69 Do not work under the machine if machine is lifted off ground and the machine is supported only with work equipment. If any control levers are moved, or there is damage to hydraulic system, work equipment or the machine will suddenly drop causing death or serious injury. DL550-5 Safety 1-47...
  • Page 70 Figure 37 accumulator, or when disposing of accumulator, charged nitrogen gas must be properly released before beginning such work. Contact your DOOSAN distributor for assistance. • Wear safety goggles and leather gloves when working on an accumulator. Hydraulic oil under pressure can penetrate skin and result in death or serious injury.
  • Page 71 Foreign material is embedded in hose covering. – Hose end is deformed. – Connection fittings are damaged or leaking. NOTE: Refer to “Hose In-service Lifetime Limit (European Standard ISO 8331 EN982 CEN)” on page 4-95, for additional European regulations. DL550-5 Safety 1-49...
  • Page 72 When charging battery or starting with power from another source in cold temperatures let battery electrolyte thaw and check that there is no leakage of battery electrolyte before starting operation. • Always remove battery from machine before charging. Safety DL550-5 1-50...
  • Page 73 “Antifreeze Concentration Tables” on page 4-100, to determine amount of protection cooling system requires. Add coolant as required. Hydraulic System Once a month, start engine and follow procedures listed in “Automatic Warming Up Operation” on page 3-10, in this manual. DL550-5 Safety 1-51...
  • Page 74 It can cause blockage of system. • Wipe off grease from piston rods. • Inspect for signs of nests (i.e. birds, rodents, etc.) Safety DL550-5 1-52...

  • Page 75: Transportation

    Never correct your steering on ramps. If necessary, drive off ramps, correct machine direction, then drive back onto ramps. • For machines equipped with a cabin, always lock door after loading machine to prevent door from suddenly opening during transportation. DL550-5 Safety 1-53...

  • Page 76: Transporting Machine

    • When passing over bridges or structures on private land, check that structure is strong enough to support weight of machine. Before traveling on public roads, check with appropriate authorities and follow their instructions. Safety DL550-5 1-54...

  • Page 77: Environment And Circumstances

    Do not travel too close to edge of a drop-off. When working on or from top of buildings or other structures, check if structure can support weight of machine and attachment. If a building structure collapses, this can cause death or serious injury. DL550-5 Safety 1-55...
  • Page 78 Do not panic and do not raise bucket, if ground should begin to collapse. Lower work equipment to improve stability of machine. Never dig under machine, if there is a potential of causing a landslide. Safety DL550-5 1-56...
  • Page 79 Also check which rules apply to ground personnel regarding exposing FG019379 cables, utilities and electrical lines. Figure 44 Consider all electrical cables as live. DL550-5 Safety 1-57...
  • Page 80 Working in Contaminated Environment When working within area which is contaminated or where there is a health risk, check local laws and regulations and contact your DOOSAN distributor for assistance with identifying what additional safety precautions need to be taken. Safety...
  • Page 81 Service Chart” on page 4-30, in this manual and/or the lubrication chart on machine. (If equipped) Be careful to choose proper greases. Contact your DOOSAN distributor to get more information. Start engine and allow it to reach normal operating temperature before operating.
  • Page 82 If machine is to stand for several days, remove batteries and store in a cool place. IMPORTANT Do not store acid type storage batteries near stacks of tires. Acid fumes can damage rubber. Safety DL550-5 1-60...
  • Page 83 Sand mixed becomes very abrasive and accelerates wear on parts if mixed with lubricants. Protect machine from dust and sand as much as possible. Park machine under cover to keep dust and sand from damaging unit. DL550-5 Safety 1-61...
  • Page 84 During electrical storms, do not enter or exit machine. • If you are off machine, keep away from machine until storm passes. • If you are in cabin, remain seated with machine stationary until storm passes. Do not touch controls or anything metal. Safety DL550-5 1-62...
  • Page 85 Avoid brushing or grinding materials that contain asbestos. • Use a vacuum cleaner that is equipped with a high efficiency particulate air filter. • Comply with applicable laws and regulations for workplace. • Stay away from areas that might have asbestos particles in air. DL550-5 Safety 1-63...
  • Page 86 Sound pressure level (LpA) at operator position 72 dB(A) (Measurement according to ISO 6396) Sound power level (LwA) around the machine (Measurement according to 2000/14/EC with 107 dB(A) applicable appendices and measuring method according to ISO 6395) Safety DL550-5 1-64...
  • Page 87 ISO 2631-1. ISO 5349, and SAE J1166. Recommendations for Reducing Vibrations: Select proper machine, equipment and attachments for a particular application. Replace any damaged seat with a genuine DOOSAN seat. Keep seat properly maintained and adjusted. • Adjust seat and suspension for weight and size of operator.
  • Page 88 Safety DL550-5 1-66...

  • Page 89: Operating Controls

    These lights will only show there is a problem that needs correction. IMPORTANT When any one or more of the warning symbols on the control console come "ON", immediately stop operation. Investigate and correct problem before proceeding with operation. DL550-5 Operating Controls...

  • Page 90: Component Locations

    Radiator Main Control Valve Engine Front Axle Pre Cleaner Driveshaft (Front) Air Cleaner Steering Cylinder Muffler Tail Pipe Driveshaft (Center) SCR Catalyst Transmission Oil Tank Driveshaft (Rear) Steering Pump Fan Pump Main Pump Rear Axle Brake Filter Operating Controls DL550-5...
  • Page 91 WL1400665 Figure 2 Reference Reference Description Description Number Number Headlight Loader Arm Bucket Cylinder Boom Cylinder Tilt Lever Adapter Bucket Lever Teeth Bucket DL550-5 Operating Controls...
  • Page 92 WL1400664 Figure 3 Reference Reference Description Description Number Number Radiator Grille Rear Light Counterweight Fuel Tank Fan Motor Battery Box Battery Disconnector Switch Operating Controls DL550-5...

  • Page 93: Operator's Area

    OPERATOR'S AREA Figure 4, identifies controls in operator's cabin. WL1400124 Figure 4 Reference Reference Description Description Number Number Steering Console and Pedal Right Side Switch Panel 252) Various Cabin Locations Seat Adjustment 272) 283) DL550-5 Operating Controls...

  • Page 94: Steering Console And Pedals

    Horn Button Front Instrument Panel Combination Switch Hour Meter Accelerator Pedal Front Keypad Steering Wheel Adjustment Hazard Warning Light Switch Lever Electric Steering High/Low Brake Pedals Switch (Optional) Steering Wheel Differential Lock Button (Manual) Kick-down Button Transmission Lever Operating Controls DL550-5...
  • Page 95 (Figure 7) or the left button at the tip of the finger tip lever (optional) (Left) of the two levers (Figure 8), will sound the horn. NOTE: Starter switch must be "ON". FG018935 Figure 6 FG018937 Figure 7 WL1300162 Figure 8 DL550-5 Operating Controls...
  • Page 96 Pull up to 2nd step - The high beams turn "ON". (It returns to "NEUTRAL" position when released.) For turn off, pull up 2nd step again. NOTE: High and low beams will only function with the headlight switch in the "||" position. FG018957 Figure 10 Operating Controls DL550-5...
  • Page 97 Figure 13) to desired position. Tilt angle is 15° to window side, 24° to driver side. Adjusting Steering Wheel Telescopic Pull lever (1, Figure 13) upward and move wheel (2, Figure WL1400127 13) to desired position. Telescopic stroke is 85 mm. Figure 12 WL1300378 Figure 13 DL550-5 Operating Controls...
  • Page 98 Do not use brake pedal as a footrest. This will cause brake disk to wear faster than normal, and this could reduce braking capability. 6. Steering Wheel Rotating steering wheel controls position of front wheels and this determines direction of machine travel. WL1300174 Figure 15 Operating Controls DL550-5 2-10...
  • Page 99 "NEUTRAL". Reverse When lever pulled back, transmission is in "REVERSE", 1st, 2nd and 3rd FG019004 gears are available. Figure 19 Rotating the switch shifts transmission between 1st, 2nd, 3rd or 4th gears. DL550-5 Operating Controls 2-11...
  • Page 100 10. Hour Meter The hour meter is used to indicate total number of operating hours on engine. The meter will flash every 4 seconds when engine is running to indicate that it is functioning properly. HAOA601L Figure 22 Operating Controls DL550-5 2-12...
  • Page 101 E-MCV is the electric control valve (optional) OFF: Return to dig is turned "OFF" Center LED light "ON": Return to dig turned "ON" Center LED light "Blinking": Press button for 1 second, Set adjusting the current bucket position DL550-5 Operating Controls 2-13...
  • Page 102 The lockup clutch automatically links the impeller (input side) with the turbine (output side). This effectively connects the engine mechanically with the transmission for direct drive. The result is no slippage, and virtually no power loss. Operating Controls DL550-5 2-14...
  • Page 103 Figure 24 turned "OFF". In this position, all directional indicator lights on front and back of machine, and instrument panel are turned "ON". NOTE: Hazard warning lights will function with starter switch in "OFF" position. DL550-5 Operating Controls 2-15...
  • Page 104 In this position, auto grease system is turned "OFF". In this position, auto grease system is turned "ON". WL1300379 Figure 26 15. Differential Lock Button (Manual) Depress switch to "LOCK" front axle differential and release switch to "UNLOCK" differential. FG019121 Figure 27 Operating Controls DL550-5 2-16...

  • Page 105: Front Instrument Panel

    Parking Brake Indicator Light High Beam Indicator Light Right Turn and Hazard Warning Emergency Steering Indicator Light Light (Optional) Brake Fluid Pressure Warning Mirror Heater Indicator Light Light Work Light Indicator Light Auto Grease Fault Indicator Light (Optional) DL550-5 Operating Controls 2-17...
  • Page 106 This meter displays speed at which the machine is traveling. FG004182 Figure 29 2. Multifunction Gauge and Graphic Information Display (See page 2-24) This section will have a more in-depth explanation of the display area. FG019107 Figure 30 Operating Controls DL550-5 2-18...
  • Page 107 "ON". NOTE: If left and right turn indicators blink together, or if they blink faster than normal, a light bulb is not operating or flasher solenoid is damaged. Repair or replace as necessary. FG004174 Figure 33 DL550-5 Operating Controls 2-19...
  • Page 108 To turn indicator light "OFF", turn starter switch "OFF" and then back "ON". HAOA660L Figure 36 9. High Beam Indicator Light This indicator light will turn "ON" when the headlights are turned to "HIGH BEAM". Figure 37 Operating Controls DL550-5 2-20...
  • Page 109 This indicator light will turn "ON" when the mirror heater is activated. FG004184 Figure 39 12. Work Light Indicator Light This indicator light will turn "ON" when the front and/or rear work lights are activated. Figure 40 DL550-5 Operating Controls 2-21...

