Doosan DL550-5 Manuals

Manuals and User Guides for Doosan DL550-5. We have 3 Doosan DL550-5 manuals available for free PDF download: Operation & Maintenance Manual, Quick Start Manual, Shop Manual

Doosan DL550-5 Operation & Maintenance Manual (393 pages)

Wheel Loader, Serial Number 10001 and Up

Brand: Doosan | Category: Compact Loader | Size: 34 MB

Table of Contents
5
Foreword

9
- Safety Messages
  10
- AEM Safety Manual (North America Only)
  11
- Intended Use
  12
- Product Information
  12
- Product Identification
  13
- Federal Emission Control Systems
  14
- Catalytic Converter
  19
Safety

23
- Safety Decals
  24
  - Information and Location for Safety Decals
    26
  - Safety Warnings
    27
  - Transmission Oil Level
    32
  - Pressure Check
    34
  - Safe Operation
    36
- General
  36
- Operation
  47
  - Before Engine Starting
    47
  - Work Site
    47
  - Check Tire Pressure and Condition
    48
  - Mounting/Dismounting
    48
  - Cleaning
    49
  - Operator Station
    49
  - Seat Belt
    50
  - Visibility Information
    51
  - Boost Starting or Charging Engine Batteries
    52
  - Work Site Rules
    52
  - Starting Engine
    53
  - Traveling
    53
  - Lifting and Digging
    55
  - Digging Beneath Overhangs
    55
  - Digging Beneath Wheel Loader
    55
  - Operation on Slopes
    56
  - Attachment
    57
  - Equipment Lowering with Engine Stopped
    57
  - Preventing Risk of Injuries or Death from Boom and Bucket
    57
  - Engine Stop
    59
  - Parking Machine
    59
- Maintenance
  60
  - Warning Tag
    62
  - Disassembling Precautions
    63
  - Use of Lighting
    64
  - Burn Prevention
    65
  - Rubber that Contains Fluorides
    66
  - Rubber and Plastics
    67
  - Check List after Fire
    67
  - Welding Repairs
    68
  - Working on Machine
    69
  - Preparation for Electrical Welding on Body Structure
    69
  - Lock Inspection Covers
    70
  - Accumulator
    70
  - Compressed Air
    70
  - Supports and Blocking for Work Equipment
    71
  - High-Pressure Lines, Tubes and Hoses
    71
  - Battery Hazard Prevention
    72
  - Preservation/Storing Machine
    73
  - Check after Long-Term Parking
    74
- Transportation
  75
- Loading and Unloading
  75
- Environment and Circumstances
  77
  - Work Site Areas Requiring Extra Caution
    77
  - Deep Digging
    77
  - Drop-Off or Edge
    77
  - Poor Visibility
    78
  - Loose or Soft Ground
    78
  - High-Voltage Cables
    79
  - Underground Operation
    79
  - Working in Water
    80
  - Operation in Extreme Conditions
    81
  - Operation in Extreme Cold
    81
  - Operation in Extreme Heat
    82
  - Operation in Dusty and Sandy Areas
    83
  - Operation in Rainy or Humid Conditions
    84
  - Operation in Saltwater Areas
    84
  - Operation at High Altitudes
    84
  - Operation During Electrical Storms
    84
  - Exhaust Ventilation
    85
  - Asbestos Information
    85
  - Silica Dust Information
    86
  - Disposal of Hazardous Materials
    86
  - Sound Level Information
    86
  - Vibration
    87
Operating Controls

