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Summary of Contents for Doosan DL550
- Page 1 Shop Manual DL550 Wheel Loader Serial Number 10001 and Up DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United 950106-00920E States and various other countries around the world. December 2012 Copyright DOOSAN 2012 Original Instructions...
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- Page 3 Table of Contents Safety Wheel Loader Safety ................SP002667 Specifications Specification for DL550................. SP002812 General Maintenance General Maintenance Instructions ............SP002454 Standard Torques ................. SP002404 Engine Engine....................SP002813 Drivetrain Transmission and Torque Converter (ZF 4WG-310) ......SP002814 Axle ZF - Multitrac (MT - L 3115 II / 3125 II)......... SP002657 Transmission Error Codes (ZF) ............
- Page 4 Main Control Valve ................SP002441 3rd Control Valve (Option) ..............SP002442 Load Isolation System ................SP002443 Cooling System..................SP002934 Pilot System..................SP002445 Hydraulic Schematic DL550 ..............SP002815 Electrical System Air Conditioner ..................SP000172 Electrical System .................. SP002816 Electrical Schematic DL550..............SP002817...
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- Page 7 SP002667 WHEEL LOADER SAFETYSP002667 Wheel Loader Safety Edition 1 Wheel Loader Safety SP002667 Page 1 Find manuals at https://best-manuals.com...
- Page 8 MEMO Wheel Loader Safety SP002667 Page 2 Find manuals at https://best-manuals.com...
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Page 9: Table Of Contents
Table of Contents Wheel Loader Safety Safety Instructions ..........5 Applicable Models ..........5 Safety Messages ..........6 Safety Decals ............7 General..............8 Transportation ............ 18 Operation ............20 Maintenance ............38 Environment and Circumstances......53 Wheel Loader Safety SP002667 Page 3 Find manuals at https://best-manuals.com... - Page 10 MEMO Wheel Loader Safety SP002667 Page 4 Find manuals at https://best-manuals.com...
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Page 11: Safety Instructions
The contents of this section apply to the following models and serial number ranges. MODEL SERIAL NUMBER RANGE DL250A 10001 and Up DL300A 10001 and Up DL420A 10001 and Up DL550 10001 and Up Wheel Loader Safety SP002667 Page 5... -
Page 12: Safety Messages
SAFETY MESSAGES Safety messages and safety decals included in this manual and on the machine provide instructions how to operate, service and maintain the machine. Safety messages and safety decals indicate potential hazards and describe safety precautions required to avoid hazards. Operator and maintenance personnel should read and understand these safety messages and decals before beginning operation or maintenance. -
Page 13: Safety Decals
Other Signal Words In addition to safety signal words, the following signal words are used to indicate proper and effective use of machine. IMPORTANT This signal word identifies procedures which must be followed to avoid damage to machine. NOTE: The word "NOTE" identifies information for effective use. -
Page 14: 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 15 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 16 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 2 To prevent personnel from being struck by flying objects, keep personnel out of work area.
- Page 17 Crushing and Cutting Keep objects away from moving fan blades. Fan blades can throw and cut objects. Do not use a wire rope that is kinked or frayed, or a wire rope with any loss of diameter. Wear leather gloves when handling a wire rope.
- Page 18 Hot Coolant and Oils - Burn Prevention Do not touch any part of an operating engine. Immediately after operations are stopped, coolant, engine oil, and hydraulic oil are at their highest temperatures. The radiator and hydraulic tank are still under pressure. Always wait for temperature to cool down.
- Page 19 Maintenance The machine and some attachments have components that reach high temperatures under normal operating conditions. The primary source of high temperatures are the engine and exhaust system. If damaged or incorrectly maintained, the electrical system can be a source of arcs or sparks. Flammable debris (leaves, straw, etc.) must be removed regularly.
- Page 20 Hydraulic System Check hydraulic tubes, hoses and fittings for damage, wear or for leaks. Hydraulic lines and hoses must be properly routed and have adequate support and secure clamps. Leaks can cause fires. Never use a flame or bare skin to check for leaks. Tighten or replace any parts that show leakage.
- Page 21 Never Use Ether Starting Aids 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.
- Page 22 Never touch injector terminal or inside of engine controller. NOTE:If it is necessary to touch injector terminal or inside engine controller, contact your DOOSAN distributor. Wheel Loader Safety SP002667 Page 16...