  • Page 110: Multifunction Gauge And Graphic Information Display

    ) button is used to move a menu item "UP" or to "LEFT". FG019322 Figure 42 Down Arrow Button Down arrow ( ) button is used to move a menu item "DOWN" or to "RIGHT". FG019323 Figure 43 Operating Controls DL550-5 2-22...
  • Page 111 FG015189 Figure 44 Selector Button SELECTION ( ) button is used to set a menu or clear the operating hour of filter/oil. FG019324 Figure 45 DL550-5 Operating Controls 2-23...
  • Page 112 Description Number Number Fuel Gauge Engine Speed Engine Coolant Temperature ECO Bar Gauge Multifunction Display Transmission Oil Temperature Display Warning Symbols Gauge Indicator Symbols DEF (AdBlue) Level Gauge Digital Clock Transmission Actual Gear Transmission Select Gear Operating Controls DL550-5 2-24...
  • Page 113 "ON" and be displayed on the in screen. Allow engine to run at "LOW IDLE" until Figure 49 temperature gauge registers in white zone again. NOTE: “10. Display Warning Symbols” page 2-28, for location of this warning symbol and others. DL550-5 Operating Controls 2-25...
  • Page 114 Indicates travel direction and gear selection. First number displays gear, and letter displays travel direction. FG019113 Figure 51 Transmission Select Gear Indicates gear range of transmission lever. FG019114 Figure 52 Engine Speed The engine speed is numerically displayed. FG014225-1 Figure 53 Operating Controls DL550-5 2-26...
  • Page 115 Go to Instrument Display Press DOWN ( ) button to move selection window to instrument display. Press SELECTION ( ) button If the operator press SELECTION ( ) button, all data in instrument display will flash. FG019116 Figure 56 DL550-5 Operating Controls 2-27...
  • Page 116 Charge Warning Symbol Engine Oil Pressure Warning Symbol Transmission Warning Symbol Engine Warning Symbol Water In Fuel Warning Symbol FG019119 Figure 60 DEF (AdBlue) Low Level Warning Symbol - EPA SCR Failure Warning Symbol (Only EPA) Operating Controls DL550-5 2-28...
  • Page 117 FG019122 Figure 63 Engine Warning Symbol This symbol indicates that engine needs to be checked. NOTE: If this symbol turns "ON", stop machine and repair cause of the problem. AQO0040L Figure 64 DL550-5 Operating Controls 2-29...
  • Page 118 1% per minute to 70% 2 sec. of highest torque Torque is reduced to Flashing 0% (low idling) within FG019175 0.5 sec. 2-10 minutes Figure 66 * Applies only to engines certified according to Tier 4. Operating Controls DL550-5 2-30...
  • Page 119 SCR system is functioning again. A service technician must then reset system so normal torque levels can be obtained again. NOTE: Torque reduction applies only to engines certified according to Tier 4. DL550-5 Operating Controls 2-31...
  • Page 120 When Auto 2-4 mode is selected, symbol is shown on lower part of screen. FG019131 Figure 70 Engine Power Mode - Power When power mode is selected, symbol is shown on lower part of screen. FG019132 Figure 71 Operating Controls DL550-5 2-32...
  • Page 121 Auto Idle When auto idle is operating, symbol is shown on lower part of screen. FG019135 Figure 74 2nd Gear Mode When 2nd gear is selected, symbol is shown on lower part of screen. BSO0510L Figure 75 DL550-5 Operating Controls 2-33...
  • Page 122 Electric Steering When electric steering is selected, symbol is shown on lower part of screen. FG004186 Figure 78 Reverse Fan When reverse fan is operating, symbol is shown on lower part of screen. FG004185 Figure 79 Operating Controls DL550-5 2-34...
  • Page 123 12. Digital Clock A digital clock, shows current time. The displayed contents are as follows. Display Description HH:mm AM/PM Hour Minute AM (PM) AM (PM) Refer to “User Menu” on page 2-38 for time. FG019345 Figure 83 DL550-5 Operating Controls 2-35...
  • Page 124 Go to Warning Display Move selection window to warning display by pressing UP ) button. FG019125 Figure 84 Enter Checking Mode Enter individual symbol checking mode by pressing SELECTION ( ) button. FG019126 Figure 85 Operating Controls DL550-5 2-36...
  • Page 125 Select warning symbol by pressing SELECTION ( button to read warning message. 010-4104-1697 010-4104-1697 Low E/G Oil Pressure Check E/G Oil Pressure FG019127 Figure 86 Delete Warning Pop-up Press ESC button to delete warning pop-up. FG019128 Figure 87 DL550-5 Operating Controls 2-37...
  • Page 126 Vehicle State  Vehicle Setup  GP Setup Press ESC button to return to previous screen. Vehicle Vehicle State Configuration Configuration WARNING FG021925 AVOID DEATH OR SERIOUS INJURY Figure 89 Do not use buttons to change menu state when traveling or operating machine. Operating Controls DL550-5 2-38...
  • Page 127 The screen displays information on filter/oil use time, Vehicle State replacement period, and remaining time. Monitoring At Vehicle State, if cursor is placed on Filter/Oil Information, press SELECTION ( ) button to Filter/Oil Information display filter/oil information. Vehicle Information FG019145 Figure 92 DL550-5 Operating Controls 2-39...
  • Page 128 ) button to change replacement period. NOTE: Press UP ( ) or DOWN ( ) button to locate it at NO. Then, press SELECTION ) button to allow pop-up window to disappear without changing replacement panel. Operating Controls DL550-5 2-40...
  • Page 129 Replacement period is 500hr exceeded! CHANGE: E/G Oil Filter AVOID DEATH OR SERIOUS INJURY TIME: REMAIN: 495hr 500hr CHANGE: Do not use buttons to change Vehicle State menu E/G Oil when traveling or operating machine. FG019150 Figure 98 DL550-5 Operating Controls 2-41...
  • Page 130 ) button to select menu. Reverse Fan Period Setting  Active LIS Vehicle Speed Setting  Auto Shut Off Time Setting  Auto Idle Enable State WL1300756 Figure 102 Press ESC button to return to previous screen. Operating Controls DL550-5 2-42...
  • Page 131 Setup" window, with cursor on " Active LIS Vehicle Speed Setting" menu, press SELECTION ( Active LIS Vehicle Speed Setting button to enter "Active LIS Vehicle Speed Setting" Auto Shut Off Time Setting window WL1300759 Figure 106 DL550-5 Operating Controls 2-43...
  • Page 132 3 seconds, and menu list will be changed according to selected setting. Reverse Fan Auto Period Setting Auto Idle Enable State  Auto Idle Disable – Auto Idle is Disabled Auto Idle Enable State WL1300780 Figure 110 Operating Controls DL550-5 2-44...
  • Page 133 SELECTION ( Password Change button to delete input password. – On Password Setting screen, input a password to display a screen to select application of FG019189 function (lock), non-application (unlock) and Figure 114 password change. DL550-5 Operating Controls 2-45...
  • Page 134 (applied) or unlock (not applied). Figure 116 IMPORTANT Be careful not to forget your password. If you have forgotten your password, contact a DOOSAN distributor. Screen Brightness Setting On "GP Setup" screen, when cursor is placed on GP Configuration "Screen Brightness Setting", press SELECTION Password Setting ) button to display screen brightness setting.
  • Page 135 Service Phone Number Setting WL1300783 Figure 119 The selected style screen is displayed as normal Default Screen Setting display screen. The screen is set as Style #1 at factory. Style #1 Style #2 FG019195 Figure 120 DL550-5 Operating Controls 2-47...
  • Page 136 Time Setting numbers of each item. If setup is completed, press SELECTION ( ) button to store setup details. TIME : 06 Press ESC button to return to previous screen. DATE 2010 / 09 FG018538 Figure 123 Operating Controls DL550-5 2-48...
  • Page 137 1 2 3 4 5 6 7 8 9 0 FG019200 Figure 125 When you input service phone numbers, if warning/ alarm is given, check input phone numbers in pop-up window. 010-4104-1697 010-4104-1697 Low E/G Oil Pressure Check E/G Oil Pressure FG019127 Figure 126 DL550-5 Operating Controls 2-49...
  • Page 138 Press ESC button to return to previous screen. Francaise (French) Language Deutsch (German) Korean, English, Chinese, Persian, Turkish, Nederlands (Dutch) Indonesian, Polish, Arabic, Russian, Thai, Hindi, Japanese, French, German, Nederlands, Italian, WL1400101 Portuguese, Spanish, Finnish, Swedish, Figure 130 Norwegian, Danish, Vietnamese, Greek Operating Controls DL550-5 2-50...
  • Page 139 ) button and move cursor to a desired Maintenance Notification Enable Pop up location. Then, press SELECTION ( ) button to select Enable or Disable. Only Warning Pop-up is enabled as a default setting. FG019205 Figure 132 DL550-5 Operating Controls 2-51...

  • Page 140: Right Side Switch Panel

    Pilot Control Valve Lever Hand-free Control Panel (Electric. Joystick) (Optional) Power Socket for 12 Volt Kick-down Button Cigarette Lighter Horn Button F/R (Forward/Reverse) Selector Starter Switch Switch Parking Brake Switch F/R (Forward/Reverse) Control Switch Pilot Cutoff Switch Operating Controls DL550-5 2-52...
  • Page 141 "KD" (5, Figure 134) button is pressed, machine can travel in reverse. When machine is driven, it can change travel direction without pressing "KD" (5, Figure 134) button. Horn Button 257) Kick-down Button 256) DL550-5 Operating Controls 2-53...
  • Page 142 (7, Figure 136)): Lever will remain in this position until boom is at a preset height, then will return to neutral automatically. Reference Description Number Boom Float Bucket Dump Boom Lower Bucket Crowd Boom Raise Bucket Return To Dig Boom Height Kick-out Operating Controls DL550-5 2-54...
  • Page 143 Horn Button  • H: Horn Button Kick-down • KD: Kick-down Switch Reference Description Number Boom Float Bucket Dump WL1300333 Boom Lower Figure 138 Bucket Crowd Boom Raise Bucket Return To Dig Boom Height Kick-out FG023252 Figure 139 DL550-5 Operating Controls 2-55...
  • Page 144 A second kick-down button (Figure 142) is on end of transmission lever. NOTE: The machine is equipped with a “Left Side Electric Steering Control Unit (Optional)” on page 2-69, there is an additional kick-down button. “3. Kick-down Button” page 2-70. AHO0900L Figure 142 Operating Controls DL550-5 2-56...
  • Page 145 "I" (ON) position. Do not operate starter switch for more than 15 seconds at a time. This will prevent damage to starter. WARNING AVOID DEATH OR SERIOUS INJURY DO NOT USE STARTING FLUIDS. The starting system could cause starting fluid to explode. DL550-5 Operating Controls 2-57...
  • Page 146 CAUTION FG019169 Figure 148 AVOID INJURY When driving or parking, the pilot cutoff switch must be set to "O" (OFF) position so the operator can fully control the movement of the joystick functions. Operating Controls DL550-5 2-58...
  • Page 147 Power Mode • Fast speed loading. WL1300335 Figure 151 • Fast speed travel. • General work. Normal Mode • Optimize fuel consumption. • Light work. Economy • Minimize fuel consumption. Mode • Reduce noise. DL550-5 Operating Controls 2-59...
  • Page 148 1 - 3 is same as Auto 1 - 4. Up and down shift are made automatically between 2nd - 3rd - 4th gears forward and between 2nd - 3rd - 4th in reverse. Kick-down button must be used for shifting to 1st gear. Operating Controls DL550-5 2-60...
  • Page 149 Center LED light "ON": Windshield wiper mounted on rear windshield of operator's cabin is turned "ON". Holding the switch, center LED light "ON" and windshield washer fluid sprays onto the rear windshield while running the rear wiper. WL1300339 Figure 156 DL550-5 Operating Controls 2-61...
  • Page 150 Center LED light "ON": The fuel heater system is turned "ON". WL1300342 Center LED light "OFF": The fuel heater system is Figure 159 turned "OFF". NOTE: The starter switch must be "ON". Operating Controls DL550-5 2-62...
  • Page 151 With starter switch turned to "I" (ON) position, an emergency warning light on the front gauge will turn "ON" for about three seconds. IMPORTANT press this switch continuously. Continuously pressing switch will cause heavy battery discharge. DL550-5 Operating Controls 2-63...
  • Page 152 Figure 163 Mode Selector Button All the mode selector buttons are used to select or reset the hands-free mode. FG018098 Figure 164 Volume - Up Button Each pressing increases the volume by 1 level. FG018099 Figure 165 Operating Controls DL550-5 2-64...
  • Page 153 Press the mode button to release the hands-free mode. Check that hands-free mode light is turned "OFF". Making a call. Enter receiver's phone number in the cellular phone and press the call button or the phone button of the cellular phone. DL550-5 Operating Controls 2-65...
  • Page 154 While driving the machine, store the cellular phone at the designated area or where subject to less motion. Stop and park the machine before entering phone numbers. Do not use the cellular phone when operating machine. Operating Controls DL550-5 2-66...
  • Page 155 F/R control switch must be in FG003977 "NEUTRAL". Figure 169 If the transmission lever is actuated (moved), the gearshift functions of the F/R control switch turned "OFF/ DEACTIVATED", forward/reverse travel again controlled transmission lever. DL550-5 Operating Controls 2-67...
  • Page 156 If the transmission lever is moved out of Figure 170 "NEUTRAL" while operating the F/R control switch, the transmission lever will override the switch. The F/R control switch system will require that F/R selector switch be pressed again, with transmission lever "NEUTRAL". Operating Controls DL550-5 2-68...