89
- Component Locations
  90
- Operator's Area
  93
- Steering Console and Pedals
  94
  - Horn Button (Two Places)
    95
  - Combination Switch
    96
  - Accelerator Pedal
    97
  - Steering Wheel Adjustment Lever
    97
  - Brake Pedal (Right and Left Pedals)
    98
  - Steering Wheel
    98
  - Kick-Down Button (Two Places)
    99
  - Transmission Lever
    99
  - Front Instrument Panel
    100
  - Hour Meter
    100
  - Front Keypad
    101
  - Transmission Cutoff Switch
    102
  - Load Isolation System (LIS) Switch
    102
  - Transmission Torque Converter Lockup Switch
    102
  - Hazard Warning Light Switch
    103
  - Electric Steering High/Low Switch
    104
  - Auto Grease System Switch
    104
  - Differential Lock Button (Manual)
    104
  - Warning and Indicator Lights
    105
- Front Instrument Panel
  105
  - Password Activated
    106
  - Speedometer
    106
  - Multifunction Gauge and Graphic Information Display
    106
  - Left Turn and Hazard Warning Light
    107
  - Parking Brake Indicator Light
    107
  - Right Turn and Hazard Warning Light
    107
  - Brake Fluid Pressure Warning Light
    108
  - Auto Grease Fault Indicator Light
    108
  - Air Cleaner Clogged Warning Light
    108
  - High Beam Indicator Light
    108
  - Emergency Steering Indicator Light
    109
  - Mirror Heater Indicator Light
    109
  - Work Light Indicator Light
    109
  - Information Display Switches
    110
- Multifunction Gauge and Graphic Information Display
  110
  - Fuel Gauge
    113
  - Engine Coolant Temperature Gauge
    113
  - Transmission Oil Temperature Gauge
    113
  - DEF (Adblue) Level Gauge
    114
  - Transmission Actual Gear
    114
  - Transmission Select Gear
    114
  - Engine Speed
    114
  - ECO Bar
    115
  - Multifunction Gauge
    115
  - Initializing Trip Meter
    116
  - Switching Display to Battery Voltage
    116
  - Display Warning Symbols
    116
  - Charge Warning Symbol
    117
  - Engine Oil Pressure Warning Symbol
    117
  - Transmission Warning Symbol
    117
  - Engine Warning Symbol
    117
  - Water in Fuel Warning Symbol
    118
  - DEF (Adblue) Low Level Warning Symbol - EPA
    118
  - SCR Failure Warning Symbol
    119
  - Indicator Symbols
    120
  - Digital Clock
    123
  - Warning Pop-Up
    124
  - User Menu
    126
  - Escape (ESC) Buttons
    126
  - Vehicle State
    127
  - Monitoring
    127
  - Filter/Oil Information
    127
  - Reset Method/Replacement Period Change Method
    128
  - Symbol Description
    129
  - Vehicle Configuration
    130
  - Vehicle Information
    130
  - Total Fuel Used
    130
  - Reverse Fan Auto Period Setting
    131
  - Active LIS Vehicle Speed Setting
    131
  - Auto Shut off Time Setting
    132
  - Auto Idle Enable/Disable State
    132
  - GP Configuration
    133
  - Password Setting
    133
  - Screen Brightness Setting
    134
  - Default Screen Setting
    135
  - Time Setting
    136
  - Service Phone Number Setting
    137
  - Unit Setting
    138
  - Language Setting
    138
  - Notification Setting
    139
- Right Side Switch Panel
  140
  - FNR Lever (Standard)
    141
  - Finger Tip Lever
    142
  - Pilot Control Valve Lever (Electric Lever)
    144
  - Starter Switch
    145
  - Parking Brake Switch
    146
  - Pilot Cutoff Switch
    146
  - Headlight Switch
    147
  - Stand Keypad
    147
  - Power Mode Switch
    147
  - Optimized Engine/Work Mode
    148
  - Transmission Shift Switch
    148
  - Front Work Light Switch
    149
  - Rear Work Light Switch
    149
  - Rear Wiper Switch
    149
  - Cooling Fan Reverse Rotation Switch
    150
  - Mirror Heating Switch
    150
  - Fuel Heater Switch
    150
  - Rotating Beacon Light Switch
    151
  - Emergency Steering Test Switch and Automatic Test
    151
  - Hands-Free Control Panel
    152
  - Call Button
    152
  - Mode Selector Button
    152
  - Volume - up Button
    152
  - How to Use the Hands-Free System
    153
  - Mode Confirm Light
    153
  - Power Socket for 12 Volt
    155
  - Cigarette Lighter
    155
  - F/R (Forward/Reverse) Selector Switch
    155
  - F/R (Forward/Reverse) Control Switch
    156
- Left Side Electric Steering Control Unit (Optional)
  157
  - Electric Steering Selector Switch
    158
  - 3Rd FNR Control Switch
    158
  - Kick-Down Button
    158
  - Electric Steering Joystick
    159
  - Armrest Cutoff Switch
    159
- Various Cabin Locations
  160
  - Cabin Light
    161
  - Storage Compartments
    162
  - Electrical Box
    162
  - Emergency Starter Switch
    163
- Heater and Air Conditioner Operation
  164
  - Location of Controls and Vents (Heater and Air Conditioner)
    164
  - Automatic Temperature Control Button
    165
  - Temperature Control Button
    166
  - Temperature Unit Selector Button
    166
  - Air Inlet Selector Button
    168
  - Fan Speed Selector Buttons
    168
  - Air Conditioner Button
    168
  - Memory Function
    169
  - Additional Operating Instructions
    169
  - Defroster Button
    169
  - LCD Display
    169
- Stereo/CD Player (Optional)
  170
- Seat Adjustment W/Air Suspension (Standard)
  171
- Seat Adjustment W/Air Suspension and Heater
  174
  - Seat Height and Firmness/Adjustment Knob
    174
  - Seat Belt Locking and Unlocking
    176
- Door Side Latch
  177
- Arm Rest
  178
- Fuse Box/Relay
  179
  - Fuse Identification
    180
  - Relays
    181
  - Circuit Breaker
    181
  - Fusible Link
    181
- Wheel Chocks
  182
- To Operate a New Wheel Loader
  183
  - Monitoring System
    183
  - New Machine Break-In Procedures
    183
Operation