- Page 23 • 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 rollover and falling objects, and result in death or serious injury.
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Page 24: Transportation
Manual for information on partial disassembly. Refer to Operation and Maintenance Manyal for information on loading, unloading and towing. The machine can be disassembled into parts for transporting. Contact your DOOSAN distributor assistance with disassembly. Loading and Unloading To prevent machine tipping or rollover when loading or unloading machine, always do the following: •... - Page 25 Transporting Machine When transporting machine on a trailer or truck, do the following: • The weight, transportation height, and overall length of machine may change depending on work equipment attached to it. Always check the machine dimensions and work equipment's dimensions before transporting.
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Page 26: Operation
OPERATION Always make sure that the machine is properly maintained. Before Engine Starting Machine Condition Every day before starting engine for first time, perform the following checks and repair machine before operating, as necessary. If these checks are not properly done death or serious injury could result. -
Page 27: Maintenance
Know appropriate work site hand signals and personnel that are authorized to give hand signals. Follow hand signals from only one person. If you need to operate on a street, protect pedestrians and cars by designating a person for work site traffic duty or by erecting fences and posting "No Entry"... - Page 28 Cleaning Remove all straw, wood chips, leaves, grass, paper and other flammable debris accumulated in engine compartment, mufflers and around battery. Remove any dirt from window glass, mirrors, handrails, and steps. Do not leave tools or spare parts in operator's cabin. Vibration of machine during operation can cause tools or spare parts to fall and damage or break control levers or switches.
- Page 29 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 30 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. Wheel Loader Safety SP002667...
- Page 31 Work Site Rules • If visibility cannot be sufficiently assured, use a flagman. The operator should pay careful attention to signals and follow instructions from flagman. • Signals should only be given by one flagman. • When working in dark places, turn "ON" work lights and front lights on the machine.
- Page 32 Starting Engine Only operate the machine from the operator's seat with your seat belt fastened. Only operate controls while engine is running. Check for proper operation of all controls and all protective devices while you operate the machine slowly in an open area. •...
- Page 33 Traveling When traveling with the machine, always keep lights on; make Travel Position sure that you are in compliance with all federal, state and local laws and regulations concerning warning flags and signs. If engine stops while machine is traveling and the machine is not equipped with an emergency steering system, it will be impossible to operate the steering system and control machine movement.
- Page 34 Be sure to observe these precautions even if a back up alarm or mirrors are installed. • Check that back up alarm works properly and that mirrors are clean, not damaged and properly adjusted. • Always latch door and windows of operator's cabin in position (open or closed).
- Page 35 Lifting and Digging The operator is responsible for any load carried when traveling on public roads and while working with the machine. • Keep loads secure so they do not fall off while operating. • Do not exceed maximum load for the machine. Machine operation will be affected when center of gravity changes, caused by extended loads and different attachments.
- Page 36 Operation on Slopes Dig evenly around work site whenever possible, trying to gradually level any existing slope. If it is not possible to level area or avoid working on a slope, it is recommended that you reduce size and cycling rate of workload. On sloping surfaces, use caution when positioning the machine before starting a work cycle.
- Page 37 Towing When necessary to tow another vehicle, towrope must be tied to towing pin on counterweight at rear of vehicle. NOTE: The machine must be used for towing only in an emergency. WARNING AVOID DEATH OR SERIOUS INJURY Do not tow machine at a speed over 10 km/h (6 MPH) and do not tow machine farther than 10 km (6 mi).
- Page 38 • If engine on problem machine will not start or there is FG019101 a failure in brake system, always contact your Figure 23 DOOSAN distributor before towing. • Never go between towing machine and towed machine during towing operation. •...
- Page 39 Equipment Lowering with Engine Stopped Before lowering any equipment with the engine stopped, clear the area around the equipment of all personnel and bystanders. The procedure to use will vary with the type of equipment to be lowered. Keep in mind most systems use a high-pressure fluid or air to raise or lower equipment.
- Page 40 When repairing or inspecting machine, with front structure raised in air, firmly support front structure. When installing supporting structure, check that it is rated and approved to support the weight of the structure. High-pressure loads between lift arm structure and support can cause support to slip, causing boom to collapse, leading to death or serious injury.
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