  • Page 157: Left Side Electric Steering Control Unit (Optional)

    WARNING AVOID DEATH OR SERIOUS INJURY Never activate Electric Steering Selector Switch when traveling on a public road. Always use the steering wheel to drive the machine. DL550-5 Operating Controls 2-69...
  • Page 158 NOTE: Kick-down is "RELEASED" when transmission is placed in "NEUTRAL" position or the switch is pressed again. Kick-down function range: FG003977 • Automatic: 2nd, 3rd, 4th gears. Figure 174 • Manual: 2nd gear. Operating Controls DL550-5 2-70...
  • Page 159 The electric steering function cannot be used in this location. The electric steering function can be used in this location. NOTE: Use the electric steering function only in the WL1400417 work site. Figure 176 DL550-5 Operating Controls 2-71...

  • Page 160: Various Cabin Locations

    VARIOUS CABIN LOCATIONS WL1300171 Figure 177 Reference Reference Description Description Number Number Cabin Light Unified Antenna Stereo/CD Player (Optional) Speakers Heater and Air Conditioner Storage Compartments Control Panel Electrical Box Auto Grease System Switch Emergency Starter Switch (Optional) Operating Controls DL550-5 2-72...
  • Page 161 4. Auto Grease System Switch (Optional) This switch is used to switch the auto grease system. In this position, auto grease system is turned "OFF". In this position, auto grease system is turned "ON". WL1300379 Figure 181 DL550-5 Operating Controls 2-73...
  • Page 162 Keep the operation manual other documents these compartments. FG023240 Figure 184 8. Electrical Box Contains relays and electric components. It is located on left side of cabin. WL1300180 Figure 185 Operating Controls DL550-5 2-74...
  • Page 163 When the toggle switch is at this position, the engine emergency start system can be executed (ON). In abnormal condition where the normal means for engine starting fails, the toggle switch must be at this position. DL550-5 Operating Controls 2-75...

  • Page 164: Heater And Air Conditioner Operation

    Rear Nozzle Front Nozzle (Defroster) The heater and air conditioner are combined into one unit to the right side of the operator's seat. If necessary, the operator can control interior cabin temperature using the operation panel. Operating Controls DL550-5 2-76...
  • Page 165 When the system is in "AUTO" mode, specifications can be manually changed by pushing another button. If a function is manually changed, the word "AUTO" does FG000088 not appear in the LCD display, but the unchanged Figure 189 functions will remain in "AUTO" mode. DL550-5 Operating Controls 2-77...
  • Page 166 This button gives the choice to select either °C (Celsius) or °F (Fahrenheit). FG000094 Figure 192 Mode Selector Button This button is used to select which combination air outlets will be used. MODE FG000096 Figure 193 Operating Controls DL550-5 2-78...
  • Page 167 Used to direct airflow to lower portion of operator's cabin and feet. This mode is mainly used for heating. FG019230 Figure 196 Used to direct airflow to the front window and to operator's feet. FG019232 Figure 197 DL550-5 Operating Controls 2-79...
  • Page 168 Figure 200 Air Conditioner Button This button is used to turn the air conditioner "ON" or "OFF". When this function is activated, an "A/C" is displayed in the upper left corner of the LCD. FG000105 Figure 201 Operating Controls DL550-5 2-80...
  • Page 169 The blower button must be on "three bars". If operating the air conditioner or heater for a long time, operate the air inlet selector button and, when smoking, vent the air to the outside to prevent irritation to eyes. DL550-5 Operating Controls 2-81...

  • Page 170: Stereo/Cd Player (Optional)

    FM Selection USB Loading Port USB Selection Sound Mode Selector Display Mode Control CD Player (Optional) TUNE VOLUME AM/FM SOUND TRACK ST RDS REG TA TP PTY AF DIR INT RPT RDM EQ FG017017 Figure 205 Operating Controls DL550-5 2-82...

  • Page 171: Seat Adjustment W/Air Suspension (Standard)

    Pulling up left side lever (3, Figure 207) allows seat backrest to be tilted forward or backward. 4. Lumbar Control Knob Rotate lumbar control knob (4, Figure 207) to increase or decrease or decrease support to lower back. DL550-5 Operating Controls 2-83...
  • Page 172 (safety) thermostat that operates between 32° - 41°C (90° - 106°F). At 41°C (106°F), the secondary (safety) thermostat stops heating the seat. If the seat is heating up to a higher then normal temperature, have seat serviced immediately. Operating Controls DL550-5 2-84...
  • Page 173 Recommendations for Limiting Vibrations Select the right machine, equipment and attachments for a particular application. Replace any damaged seat by a DOOSAN genuine part. Keep the seat maintained and adjusted. • Adjust the seat and suspension for the weight and size of the operator.

  • Page 174: Seat Adjustment W/Air Suspension And Heater

    Lift backrest tilt adjustment lever (3, Figure 208) and allow cushion to angle forward or lean backward into desired position and release handle. 4. Lumbar Control Knob Rotate lumbar control knob (4, Figure 209) to increase or decrease support to lower back. Operating Controls DL550-5 2-86...
  • Page 175 (safety) thermostat that operates between 38° - 43°C (100°F - 109°F). At 43°C (109°F), the secondary (safety) thermostat stops heating the seat. If the seat is heating up to a higher then normal temperature, have seat serviced immediately. DL550-5 Operating Controls 2-87...

  • Page 176: Seat Belt

    Adjust belt length so it is comfortably tight against operator's pelvic region (hip area). HAOB140L Figure 210 Press button (3, Figure 211) in center of buckle (2) and pull out belt (1) to unlock. HAOB150L Figure 211 Operating Controls DL550-5 2-88...

  • Page 177: Door Side Latch

    To release doors from both sides of the cabin, pull handles (Figure 214 and Figure 215) in direction of arrows. The handles are located on both sides of the operator's seat. WL1300381 Figure 214 WL1300382 Figure 215 DL550-5 Operating Controls 2-89...

  • Page 178: Arm Rest

    FG019242 Figure 217 ARM REST Clamp (1, Figure 218) is used to allow armrest (2) to be moved to the most convenient position for operator. Unclamp and adjust the height to desired position. WL1300269 Figure 218 Operating Controls DL550-5 2-90...

  • Page 179: Fuse Box/Relay

    Figure 219 AVOID DEATH OR SERIOUS INJURY If any fuse is blown, turn "OFF" the starter switch and shut off the power supply. Repair the cause if needed and replace the fuse with a new one. DL550-5 Operating Controls 2-91...
  • Page 180 Hour Meter Air Conditioner, Heater Fuel Heater, EGR Headlight Work Light (Rear) Seat Suspension (Optional), Back up Light Seat Warmer (Optional), Speed Sensor Mirror Heater SCR Controller Work Light (Front) GPS, Stereo, Pilot Buzzer TCU, A/C Controller Operating Controls DL550-5 2-92...
  • Page 181 AVOID DEATH OR SERIOUS INJURY When changing the fusible link, replace the fusible link with the same capacity part. Otherwise, a fire could break out in the wiring harness and/or other components of the circuit. Always use original DOOSAN parts. DL550-5 Operating Controls 2-93...

  • Page 182: Wheel Chocks

    A pair of wheel chocks are supplied with the machine, and are stored on the frame. These wheel chocks must be used always when it is necessary to secure the machine for repairs or for transport. WL1400686 Figure 224 WL1400626 Figure 225 Operating Controls DL550-5 2-94...

  • Page 183: To Operate A New Wheel Loader

    New Machine Break-in Procedures All DOOSAN machines are inspected before leaving the factory. However, it is required that operator follow these steps during the initial break-in period. Failure to follow these steps can result in damage to the equipment or reduced performance.

  • Page 184: Starting And Stopping Engine

    Check for damage, wear, crack, oil leakage, play in work equipment, cylinders, linkages and hoses. • Check the frame, transmission and axles for; damage, cracks, oil leakage and loose bolts. • Check for problems in doors, handrails, steps and loose bolts. Operation DL550-5...
  • Page 185 After starting machine • Check that all operational controls and components are in proper operating condition and are functioning correctly. Stop operation and correct any problems before continuing work. DL550-5 Operation...
  • Page 186 15. Check inflation pressure of tires. 16. The level in the reductant tank. (if the engine is equipped with an Selective Catalytic Reduction System. (SCR)) IMPORTANT Running the engine without reductant will damage the Selective Catalytic Reduction (SCR) system. Operation DL550-5...
  • Page 187 Hydraulic oil temperature gauge FG018147 Figure 1 • Engine rpm (0 rpm) digital readout NOTE: If all the indicator lights do not come "ON" when the key is first turned, correct the cause of the problem before machine operation. DL550-5 Operation...
  • Page 188 Figure 2 If the machine has a battery disconnect switch: Turn "ON" the power using the battery disconnect switch. The battery disconnect switch is located in the radiator grille of the rear side of machine. WL1400329 Figure 3 Operation DL550-5...
  • Page 189 WL1300211 Figure 5 Make sure transmission neutral lock is in the "N" (NEUTRAL LOCK) position. WL1400129 Figure 6 Set pilot cutoff switch to "O" position. This will "LOCK" pilot control valve lever (joystick). FG019178 Figure 7 DL550-5 Operation...
  • Page 190 IMPORTANT The starter motor can only be cranked twice for 30 seconds at a time. After that, it must rest and cool for at least five (5) minutes before attempting to start the engine again. FG018149 Figure 11 Operation DL550-5...
  • Page 191 Allowing the engine to idle will dissipate heat. After engine has cooled, check coolant level, look for signs of leaks, clogged or dirty radiator fins (radiator core), and fan belt tension. DL550-5 Operation...
  • Page 192 Engine operating speed range. Controlled by the EMS control system. Unsuitable operating speed, but a slightly higher engine speed than normal 2,100 - 2,600 rpm maximum operating speed can occur when load is light. 2,600 - 3,000 rpm Prohibited (Too High) engine speed. Operation DL550-5 3-10...
  • Page 193 After starting engine, remove cord and store it at safe place. Don't move the machine before removing the cord. NOTE: Do not test heater before installation. This will cause the heater to fail and void the warranty. DL550-5 Operation 3-11...
  • Page 194 The removable and fixed filters are the most sensitive operational parts of the precleaner. Unless they are kept Figure 16 clean, the precleaner cannot operate properly. IMPORTANT A plugged filter can lead to excessive engine wear and can also cause loss in engine power. Operation DL550-5 3-12...