183
- Inspection before Starting Engine
  184
- Starting and Stopping Engine
  184
  - Engine Start
    188
  - After Start Limit Logic
    192
  - Automatic Warming up Operation
    192
  - Engine Speed Range
    192
  - Plug Heater
    193
  - Check Oil Bath Precleaner
    194
- Emission Control System
  195
  - Reaction to Faults in SCR System (Only EPA)
    195
  - Coolant Temperature
    196
  - Charging Indicator Light
    197
  - Engine Oil Pressure
    197
  - Stopping Engine
    197
  - Checks and Maintenance after Stopping Engine
    199
- Machine Travel
  200
- If Engine Stalls While Traveling
  203
- Working in Water
  203
- Towing
  204
- F/R (Forward/Reverse) Travel Control System
  206
- Machine Shut down
  207
- Arm Angle Sensor Switch
  209
- Bucket Angle Indicator
  209
- Operation of Attachment
  209
- Adjustment of Bucket Position Switch
  210
- Bucket Angle Sensor Switch
  210
- Operation under Abnormal Conditions
  211
- Long Term Storage
  216
- After Storage
  217
- Auto Grease System (Optional)
  218
  - Location
    220
  - Lubricants
    221
  - Lubricant Filling
    224
  - Lubricant Hazards
    224
  - Filler Coupling
    225
  - Filling Cylinder
    225
  - Pump Display and Control Elements of Control Screen
    227
  - Three-Digit LED Display
    228
  - LED Display
    230
  - Pump Display Mode
    231
  - Change Lubrication Interval Times
    233
  - Pump Programming
    233
  - Configure System Monitoring
    234
  - Change Operating Modes
    235
  - Change Access Code
    236
  - Display Ranges
    237
  - Programming Ranges
    237
  - Display Faults
    240
  - Troubleshooting
    240
  - Fault Types
    241
  - Maintenance and Repair
    242
  - Recording Fault Times
    242
  - Block Operation
    243
  - Duration of Block Pause
    243
  - No Signal from Piston Detector During Pump Cycle
    243
  - Malfunctions on Pump Units
    244
Inspection, Maintenance and Adjustment