  • Page 195: Emission Control System

    Every 2 sec. the highest torque Flashing Torque is reduced to 0% FG019176 After 4 hours rapidly (low idling) within 2-10 Figure 18 Every 0.5 sec. minutes * Applies only to engines certified according to Tier 4. DL550-5 Operation 3-13...
  • Page 196 If operated for extended periods under an extremely light load, the engine may have difficulty in maintaining normal operating temperature. At an increased load, the temperature rises to the normal value. IMPORTANT An excessively high coolant temperature can damage the engine. Operation DL550-5 3-14...

  • Page 197: Stopping Engine

    Allow engine to idle for three - five (3 - 5) minutes to cool down, before stopping the engine. If not allowed to idle, heat surge may develop which will damage the engine. Park machine on firm and level ground. Move transmission lever to "NEUTRAL" position. WL1300175 Figure 19 DL550-5 Operation 3-15...
  • Page 198 Put pilot cutoff switch to "O" (LOCK) position. This will "LOCK" pilot control valve lever (joystick). Allow engine to idle for 3 - 5 minutes to cool down. FG019178 Figure 22 Rotate starter key to "O" (OFF) position and stop engine. Remove key. FG018156 Figure 23 Operation DL550-5 3-16...
  • Page 199 Check that power supply has been turned "OFF". Check the cooling system for the correct antifreeze mixture. At temperatures below 0°C (32°F), prepare for the next start by connecting the engine heater (if equipped). DL550-5 Operation 3-17...

  • Page 200: Machine Travel

    Lock out all control systems and stop engine to avoid accidental activation of controls. Unlatch articulated frame lock bar between front and rear frames before traveling. Secure lock plate to rear frame (Figure 24). FG026276 Figure 24 Operation DL550-5 3-18...
  • Page 201 (joystick) is activated. FG019178 Figure 26 Press brake pedal. WL1300215 Figure 27 Set transmission neutral lock in the "D" (DRIVE) position. WL1400129 Figure 28 DL550-5 Operation 3-19...
  • Page 202 When traveling at high-speed or on a steep hill, do not make sharp changes in direction. This could cause vehicle to tip or roll-over. WL1300346 When traveling or changing direction, always look in Figure 31 travel direction. Keep bystanders away from work area. Operation DL550-5 3-20...

  • Page 203: If Engine Stalls While Traveling

    Do not enter rivers whose riverbed is steep or has a rapid flow. IMPORTANT Avoid use of the loader in salt water. Salt water will cause rust which will shorten the life of the machine. DL550-5 Operation 3-21...

  • Page 204: Towing

    • Check towrope or tow bar for damage and make sure it has sufficient strength for work. • When necessary to descend a grade, another towing vehicle must be used in rear to provide additional braking. Operation DL550-5 3-22...
  • Page 205 Always attach wire rope onto left and right hooks and secure in position. • If engine on problem machine will not start or there is a FG019101 failure in brake system, always contact your DOOSAN Figure 32 distributor. • Never go between towing machine and towed machine during towing operation.

  • Page 206: F/R (Forward/Reverse) Travel Control System

    The transmission lever is moved out of "NEUTRAL" into "FORWARD" or "REVERSE". FG015182 Figure 35 The starter switch is turned "OFF". When the system is deactivated, the F/R selector indicator light will be turned "OFF". Operation DL550-5 3-24...

  • Page 207: Machine Shut Down

    "LOCK" transmission lever. Whenever machine is parked, "LOCK" transmission lever in "NEUTRAL" to prevent accidental machine movement. WL1400129 Figure 38 Set parking brake switch to "I" (ENGAGED) position. This will ensure that parking brake is "ENGAGED". WL1300285 Figure 39 DL550-5 Operation 3-25...
  • Page 208 Leaving machine in gear will provide no braking effect because transmission clutch 2876A is hydraulically operated. When engine is turned Figure 42 "OFF", there is no hydraulic pressure in transmission and clutch is not engaged. Operation DL550-5 3-26...

  • Page 209: Operation Of Attachment

    Top of bucket side plate indicates angle of bottom of bucket. Top of side plate is parallel with bottom of bucket. If bottom of bucket is not visible, top of side plate will be visible. FG001661 Figure 44 DL550-5 Operation 3-27...

  • Page 210: Adjustment Of Bucket Position Switch

    OFF : Return to dig is turned "OFF". Center LED light "ON": Return to dig turned "ON". Center LED light "Blinking": Press button for 1 second, Set adjusting the current bucket position. WL1300349 Figure 46 FG021591 Figure 47 Operation DL550-5 3-28...

  • Page 211: Operation Under Abnormal Conditions

    Table and Chart Section 4, in this manual, or lubrication chart on machine. (If equipped) Choose proper greases for auto grease system. Contact your DOOSAN distributor to get more information. Start engine and allow it to reach normal operating temperature before operating.
  • Page 212 Batteries self-discharge at a higher rate if left standing for long periods at high temperatures. If machine is to stand for several days, remove batteries and store in a cool place. Operation DL550-5 3-30...
  • Page 213 WARNING AVOID DEATH OR SERIOUS INJURY Wear goggles when using compressed air to prevent face or eye injury. Use care when servicing fuel system to prevent dust and sand from entering tank. DL550-5 Operation 3-31...
  • Page 214 Lubricate machine as prescribed on lubrication chart on machine or Periodic Service Table and Chart, Section 4, in this manual. Shorten lubricating intervals for parts exposed to salt water. Check operating controls to ensure proper functionality and that they return to "NEUTRAL" when released. Operation DL550-5 3-32...
  • Page 215 During electrical storms, do not enter or exit machine. • If you are off machine, keep away from machine until storm passes. • If you are in cabin, remain seated with engine off until storm passes. Do not touch controls or anything metal. DL550-5 Operation 3-33...

  • Page 216: Long Term Storage

    NOTE: When sealing with tape, be sure to extend tape approximately inch (25 mm) beyond opening to ensure a good seal. Operation DL550-5 3-34...

  • Page 217: After Storage

    It can cause blockage of system. • Change all filters. • Inspect for signs of nests. (i.e., birds, rodents, etc.) • When starting the engine after long-term storage, follow the "Hydraulic Oil Warm-up" procedures listed in this manual. DL550-5 Operation 3-35...

  • Page 218: Auto Grease System (Optional)

    AUTO GREASE SYSTEM (OPTIONAL) Overview DOOSAN Auto grease system is called "progressive system". 9, 10 1, 2 7, 8 13, 14 22 11, 12 19 15, 16 20, 21, 23 WL1400156 Figure 48 Operation DL550-5 3-36...
  • Page 219 Articulated Joint (Bottom) Bucket Pin (Middle) Rear Axle Pivot Tilt Lever (Bottom) Rear Axle Pivot Lever Pin Driveshaft Intermediate Bearing Tilt Lever (Top) Rear Axle Pivot Lift Cylinder (Right, Front) Lift Cylinder (Left, Front) Arm Foot End (Right) DL550-5 Operation 3-37...
  • Page 220 Location WL1400627 Figure 49 Reference Reference Description Description Number Number AGS Pump Master Feeder and Secondary Feeder (Front frame) Secondary Feeder (Rear Frame) Secondary Feeder (Tilt Lever) Operation DL550-5 3-38...
  • Page 221 Lubricating grease containing up to 5% MoS2 (molybdenum disulfide) as an additive can be delivered with piston pumps and progressive feeders. NLGI grade 2 grease containing solids such as graphite and copper (e.g. chisel paste) can be delivered. DL550-5 Operation 3-39...
  • Page 222 Lubricants can be tested in the company's laboratory for their suitability for pumping in centralized lubrication systems (e.g., "bleeding"). Operation DL550-5 3-40...
  • Page 223 Note that in rare cases, there may be lubricants whose properties are within permissible limit values but whose other characteristics render them unsuitable for use in centralized lubrication systems. For example, synthetic lubricants may be incompatible with elastomers. DL550-5 Operation 3-41...
  • Page 224 The conical head nipple can be twisted onto the position (Figure Figure 51 51, 2), for example to gain better access. As an alternative, the connection (Figure 51, 2) can be used to mount a lubricant return or filler coupling. Operation DL550-5 3-42...
  • Page 225 (part No. 600102-00012) (Figure 54, 3). The caps (Figure 54, 4) on the socket and filling cylinder must be removed before filling. Filling Cylinder 169-001-171 Filling Socket 169-000-174 WL1300113 Figure 54 DL550-5 Operation 3-43...
  • Page 226 Part No. 400323-00327 Figure 55 Figure 56 Cleaning When pressurized air and/or pressurized water is used for cleaning, be careful water is not to get into auto grease system. Water can cause malfunctions or damage of system. Operation DL550-5 3-44...
  • Page 227 UP or DOWN key • Display values and parameters • Set values and parameters • Switch between programming mode and display mode SET key • Confirm values • Trigger interim lubrication DK key • Delete fault notification DL550-5 Operation 3-45...
  • Page 228 Fault: Piston detector has been stopped. The control unit is currently in The values shown after this are FAULT mode.  Operation Hour Meter the number of hours, the operational sequence control unit has operated. has been stopped. Operation DL550-5 3-46...
  • Page 229 FAULT mode. No signal from the piston detector. Unlike in normal mode, the Block Mode control unit is still the monitoring sequence. A fault notification is issued if the fault remains for three pump cycles times. DL550-5 Operation 3-47...
  • Page 230 COP = CS monitoring is active during the pump cycle. (Not applied COP = OFF monitoring is switched off to DOOSAN auto grease system.) The LED light turns "ON" when a changeover signal is received. The operating voltage is present on the pump unit and control unit. The control unit is in operating status FAULT.
  • Page 231 Display pump cycle  Example: Timer operation Example: System is currently in operating status Pause, current tCO display (timer contact) not possible Display the preset value  Example: 4 min. (factory setting)  Display is in minutes Display system monitoring DL550-5 Operation 3-49...
  • Page 232 13, 14 Example: 1st part of 2nd part of total value total value Write Total value: 00033.8 h down. Maximum value: 99999.9 h Display clears Oh and Fh values are stored in EEPROM and cannot be deleted. Operation DL550-5 3-50...
  • Page 233 "pump cycle time in timer operation"  Press briefly "CONTACT" LED flashes (confirm new value) Pump cycle time 4.0 min. (factory setting)  Note the operating mode/set duration  (display in minutes) Press briefly Set new value  Example: 3 min. DL550-5 Operation 3-51...
  • Page 234 Monitoring by piston detector "CS" LED flashes Press either until Not permitted for progressive systems! Confirm new setting Press briefly New settings are written to memory, the valves are activated and the display clears Press for more than 2s Operation DL550-5 3-52...
  • Page 235 Display pump cycle time in timer operation Press briefly to confirm counter operation Change from pump cycle time to counter operation, special application Confirm new setting Press briefly New settings are written to memory and the display clears Press for more than 2s DL550-5 Operation 3-53...
  • Page 236 (confirm code) new code is set  Example: 666 NOTE: Do not enter 321. Press either until Confirm new code Press briefly New code is written to memory and the display clears Press for more than 2s Operation DL550-5 3-54...
  • Page 237 WARNING AVOID DEATH OR SERIOUS INJURY The described product is pressurized during operation. The product must therefore be depressurized before starting assembly, maintenance or repair work. DL550-5 Operation 3-55...
  • Page 238 IMPORTANT Only original spare parts from DOOSAN may be used. Arbitrary alterations to products and the use of non-original spare parts and accessories are not permitted and nullify the statutory warranty.
  • Page 239 Please contact an SKF service office. commissioning the machine/vehicle Inspection of electrical Tighten loose contacts. Clean any Semi-annual connections and contacts corroded electrical contacts with a wire firm attachment brush, then apply a small amount of and corrosion contact grease after installation DL550-5 Operation 3-57...
  • Page 240 (See “Pump Display Mode” on page 4-49.) Fault Pressure Switch: No signal from pressure switch during pump cycle.  (Not applied to DOOSAN auto grease system) Fault Low Level: The level in the reservoir has fallen below the minimum fill level.
  • Page 241  malfunction has is generated. affected the proper LED functioning light turns "ON". lubrication system.  Malfunctions must always be remedied immediately. DL550-5 Operation 3-59...
  • Page 242 Inspect electrical connections in case of malfunction notifications. • Replace defective fuses with new fuses of the same performance and characteristics. The purity of the lubricants used is the decisive factor in the service life of the pump elements. Operation DL550-5 3-60...
  • Page 243 Normal Operation Block Pause tPA Block Pause 0.1 h 6 min. 0.2 h 12 min. 0.3 h and longer 15 min. WL1300072 Figure 61 Fault notification on device  • Determine and remedy cause of fault display DL550-5 Operation 3-61...
  • Page 244 (This indicated when the outlet can be closed with a finger once the main line is removed.) • Lubricant too stiff • If necessary, adjust lubricant to work properly lowest working temperature. Operation DL550-5 3-62...
  • Page 245 20°C is 200 bar. discharges. feeder blockage or blocked lubrication point. • Valve is damaged • Replace pressure regulating valve. contaminated, so it does not close properly. DL550-5 Operation 3-63...
  • Page 246 Operation DL550-5 3-64...

  • Page 247: Inspection, Maintenance And Adjustment

    Check operational hour meter reading daily to see if necessary maintenance is scheduled to be performed. DOOSAN Genuine Replacement Parts Use DOOSAN genuine parts specified in Parts Book as replacement parts. DOOSAN Genuine Lubricants For lubrication of the machine, use DOOSAN genuine lubricants.
  • Page 248 Clean electrical components, especially starting motor and alternator, to avoid accumulation of dust. • When checking and replacing oil or filters, move the machine to a place where there is no dust and take care to prevent dust from entering system. Inspection, Maintenance and Adjustment DL550-5...
  • Page 249 For details of checks when operating engine, see “Safety Precautions” on page 4-4 and pay careful attention to safety. – Are inspection and maintenance items working properly? – Is there any leakage of fuel or oil when engine speed is raised? DL550-5 Inspection, Maintenance and Adjustment...

  • Page 250: Safety Precautions

    The dealer must also, if the warranty is to apply, complete a Delivery Report form which must be signed by both the dealer and the owner/operator when the machine is delivered by the dealer. Inspection, Maintenance and Adjustment DL550-5...
  • Page 251 Lower bucket or work tool to the ground. Put pilot cutoff switch to "O" (LOCK) position. This will "LOCK" pilot control valve lever (joystick). Allow engine to idle for 3 - 5 minutes to cool down. Figure 4 FG019178 DL550-5 Inspection, Maintenance and Adjustment...
  • Page 252 OPERATE" Warning Tag on cabin door or work lever. WARNING AVOID DEATH OR SERIOUS INJURY engine must running while performing maintenance, always have one person in cabin. Never leave cabin with engine running. EX1301177 Figure 8 Inspection, Maintenance and Adjustment DL550-5...
  • Page 253 Do not use hand grip (A, Figure 9) of cabin door as a support when entering, leaving or climbing the machine. It is not strong enough to be used as a support. It should only be used for closing the door. FG020094 Figure 11 DL550-5 Inspection, Maintenance and Adjustment...
  • Page 254 Attach a black and yellow label to the steering wheel. Connect the articulated frame lock bar. Block the wheels in a suitable way (with, for example, wheel chocks). Allow the engine and hot machine parts to cool. Inspection, Maintenance and Adjustment DL550-5...
  • Page 255 Filling Point, Hydraulic Oil Draining, Hydraulic Oil Ventilation Filters, Cabin Fan, Brake and Pilot Filter Battery Centrifugal Oil Cleaner Alternator Belt Oil Dipstick, Engine Transmission Oil Filter Oil Filter, Engine 2nd Filter DEF Breather Draining Engine Oil DL550-5 Inspection, Maintenance and Adjustment...
  • Page 256 Having too much or too little oil can cause operational problems. • If oil is not clear in color, there may be water or air getting into circuit. In such cases, contact your DOOSAN distributor. • When changing oil, always replace related filters at same time.
  • Page 257 Shorten the time period between Oil drain intervals (more frequent oil drain intervals). • Increase overall operating costs. Failures that result from use of improper fuels are not DOOSAN factory defects. Therefore the cost of repairs would not be covered by a DOOSAN warranty.
  • Page 258 DEF (AdBlue) may smell a foul odor if the temperatures of the DEF (AdBlue) is high. • DOOSAN recommends that temperature of the DEF (AdBlue) is between 4°C (39°F) to 60°C (140°F). • If the temperature rises about 60°C (140°F), the DEF (AdBlue) concentration might be high because of the evaporation.

  • Page 259: Coolant And Water For Dilution

    1 year or 2,000 hours. Therefore, it is recommended to use authorized genuine DOOSAN antifreeze solution. When using DOOSAN coolant, there is no need to use a corrosion resistor. For details, see “Engine Cooling System” on page 4-98.
  • Page 260 Before installing a radio receiver or other wireless equipment, contact your DOOSAN distributor to discuss steps necessary to prevent electromagnetic interference. • When working in saltwater areas or in or around snow, carefully clean the electrical system to prevent corrosion.
  • Page 261 • Commercially available lubricants can cause harm to the machine. Use sparingly. DOOSAN does not recommend any commercially available lubricant additive. • When starting the engine in temperatures below 0°C (32°F), be sure to use the recommended multigrade oil,...

  • Page 262: Lifting Machine

    • The installation of a two-way radio, lever steering or similar equipment must be done by a qualified person, because a faulty installation can cause interference with electronic components controlling vital machine functions. Inspection, Maintenance and Adjustment DL550-5 4-16...
  • Page 263 "OFF". Such pipes and hoses should only be disconnected by trained personnel. • When looking for leaks, use a piece of paper or wood, not your hand. Always wear eye and face protection. DL550-5 Inspection, Maintenance and Adjustment 4-17...
  • Page 264 NOTE: If a high-pressure jet is used for cleaning prevent damage to electrical connectors and insulation by covering and protecting the components. Inspection, Maintenance and Adjustment DL550-5 4-18...
  • Page 265 In addition to the health hazard, welding over a painted surface will also be of an inferior quality and strength. Never weld directly on a painted surface. DL550-5 Inspection, Maintenance and Adjustment 4-19...
  • Page 266 (a solution or suspension of calcium hydroxide, i.e. slaked lime in water). After the work has been completed, the gloves must be washed in limewater and then discarded. Inspection, Maintenance and Adjustment DL550-5 4-20...
  • Page 267 Hydrofluoric Acid Burn Jelly or something similar. Seek medical advice immediately. Symptoms may not appear until several hours after initial contact. Discard gloves, rags etc. which are suspected of having touched burned rubber that contains fluorides. DL550-5 Inspection, Maintenance and Adjustment 4-21...

  • Page 268: Preventive Maintenance

    Keep this number on file, in case the machine is stolen. Figure 17 WL1300041 Machine Type Doosan Infracore Co., Ltd. 7-11, Hwasu-dong, Dong-gu, Model Name Incheon, Korea Product MODEL Identification...
  • Page 269 The following engine data is mandatory when communicating with a SCANIA Authorized Repair Location- or when sourcing service parts: Reference Description Number WL1300184 Figure 20 DOOSAN’S "OWN" Engine Plate SCANIA’S Standard Plate DL550-5 Inspection, Maintenance and Adjustment 4-23...
  • Page 270 TABLE OF RECOMMENDED LUBRICANTS IMPORTANT It is highly recommend to use DOOSAN Genuine Products, or products which meet the specifications below. Using other products can damage equipment. NOTE: Refer to Maintenance Intervals Table for application points. (If equipped) See “Lubricants” on page 3-41 for more information of lubricants.
  • Page 271 Engine oil must meet API CI-4/ACEA E5, E7 or API CJ-4/ACEA E9. Hydraulic oil change interval is 2,000 hours, only when DOOSAN Genuine Oil is used. If other brands of oil is used, guaranteed change interval is 1,000 hours. Note that mixing ratio is for reference purpose only, and is not an absolute standard.
  • Page 272 Alugard G48 by BASF Others meeting or exceeding ASTM D3306 NOTE: Mixing ratio is for reference purpose only and is not an absolute standard. IMPORTANT Do not mix oils from different manufacturers. DOOSAN does endorse specific brands does recommend that owners select quality oils whose...

  • Page 273: Transmission Oil

    Lubricant Classes for Service Fills (1) "03A, 03B, 03C, 03D, 03E, 03G, 03H, 03K only at Ambient Temperatures Below - 10°C: 03F" (1) The current list can be requested from any DOOSAN, ZF after-sales service center or accessed on the Internet under www.zf.com...

  • Page 274: Braking

    Scuffing resistance FZG A/8.3/90°C fail load stage Lubricant Classes for Service Fills (1) ZF-Powerfluid Plus, 05F (1) The current list can be requested from any DOOSAN, ZF after-sales service center or accessed on the Internet under www.zf.com Oil Change Intervals...

  • Page 275: Fluid Capacities

    Base Number) must be at least 12 (ASTM 2896). Check with your oil manufacturer/supplier that oil meets these requirements. operation extremely ambient temperature, consult your nearest Doosan distributor on how to avoid starting difficulties. FLUID CAPACITIES Component Capacity Minimum 34liters (9.0 U.S.