247
- Maintenance Information
  247
  - Welding Instructions
    248
  - Hydraulic Hose Installation
    249
  - Checks after Inspection and Maintenance Works
    249
  - Safety Precautions
    250
- Machine Setup Position for Maintenance
  251
- Maintenance Handling Access
  253
  - Entering/Leaving/Climbing on Machine
    253
  - Service Position
    254
  - Service Points
    255
- Handling Oil, Fuel, DEF (Adblue) Coolant
  256
  - DEF (Adblue)
    258
  - Non-Permitted Container Materials for Storing DEF (Adblue)
    258
  - Allowable DEF (Adblue) Storage Days
    258
  - Coolant and Water for Dilution
    259
  - Grease
    259
- Electrical System Maintenance
  260
- Filters
  260
- Recommend Fuel, Coolant, and Lubricant
  261
- Preventive Maintenance
  268
  - Product Identification Number (PIN) Location
    268
  - Component Serial Numbers
    269
  - Engine Identification
    269
  - Engine Data Plate
    269
- Table of Recommended Lubricants
  270
  - Recommended Grease for Auto Grease System
    271
  - Recommended DOOSAN Genuine Grease for Auto Grease System
    271
- Transmission Oil
  273
  - Oil Grade of Transmission
    273
  - Oil Change Intervals
    273
  - Load Class
    273
- Axle Oils
  274
- Oil Grade ZF-Powerfluid
  274
- Fluid Capacities
  275
- Engine Oil Drain Intervals by Duty Cycle (Hours)
  275
- Lubrication and Service Chart
  276
  - Greasing Bearings
    276
  - Symbols for Lubrication and Service Chart
    277
- Maintenance Intervals
  280
- 10 Hour / Daily Service
  282
- Grease Front Attachment Pins
  282
- Check Engine Oil Level
  282
- Check Transmission Oil Level
  283
- Check Hydraulic System Oil Level
  284
- Check for Leaks in Hydraulic System
  285
- Fill Fuel Tank
  285
- Check for Leaks in Fuel System
  286
- Drain Fuel Condensation
  286
- Fill DEF (Adblue) Tank
  286
- Check Coolant Level
  287
- Check Level of Windshield Washer Liquid
  287
- Inspect Bucket Teeth and Side Cutters for Signs of Wear
  288
- Inspect Cooling Fan Blade
  288
- Check Engine Air Intake Precleaner
  288
- Check Air Intake System
  289
- Inspect Structure for Cracks and Faulty Welds
  289
- Inspect Seat Belt for Proper Operation
  289
- Inspect Mirrors for Damage and Adjust and Clean as Required
  289
- Check Operation of All Switches
  290
- Check Operation of All Exterior Lights, Horn and Control Console Indicator and Monitor Lights
  290
- Start Engine, Check Starting Ability, and Observe Exhaust Color at Start-Up and at Normal Operating Temperature. Listen for any Abnormal Sounds
  290
- Check that Back up Alarm and Rear Camera (if Equipped) Is Working Properly
  290
- Inspect All Tires for Correct Tire Pressure and Signs of Damage or Abnormal Wear
  290
- Check Operation of All Controls and Linkages
  291
- 50 Hour / Weekly Service
  292
- Perform All Daily Service Checks
  292
- Grease Front Attachment Pins
  292
- Grease Steering Cylinder Rod and Head Ends
  293
- Grease Upper and Lower Center Pins
  294
- Change Engine Oil and Filter (after First 50 Hours)
  295
- Change Hydraulic Full Flow Filter (after First 50 Hours)
  295
- Clean Exterior of Radiator, Oil Cooler and Air Conditioner Condenser
  295
- Check Air Conditioner and Alternator Belt Tension (after First 50 Hours)
  295
- Clean Air Conditioner Outer Filter
  296
- Perform All Daily and 50 Hour Service Checks
  297
- Braking - Test
  297
- 250 Hour / Monthly Service
  297
- Parking Brake Test
  299
- Drain Water from Hydraulic Oil Tank
  301
- Grease Front Attachment Pins
  302
- Check Air Conditioner Belt Tension
  304
- Grease Driveshafts
  304
- Change Transmission Oil and Filter (after First 250 Hours)
  305
- Fuel Water Trap
  305
- Auto Grease System (if Equipped)
  305
- Clean Oil Bath Precleaner (Optional)
  306
- Clean Outer Air Cleaner Filter
  308
- 500 Hour / 3 Month Service
  308
  - Change Hydraulic System Brake and Pilot Filter
    310
  - Change Engine Oil
    311
  - Change Engine Oil Filter
    312
  - Clean Centrifugal Oil Cleaner
    313
  - Check and Adjust Valve Clearance
    315
  - Clean Air Conditioner Inner Filter
    316
  - Check Hydraulic Oil Contamination
    317
  - Change Water Separator
    318
- 1,000 Hour / 6 Month Service
  318
  - Change Fuel Filter
    319
  - Bleeding Fuel System
    321
  - Change DEF (Adblue) Breather Filter
    322
  - Change DEF (Adblue) Filter
    323
  - Drain and Change Transmission Oil and Filter
    324
  - Change Air Conditioner Inner Filter
    325
  - Check and Adjust Engine
    325
  - Clean Fuel Tank and Strainer
    326
  - Check Air Conditioner Refrigerant
    327
  - Change Air Breather Filter
    328
  - Change Hydraulic Full Flow Filter
    329
  - Change Fuel Cap Filter
    330
  - Check Drive Belt
    332
  - Change Axle Differential and Planetaries Oil
    333
- 1,500 Hour / 9 Month Service
  333
  - Change Outer Air Cleaner Filter
    335
  - Change Inner Air Cleaner Filter
    335
  - Change Pipes and Hoses
    335
- 2,000 Hour / Yearly Service
  335
  - Change Radiator Coolant
    336
  - Change Hydraulic Oil and Clean Oil Suction Strainer
    337
  - Bleed Brakes
    339
  - Check Brake Accumulator
    340
  - Hose In-Service Lifetime Limit
    341
- 12,000 Hour / 6 Year Service
  341
- Standard Bolt Torque Chart
  342
- Check Battery Condition
  343
- Electrical System
  343
- Engine Cooling System
  344
  - Types of Antifreeze
    345
  - Antifreeze Concentration Tables
    346
  - Table of Standards for Allowed Tap Water
    346
- Handling of Accumulator
  347
  - Pilot Accumulator
    347
  - Brake Accumulators
    348
  - LIS Accumulator
    348
  - Steering Accumulator
    348
- Hydraulic Pressure Checks
  349
  - Steering Pump Load Sensing Pressure
    349
  - Pilot Supply Pressure
    349
  - Main Pump Pressure
    350
  - Brake Charging Pressure
    350
  - Steering Pump Pressure
    350
  - Transmission Clutch Pressure
    351
  - Main Pump Load Sensing Pressure
    351
  - Fan Motor Pressure and Fan Speed
    352
  - Checking Maximum Fan Speed, Checking
    353
- Long Term Storage
  354
- Parking Brake Adjustment
  355
  - Emergency Release of Parking Brake
    355
  - Adjustment Procedure for Parking Brake
    356
- Severe Conditions Maintenance
  357
  - Inflating Tires
    358
  - Wheel Nut, Tightening Check
    358
  - Wheel Nut Torque
    359
  - Check Tire for Damage
    359
  - Recommended Air Pressure
    360
- Transmission Recalibration
  361
- Transporting Machine
  363
Transportation