  • Page 276: Lubrication And Service Chart

    Between 10 and 15 strokes with a normal handheld grease gun is required to grease one of the bearings for the lifting arms. Wipe off grease fittings and grease gun before greasing, so dirt and sand is not introduced through the grease fittings. Inspection, Maintenance and Adjustment DL550-5 4-30...
  • Page 277 Engine Oil Filter Gear Oil (Axle) Hydraulic Oil Brake Filter Hydraulic Oil Return Filter Level check Coolant Hydraulic Oil Tank Breather Air Cleaner Filter Fuel Cap Filter DEF (AdBlue) DEF (AdBlue) Filter DEF (AdBlue) Breather Filter DL550-5 Inspection, Maintenance and Adjustment 4-31...
  • Page 278 Lubrication and Service Chart 15, 25 2000h 1500h 1000h 500h 250h 16, 24 250h 500h 1000h 1500h 2000h WL1400776 Figure 21 Inspection, Maintenance and Adjustment DL550-5 4-32...
  • Page 279 For additional service items see list of “Maintenance Intervals” on page 4-34. NOTE: This capacity may include the tank (reservoir), lines, pipes and components and attachment. Observe all sight gauge and level indicators to ensure that systems and compartment are refilled to the proper level. DL550-5 Inspection, Maintenance and Adjustment 4-33...

  • Page 280: Maintenance Intervals

    Check Air Conditioner Belt Tension 4-58 Grease Driveshafts 4-58 Change Transmission Oil and Filter (After First 250 Hours) 4-59 Fuel Water Trap 4-59 Auto Grease System (If Equipped) 4-59 Clean Oil Bath Precleaner (Optional) 4-60 Inspection, Maintenance and Adjustment DL550-5 4-34...
  • Page 281 Change Hydraulic Oil and Clean Oil Suction Strainer 4-91 Bleed Brakes 4-93 Check Brake Accumulator 4-94 12,000 Hour / 6 Year Service Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) 4-95 DL550-5 Inspection, Maintenance and Adjustment 4-35...

  • Page 282: Hour / Daily Service

    Remove dipstick and check oil level mark. Oil level must be between "LOW" and "FULL" marks. Add through fill cap (2, Figure 22). NOTE: See “Table of Recommended Lubricants” on page 4-24 for information on the correct type of oil. Inspection, Maintenance and Adjustment DL550-5 4-36...
  • Page 283 Refer to “Table of Recommended Lubricants” on page 4-24, of this manual for recommended oil for the operating conditions. Stop engine when done. COLD HAAD4540 Figure 25 Transmission Sight Gauge DL550-5 Inspection, Maintenance and Adjustment 4-37...
  • Page 284 (4) slides over the top of the rod. Be certain that this spring does not fall into the tank during reassembly. If filter assembly was removed, insert assembly into the tank and make sure it is securely in place. FG002188 Figure 28 Inspection, Maintenance and Adjustment DL550-5 4-38...
  • Page 285 Securely tighten cap after fueling. NOTE: If breather holes in cap are clogged, a vacuum may form in the tank preventing proper fuel flow to engine. Keep holes in fuel cap clean. FG001690 Figure 31 DL550-5 Inspection, Maintenance and Adjustment 4-39...
  • Page 286 If gauge pointer moves into red zone (1, Figure 34), SCR gauge symbol (2, Figure 34) will turn "ON", and be displayed on screen. Stop operation and immediately and add DEF (AdBlue). WL1400777 Figure 34 Inspection, Maintenance and Adjustment DL550-5 4-40...
  • Page 287 Check fluid level in windshield washer tank, below the platform. Open fill cap and add fluid. NOTE: Use a washer liquid that is rated for all seasons. This will prevent freezing during cold weather operation. FG020158 Figure 36 DL550-5 Inspection, Maintenance and Adjustment 4-41...
  • Page 288 Do not allow replaceable bucket teeth to wear down to the point that bucket adapter is exposed. (Figure 37) NOTE: These instructions are only for DOOSAN OEM buckets. If you are using other manufacturers' FG001694 buckets, refer to their specific instructions.
  • Page 289 Block tires. Check the engine intake hose and hose clamps for damage and tightness. NOTE: If damaged, wrinkled or loose, replace and tighten or contact your DOOSAN distributor. IMPORTANT Severe engine damage will result from running machine with unfiltered air. WL1300198...
  • Page 290 Camera (If equipped) is Working Properly. Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear Inflate tires to proper operating pressure for working conditions. See “Tires” on page 4-112. Inspection, Maintenance and Adjustment DL550-5 4-44...
  • Page 291 With engine at rated speed, operate all the controls. Follow cold weather hydraulic system warm-up procedures. Note any slow operations or unusual movements. Determine the cause and repair all problems before operating. DL550-5 Inspection, Maintenance and Adjustment 4-45...

  • Page 292: Hour / Weekly Service

    50 hours. If bucket is being used in water, grease fittings immediately after machine is removed from water. Figure 42 FG018927 Bucket hinge pins, 2 locations (Figure 43). WL1300199 Figure 43 Inspection, Maintenance and Adjustment DL550-5 4-46...
  • Page 293 Figure 46. FG019099 Figure 45 Pivot Cover Rear Pivot Front Pivot WL1400630 Figure 46 Grease Steering Cylinder Rod and Head Ends Steering cylinder rods, 2 locations, one on each side of machine. FG001707 Figure 47 DL550-5 Inspection, Maintenance and Adjustment 4-47...
  • Page 294 Steering Cylinder (Left) Head Ends WL1400687 Figure 48 Grease Upper and Lower Center Pins Center pins, upper (Figure 49) and lower (Figure 50). Two locations on right side of machine. FG001709 Figure 49 FG001710 Figure 50 Inspection, Maintenance and Adjustment DL550-5 4-48...
  • Page 295 You can swing the fan guard out for easier FG021974 cleaning of the fan blades and radiator. Figure 51 WARNING AVOID DEATH OR SERIOUS INJURY Before cleaning, stop cooling fan by stopping engine to prevent death or serious injury from fan rotation. DL550-5 Inspection, Maintenance and Adjustment 4-49...
  • Page 296 Figure 52 WARNING AVOID DEATH OR SERIOUS INJURY All service and inspection of the air-conditioning system must be performed with the starter switch in the "O" (OFF) position. Inspection, Maintenance and Adjustment DL550-5 4-50...

  • Page 297: Hour / Monthly Service

    Start the engine. Raise the work equipment so it is about 400 mm above the ground. Move the machine to a flat and level area. Apply the service brake. (Figure 53) WL1400677 Figure 53 DL550-5 Inspection, Maintenance and Adjustment 4-51...
  • Page 298 Figure 57 Reduce the engine speed to low idle. Move the 1. Brake Pedal transmission lever to the neutral position. Engage the 2. Accelerator Pedal parking brake. Lower the work equipment to the ground. Inspection, Maintenance and Adjustment DL550-5 4-52...
  • Page 299 Check for adequate traction. Drive the wheel loader up the incline with the heavy end of the machine facing uphill. (Figure 58) WL1400681 Figure 58 Apply the service brake. (Figure 59) WL1400677 Figure 59 DL550-5 Inspection, Maintenance and Adjustment 4-53...
  • Page 300 Lower the work equipment to the ground. 11. Stop engine. Remove key. If the machine moved during the test, contact your dealer for a brake inspection. Make any necessary repairs before the machine is returned to operation. Inspection, Maintenance and Adjustment DL550-5 4-54...
  • Page 301 Loosen drain valve from bottom of Figure 63 tank (Figure 63). Allow all water and sediment to drain out. Tighten drain valve. NOTE: Dispose drained fluids according applicable environmental laws and regulations. DL550-5 Inspection, Maintenance and Adjustment 4-55...
  • Page 302 250 hours. If bucket is being used in water, grease fittings immediately after machine is removed from water. FG027696 Figure 64 Arm-Lever connecting pin, 1 location (Figure 65). FG001696 Figure 65 Bucket cylinder rod end, 1 location (Figure 66). FG024552 Figure 66 Inspection, Maintenance and Adjustment DL550-5 4-56...
  • Page 303 Lift cylinder heads (left, right), 2 locations (Figure 69). WL1300208 Figure 69 Loader arm foot ends, 2 locations on each side of machine. Greased from two remote grease points (Figure 70). WL1300209 Figure 70 DL550-5 Inspection, Maintenance and Adjustment 4-57...
  • Page 304 WL1400689 Figure 72 Grease Driveshafts Grease fitting for center bearing, 1 location. Use remote grease fitting mounted on frame (3, Figure 73). Reference Remote Grease Fittings Driveshaft Center Bearing WL1400688 Figure 73 Inspection, Maintenance and Adjustment DL550-5 4-58...
  • Page 305 Auto Grease System (If Equipped) Grease in the reservoir of the central lubrication pump is consumed in approximately one or two months. Check and fill the reservoir of the central lubrication pump if necessary. DL550-5 Inspection, Maintenance and Adjustment 4-59...
  • Page 306 FG018321 Figure 77 Wash filter if needed. • If element is plugged with dirt, lint or chaff (even partially), wash it thoroughly with solvent. FG018322 Figure 78 Inspection, Maintenance and Adjustment DL550-5 4-60...
  • Page 307 Inspect the lower parts of body assembly and center tube for damage. Replace broken, cracked, or missing parts. FG018324 Figure 80 Reassemble the filter assembly with serviced oil cups. Add oil. FG018325 Figure 81 DL550-5 Inspection, Maintenance and Adjustment 4-61...

  • Page 308: Hour / 3 Month Service

    Remove and clean rubber evacuator valve (1, Figure 83) from bottom of air cleaner housing cover (2, Figure 83). Inspect seal lips for wear or damage. Replace valve if necessary. NOTE: Install evacuator valve with lips parallel to the cover. Inspection, Maintenance and Adjustment DL550-5 4-62...
  • Page 309 After filter service, be sure to install cover with arrows pointing "UP". NOTE: If after cleaning the outer filter, the air cleaner FG000412 clogged indicator remains "ON", replace the Figure 85 outer and inner filters. Do not clean inner filter. DL550-5 Inspection, Maintenance and Adjustment 4-63...
  • Page 310 Use a nonflammable, nontoxic solvent to clean out cover (4, Figure 87). Insert a new filter (3, Figure 87) into cover (4). Install a new O-ring (2). Screw cover (4, Figure 87) onto filter head (1). WL1400140 Figure 87 Inspection, Maintenance and Adjustment DL550-5 4-64...
  • Page 311 In certain engines the oil is pumped out using a bilge pump. Clean the magnet on the plug. FG019023 Install oil plug. Figure 88 Fill with oil from 34 - 45 liters (9.0 - 11.9 U.S. gal.). Check the level on the oil dipstick. DL550-5 Inspection, Maintenance and Adjustment 4-65...
  • Page 312 Remove old filter from the cover. NOTE: Remember that oil splashes. Be sure to wear gloves and protective goggles. Assemble new filter and tighten filter cover to 25 N.m. FG019025 Figure 90 Inspection, Maintenance and Adjustment DL550-5 4-66...
  • Page 313 Never strike on the rotor directly as this can damage the bearings. FG019029 Remove strainer from the rotor cover. If the strainer is stuck, insert a screwdriver between the rotor cover and Figure 94 strainer and carefully pry them apart. DL550-5 Inspection, Maintenance and Adjustment 4-67...
  • Page 314 13. Refit the rotor and screw it by hand to make sure it rotates easily. FG019032 Figure 97 14. Renew the O-ring on the centrifugal oil cleaner housing 15 N . m cover. Tighten the locknut. FG019053 Figure 98 Inspection, Maintenance and Adjustment DL550-5 4-68...
  • Page 315 Check and Adjust Valve Clearance NOTE: Checking and adjusting valve clearances must be done after first 500 hours of operation. Contact your DOOSAN distributor. Valve clearances must be adjusted when the engine is cold, or at least 30 minutes after running. WARNING AVOID DEATH OR SERIOUS INJURY Secure the starting device when working on the engine.
  • Page 316 1,500 hours thereafter. See page 4-89. Change Air Conditioner Outer Filter NOTE: Clean air-conditioning filter every 50 hours and replace with a new one every 500 hours of service. See “Clean Air Conditioner Outer Filter” on page 4- Inspection, Maintenance and Adjustment DL550-5 4-70...
  • Page 317 Figure 103. Hydraulic oil must be monitored during intervals of 500hours by the oil sampling kit below. Allowable contamination: Within ISO/17/14 by ISO4406 WL1400651 Figure 103 (within NAS 8 by NAS 1638). DL550-5 Inspection, Maintenance and Adjustment 4-71...

  • Page 318: Hour / 6 Month Service

    Start engine. After engine has run for a couple of minutes, stop engine and look for signs of leaks. If the engine does not start, fuel system may need priming. Prime hand pump on the engine fuel filter. Inspection, Maintenance and Adjustment DL550-5 4-72...
  • Page 319 105) on its bottom before its replacement. IMPORTANT A large amount of fuel may spurt abruptly. Make sure to put a container under the filter to collect drained fuel. (Total draining amount: approximately 2 L) Figure 106 DL550-5 Inspection, Maintenance and Adjustment 4-73...
  • Page 320 11. When all fuel is completely drained, remove element gently and remove fuel left on the bottom completely. (Use Doosan Suction Tool (850329-00295) to suck the remaining fuel and foreign substances in the secondary filter housing).
  • Page 321 Normally, about 3 liters (0.79 U.S. gal.) of fuel must be drained before no more air bubbles come through the hose. Close the bleeder valve (4, Figure 105), remove hose and tighten the hand pump (3, Figure 105) handle. DL550-5 Inspection, Maintenance and Adjustment 4-75...
  • Page 322 Change DEF (AdBlue) Breather Filter Open the DEF tank steel cover. WL1300169 Figure 111 Replace the DEF breather filter. Screw on the DEF tank cover. WL1300170 Figure 112 Inspection, Maintenance and Adjustment DL550-5 4-76...
  • Page 323 Replace the filter and check the O-ring and insulation. Wipe clean with lukewarm water before you reinstall the filter cover to remove any crystals. Screw on the filter cover again. Tightening torque 80 N.m (59 ft lb). FG019062 Figure 115 DL550-5 Inspection, Maintenance and Adjustment 4-77...
  • Page 324 15. Thread filter onto filter head. Tighten filter 1/2 turn after filter gasket contacts filter head. Filter must be torqued to 1.6 - 2.1 kg•m (11.5 - 15 ft lb). FG019056 Figure 117 Inspection, Maintenance and Adjustment DL550-5 4-78...
  • Page 325 If the machine is being operated in a dusty environment, cleaning and replacement must be performed more frequently. Check and Adjust Engine Contact your DOOSAN distributor or engine dealer for checking and adjusting the following items: • Engine compression pressure.
  • Page 326 11. Clean inside of the tank and suction strainer. 12. Install the inspection cover with a new gasket. Tighten the bolts. Do not overtighten. 13. Close drain valve. 14. Fill fuel tank. 15. Check for any leaks at cover and plug. Inspection, Maintenance and Adjustment DL550-5 4-80...
  • Page 327 Refrigerant Almost clear. Normal Any bubbles disappear if the engine speed is increased to 1,500 rpm. High No bubbles are seen. Contact your DOOSAN distributor inspection recharging refrigerant. A flow of bubbles is visible. DL550-5 Inspection, Maintenance and Adjustment 4-81...
  • Page 328 (2, Figure 121). Figure 121 10. Change a filter cartridge (3, Figure 121) and assemble the breather cap by tightening bolt. NOTE: Used filter should always be disposed of according to applicable environmental laws and regulations. Inspection, Maintenance and Adjustment DL550-5 4-82...
  • Page 329 122). Set spring (4, Figure 122) into place on element filter (7, Figure 122). Set cover (2, Figure 122) into place over element filter (7, Figure 122). Install bolts (1, Figure 122) through cover (2, Figure 122) and tighten them. WL1400654 Figure 122 DL550-5 Inspection, Maintenance and Adjustment 4-83...
  • Page 330 FG015684 Figure 124 After disassembly, carefully lay it as shown in Figure 125. FG015685 Figure 125 After disassembly as shown in Figure 125, disengage rubber as shown on (Figure 126). FG015686 Figure 126 Inspection, Maintenance and Adjustment DL550-5 4-84...
  • Page 331 After disassembly as shown on (Figure 126), you may now exchange it to a new filter as shown in (Figure 127). FG015687 Figure 127 After exchanging to a new filter, you may now assemble back in reverse order. FG015688 Figure 128 DL550-5 Inspection, Maintenance and Adjustment 4-85...
  • Page 332 If the drive belt is starting to become worn, it may be able to be re-adjusted. FG019066 Figure 131 NOTE: If the belt is worn down to the cord, the drive belt must be replaced. FG019067 Figure 132 Inspection, Maintenance and Adjustment DL550-5 4-86...

  • Page 333: Hour / 9 Month Service

    NOTE: See “Fluid Capacities” on page 4-29 for capacity. NOTE: Dispose drained fluids according applicable environmental laws and regulations.  NOTE: Plug Size: M24 x 1.5 Tightening Torque: 7.1 kg•m (51 ft lb) DL550-5 Inspection, Maintenance and Adjustment 4-87...
  • Page 334 Plug Size (1, Figure 135): M36 x 1.5 Tightening Torque: 13.2 kg•m (95 ft lb) Plug Size (2, Figure 135): M36 x 1.5 Tightening Torque: 13.2 kg•m (95 ft lb) FG019084 Figure 135 Rear Axle Inspection, Maintenance and Adjustment DL550-5 4-88...

  • Page 335: Hour / Yearly Service

    The best way to maintain proper braking and steering operation and to maintain maximum performance is to replace hoses regularly. If any brake or steering hoses become damaged, replace them immediately despite time interval since their last replacement. DL550-5 Inspection, Maintenance and Adjustment 4-89...
  • Page 336 Run engine at low idle until coolant temperature gauge reaches the "BLUE ZONE". Run engine for another ten minutes. Allow engine to cool. Drain flushing fluid and fill system with water. Run engine again to allow water to completely circulate. Inspection, Maintenance and Adjustment DL550-5 4-90...
  • Page 337 (Figure 140). Then operate controls to lower boom. (Figure 141). This will drain oil out of boom and bucket cylinders. Replace full flow hydraulic filters as described under “Change Hydraulic Full Flow Filter” on page 4-83. FG014462 Figure 140 DL550-5 Inspection, Maintenance and Adjustment 4-91...
  • Page 338 Check tank sight gauge. (See Figure 27 on page 4-38). Oil level must be between upper limit and lower limit on sight gauge. Remove cover and add oil if necessary. FG014464 Figure 143 FG023245 Figure 144 Inspection, Maintenance and Adjustment DL550-5 4-92...
  • Page 339 Open bleeder screw using 14 mm wrench. Close bleeder screw. Release brake pedal. Repeat steps 4 thru 7, until air bubbles are not seen in the HLB3018L brake line. Figure 146 Perform bleeding procedure on other three locations. DL550-5 Inspection, Maintenance and Adjustment 4-93...
  • Page 340 10. Count the number of times you can depress the right-hand brake pedal before the brake warning light comes on. 11. If the number counted is less than five, there is a problem with the accumulator. Contact your DOOSAN distributor. Inspection, Maintenance and Adjustment DL550-5...

  • Page 341: Hour / 6 Year Service

    Hose In-service Lifetime Limit (European Standard ISO 8331 and EN982 CEN) European regulations state that in-service life of any hydraulic hose may not exceed six (6) years. DOOSAN recommends the following: • Hoses at the customer premises cannot be stored more than two (2) years before being discarded or installed on a machine.

  • Page 342: Standard Bolt Torque Chart

    22 mm x std. 54.90 77.86 93.08 22 mm x 1.5 61.00 86.02 105.00 24 mm x std. 71.00 100.00 120.00 24 mm x 2.0 78.00 109.95 130.00 27 mm x 2.0 115.06 160.00 1157 195.00 1410 Inspection, Maintenance and Adjustment DL550-5 4-96...

  • Page 343: Electrical System

    Colors may vary from one battery manufacturer to another. Always refer to instructions on battery. The batteries should always be replaced in pairs. Using an old battery with a new one will shorten the life span of the new battery. DL550-5 Inspection, Maintenance and Adjustment 4-97...

  • Page 344: Engine Cooling System

    Do not use more than 50% antifreeze in the mixture unless additional antifreeze protection is required. Never use more than 60% antifreeze under any condition. Inspection, Maintenance and Adjustment DL550-5 4-98...
  • Page 345 Types of Antifreeze Ethylene Glycol - DOOSAN Genuine Antifreeze Solution  (for all seasons) Ethylene glycol is a very hazardous material to human beings, animals and environment. Drain of coolant must be disposed of by an authorized waste material treatment service provider.
  • Page 346 Antifreeze Concentration Tables Ethylene Glycol - DOOSAN Genuine Antifreeze Solution (for all seasons) (2,000 Hour/1 Year) Ambient Temperature Cooling Water Antifreeze -20°C (-4°F) -25°C (-13°F) -30°C (-22°F) -40°C (-40°F) NOTE: The concentration shall be kept at 50% and in worst case at 30% minimum for the least corrosion resistance.

  • Page 347: Handling Of Accumulator

    • Do not weld on accumulators, or try attaching anything to them. • When replacing an accumulator, contact a DOOSAN distributor to ensure that gas is properly released. • Wear safety goggles and protective gloves when working on an accumulator. Hydraulic oil under pressure can penetrate the skin and cause serious injuries.
  • Page 348 Stop engine. Allow enough time that steering cylinder pressure is decreasing by own internal leakage. FG021937 Remove accumulators by unscrewing them very slowly. Figure 152 NOTE: This also applies to the hoses related with accumulators. Inspection, Maintenance and Adjustment DL550-5 4-102...

  • Page 349: Hydraulic Pressure Checks

    Turn adjusting screw counterclockwise to lower relief pressure. Tighten locknut after adjustment. WL1400658 Figure 154 If the pressure doesn't change, the maximum current value of pump control must be changed by DMS. DL550-5 Inspection, Maintenance and Adjustment 4-103...
  • Page 350 (100 ~ 160 bar (1,450 ~ 2,321 psi)). WL1400660 Figure 156 Steering Pump Pressure Attach gauge to port (Figure 157). Pressure cutoff setting for steering pump: 280 ±10 kg/cm (275 ±10 bar (3,989 ±145 psi)). WL1400661 Figure 157 Inspection, Maintenance and Adjustment DL550-5 4-104...
  • Page 351 Adjust screw on main pump pressure regulator (Figure 159). Loosen locknut and turn screw clockwise to raise pressure cutoff setting. Turn screw counterclockwise to lower pressure cutoff setting. Tighten locknut after pressure has been adjusted. WL1400653 Figure 159 DL550-5 Inspection, Maintenance and Adjustment 4-105...
  • Page 352 Fan Pump Pressure (30 ±5 bar (435 ±73 psi)) (150 ±10 bar (2,176 ±145 psi)) Control Current 530 ±50 mA 230 ±25 mA Control Current (mA) Fan Pump (kg/cm Fan In (kg/cm WL1400662 Figure 160 Inspection, Maintenance and Adjustment DL550-5 4-106...
  • Page 353 Maximum fan motor pressure: 127 ±10 kg/cm (125 ±10 bar (1,813 ±145 psi)) (The fan speed is approximately 1,200 ±50 rpm at this pressure) If fan speed requires adjusting, adjust control current by DMS. DL550-5 Inspection, Maintenance and Adjustment 4-107...
  • Page 354 If desired, cooling system can be completely drained. If system is drained, place a sign in operator's cabin to warn operator there is no coolant in engine. Inspection, Maintenance and Adjustment DL550-5 4-108...