363
- Unloading
  366
- Lifting Machine
  367
  - Braking Troubleshooting
    369
  - Electrical System Troubleshooting
    370
  - Engine Troubleshooting
    370
  - Hydraulic System Troubleshooting
    373
  - Steering Troubleshooting
    375
  - Travel System Troubleshooting
    376
- General Specifications
  379
- Working Range and Dimensions
  380
- Bucket Capacity
  382
- Working Capacities
  382
- Approximate Weight of Workload Materials
  383
- Material Weight
  383
Index

385

Doosan DL550-5 Quick Start Manual (60 pages)

Brand: Doosan | Category: Front End Loaders | Size: 1 MB

Doosan DL550-5 Shop Manual (14 pages)

Wheel Loader

Brand: Doosan | Category: Compact Loader | Size: 1 MB

Doosan Categories

Air Compressor Excavators Engine Forklifts Compact Loader

More Doosan Manuals

Doosan DL550-5 Manuals

Doosan DL550-5 Operation & Maintenance Manual (393 pages)

Table of Contents

Foreword

Safety

Operating Controls

Operation

Inspection, Maintenance and Adjustment

Transportation

Index

Doosan DL550-5 Quick Start Manual (60 pages)

Table of Contents

Doosan DL550-5 Shop Manual (14 pages)

Table of Contents

Related Products

Doosan Categories