  • Page 355: Parking Brake Adjustment

    The machine does not have any brake function and must be secured, by proper means, against moving. Before putting the machine into operation again, the brake has to be properly FG023268 adjusted according to specifications. Figure 164 DL550-5 Inspection, Maintenance and Adjustment 4-109...
  • Page 356 (5). Mount the screw cap (6, Figure 162) and manually tighten as far as possible. Actuate the brake valve several times and check the braking efficiency of the parking brake on a slope. Inspection, Maintenance and Adjustment DL550-5 4-110...

  • Page 357: Severe Conditions Maintenance

    Use a gauge to check antifreeze to be sure that it will provide protection for coldest temperature expected. Use a hydrometer to check condition of batteries. In extremely cold weather, remove batteries at night and store them in a warm area. DL550-5 Inspection, Maintenance and Adjustment 4-111...

  • Page 358: Tires

    After having changed a tire or if the wheel has been removed and installed for any other reason, the wheel bolts must be checked for tightness after eight hours of operation. Tighten wheel nuts to 85 kg•m (615 ft lb). Inspection, Maintenance and Adjustment DL550-5 4-112...
  • Page 359 Stay away until tire and rim cools down. If the following problems are found in tires, the tires must be Tread replaced with new tires. For the replacement contact DOOSAN distributor or a tire Side walls manufacturer's local dealer. Breakers •...
  • Page 360 If L5 tires are used for loading and carrying operations, special attention must be paid to the transporting distances. Radial tires are preferred for loading and carrying operations, as the build-up of heat is less with this type of tire. Inspection, Maintenance and Adjustment DL550-5 4-114...

  • Page 361: Transmission Recalibration

    TCU is a separate component, the AEB-cycle must be started only after the installation of transmission and TCU in the machine, thus insuring the correct programing between the transmission and the electronics. Call the nearest DOOSAN distributor to ask about correct AEB setting. DL550-5...
  • Page 362 Inspection, Maintenance and Adjustment DL550-5 4-116...
  • Page 363 If required, add blocking under the ramp to provide additional support. The ramp angle must be less than a 15° angle. Ramps FG028819 steeper than this can cause traction or stability problems Figure 1 when loading or unloading. DL550-5 Transportation...
  • Page 364 Set pilot cutoff switch to "O" (LOCKED) position. (Figure FG028821 Figure 3 Stop engine by turning key to "O" (OFF) position (Figure 10. Remove key from starter switch. FG018156 Figure 4 11. Install articulated frame lock. (Figure 5). FG028839 Figure 5 Transportation DL550-5...
  • Page 365 NOTE: To avoid air being forced down the exhaust pipe when transporting, it must be covered with suitable protection (2, Figure 7) (not plastic). This will prevent turbocharger damage. FG028822 Figure 8 DL550-5 Transportation...
  • Page 366 Set articulated frame lock to "UNLOCK" position. Turn battery disconnect switch to "ON" direction. Start the engine. Set pilot cutoff switch to "I" (UNLOCKED) position. Set parking brake switch to "O" (DISENGAGED) position. 10. Drive machine slowly for unloading. FG028835 Figure 10 Transportation DL550-5...
  • Page 367 Place protective material between the cables and the machine to prevent damage. The maximum angle between the cables must not exceed 45°. 10. While machine is lifted, keep the machine horizontal and lift the machine slowly to keep it balanced. DL550-5 Transportation...
  • Page 368 Transportation DL550-5...
  • Page 369 If the cause of the operating problem cannot be determined, contact your DOOSAN distributor. Never perform an adjustment or the disassembly of the hydraulic, electrical or electronic components without first contacting a DOOSAN distributor.
  • Page 370 Water or dirt in fuel system. fuel filter and new fuel. Air in fuel system. Purge air from system. Engine stop control failed. Contact your DOOSAN dealer. Blown fuse. Replace fuse. Engine starts, runs only at low Engine oil viscosity incorrect.
  • Page 371 Replace fuel filter. Water or dirt in fuel system. Clean system and add new fuel. Clogged or dirty fuel injectors. Contact your DOOSAN distributor. Engine has poor power. Plugged air intake system. Clean system and replace filter. Clogged or dirty fuel injectors.
  • Page 372 Clean. Scale or mineral build up inside Flush or professionally clean. radiator. Defective alarm switch (gauge is in Contact your DOOSAN distributor. green). Low water pump flow. Thermostat stuck or missing. Engine does not start when the Fuel filter clogged.

  • Page 373: Hydraulic System

    HYDRAULIC SYSTEM Problem Cause Remedy None of the controls function (loud Hydraulic pump failed. Contact your DOOSAN dealer. noise from pumps). Low hydraulic oil level. Add hydraulic oil as required. Suction line plugged or damaged. Clean or replace as required.
  • Page 374 Clean and repair valve. Check valve internal leakage. Repair or replace valve. Damaged cylinder or pump. Repair or replace pump or cylinder. Cylinder internal leakage. Repair or replace cylinder. Damaged cylinder rod. Replace rod. Pilot valve failure. Replace pilot valve. Troubleshooting DL550-5...
  • Page 375 Damage to control spring damping Replace priority valve. inside priority valve. Steering wheel shakes. Bearing chattering in axle end Replace bearing. differential. Tire pressure not equal in left side Equalize tire pressure. and right side tires. DL550-5 Troubleshooting...

  • Page 376: Travel System

    Low transmission fluid, or low Add fluid or change fluid. quality fluid. Worn transmission parts. Replace parts. Broken gears or bearings. Replace parts. Transmission fails to operate. Damaged transmission clutch Replace disks. disks. Damaged wires in transmission Repair wires. control wire harness. Troubleshooting DL550-5...
  • Page 377 Lubricate universal joints. Worn slip joint spline. Replace slip joint. Noisy Front or Rear Axle. Worn or broken gears. Replace gears. Low oil level, poor quality oil. Add oil, change oil. Worn bearings. Replace bearings. Worn shaft spline. Replace spline. DL550-5 Troubleshooting...
  • Page 378 Troubleshooting DL550-5 6-10...

  • Page 379: Specification

    (Out Tire Edge) Rated Operating Load 10,815 kg (23,843 lb) Maximum Breakout Force (Bucket) 247 kN (55,528 lb.f) Arm Raise Time 6.4 ±0.5 Sec. Bucket Dump Time 1.4 ±0.3 Sec. Arm Lowering Time 4.2 ±0.4 Sec. Maximum Gradeability 30° (58%) DL550-5 Specification...

  • Page 380: Working Range And Dimensions

    WORKING RANGE AND DIMENSIONS Figure 1, illustrates exterior machine dimensions and working range of machine when it is equipped with a standard bucket. I" H" B(D) WL1300517 Figure 1 Specification DL550-5...
  • Page 381 Maximum Tilt Angle at Fully 67 ° Raised Turning Radius 6,550 mm (Outer Tire Edge) (21' 6") 6,525 mm (Counterweight Edge) (21' 5") 7,565 mm 7,515 mm 7,565 mm 7,515 mm (Bucket Edge) (24' 10") (24' 8") (24' 10") (24' 8") DL550-5 Specification...

  • Page 382: Working Capacities

    Static Tipping Load @ Max. Reach - Straight 24,490 (53,991) *** Do not lift the load which exceeds legal "Rated Static Tipping Load @ Max. Reach - Full Turn 21,625 (47,675) Operating Load" when you Rated Operating Load 10,815 (23,843) work with the specific tools. Specification DL550-5...

  • Page 383: Approximate Weight Of Workload Materials

    1,746 kg/m Clay, DAMP, natural bed (2,943 lb/yd 1,506 kg/m Cement, portland, DRY granular (2,583 lb/yd 1,362 kg/m Cement, portland, DRY clinkers (2,295 lb/yd 1,522 kg/m Dolomite, crushed (2,565 lb/yd 1,202 kg/m Earth, loamy, DRY, loose (2,025 lb/yd DL550-5 Specification...
  • Page 384 929 kg/m Salt (1,566 lb/yd 529 kg/m Snow, light density (891 lb/yd 1,522 kg/m Sand, DRY, loose (2,565 lb/yd 1,922 kg/m Sand, WET, packed (3,240 lb/yd 1,362 kg/m Shale, broken (2,295 lb/yd 529 kg/m Sulfur, broken (891 lb/yd Specification DL550-5...

  • Page 385: Index

    Check Drained Oil and Used Filter 3-51 Pump Programming 3-12 Check Oil Bath Precleaner (Optional) 3-58 Troubleshooting 1-26 Check Tire Pressure and Condition 3-10 Automatic Warming Up Operation Checks After Inspection and Maintenance Works Avoid Mixing Lubricants Axle DL550-5 Index...
  • Page 386 Equipment Lowering with Engine Stopped 2-89 Door Side Latch 2-38 Escape (ESC) Buttons DOOSAN Genuine Lubricants 1-63 Exhaust Ventilation DOOSAN Genuine Replacement Parts 2-22 Down Arrow Button 4-58 Driveshaft - Grease 1-55 2-68 Drop-off or Edge F/R (Forward/Reverse) Control Switch...
  • Page 387 Handling Oil, Fuel, DEF (AdBlue) Coolant 2-21 Work Light Indicator Light 2-65 Hands-free Microphone Inspection Before Starting Engine 2-15 Hazard Warning Light Switch Inspection, Maintenance and Adjustment 2-59 Headlight Switch Intended Use Heater and Air Conditioner 2-81 Additional Operating Instructions DL550-5 Index...
  • Page 388 1-51 Preservation/Storing Machine Multifunction 1-15 Pressurized Fluids Gauge and Graphic Information Display Switch Pressurized Gas and Fluid 2-22 Preventing Risk of Injuries or Death From Boom and 2-18 Multifunction Display 1-35 Bucket 2-27 Multifunction Gauge 4-22 Preventive Maintenance Index DL550-5...
  • Page 389 3-15 Engine Stop 4-31 for Lubrication and Service Chart 3-25 Machine 2-32 Indicator Signal Words 2-31 SCR System Warning Light 1-64 Silica Dust Information 2-30 Water In Fuel Warning 1-64 Sound 2-74 Speakers Specification 4-112 Tires 2-18 Speedometer DL550-5 Index...
  • Page 390 Working In Contaminated Environment 2-38 1-58 User Menu - Access and Escape Buttons Working In Water 3-21 Working in Water 1-47 Working on Machine 4-19 Working on Painted Surfaces 4-69 Valve Clearance Working Range and Dimensions 2-42 Vehicle Setup Index DL550-5...
  • Page 392 2905 Shawnee Industrial Way Suite 100 Suwanee, GA 30024...

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