Doosan DL550-5 Manual

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

Copyright Doosan 2011Operation and Maintenance Manual
Operation & Maintenance Manual
DL550-5 WHEEL LOADER
Serial Number 10001 and Up
950106-01245NA-1
July 2014
Copyright DOOSAN 2014
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

Table of Contents
I
DL550-5
Table of Contents
Foreword ....................................................................................0-1
Safety Messages ............................................................................... 0-2
AEM Safety Manual (North America Only) ........................................ 0-3
Product Information............................................................................ 0-4
Product Identification ......................................................................... 0-5
Federal Emission Control Systems.................................................... 0-6
Safety..........................................................................................1-1
Safety Decals..................................................................................... 1-2
General ............................................................................................ 1-14
Operation ......................................................................................... 1-25
Maintenance .................................................................................... 1-38
Transportation.................................................................................. 1-53
Environment and Circumstances ..................................................... 1-55
Operating Controls....................................................................2-1
Component Locations ........................................................................ 2-2
Operator's Area.................................................................................. 2-5
Steering Console and Pedals ............................................................ 2-6
Front Instrument Panel .................................................................... 2-17
Multifunction Gauge and Graphic Information Display..................... 2-22
Right Side Switch Panel................................................................... 2-52
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

DL550-5Table of Contents
II
Seat Belt .......................................................................................... 2-88
Door Side Latch ............................................................................... 2-89
Arm Rest .......................................................................................... 2-90
Fuse Box/Relay................................................................................ 2-91
Wheel Chocks.................................................................................. 2-94
Operation....................................................................................3-1
To Operate a New Wheel Loader ...................................................... 3-1
Starting and Stopping Engine ............................................................ 3-2
Emission Control System................................................................. 3-13
Machine Travel ................................................................................ 3-18
If Engine Stalls While Traveling ....................................................... 3-21
Working in Water ............................................................................. 3-21
Towing ............................................................................................. 3-22
F/R (Forward/Reverse) Travel Control System................................ 3-24
Machine Shut Down......................................................................... 3-25
Operation of Attachment .................................................................. 3-27
Bucket Angle Indicator ..................................................................... 3-27
Adjustment of Bucket Position Switch.............................................. 3-28
Operation Under Abnormal Conditions ............................................ 3-29
Long Term Storage .......................................................................... 3-34
Auto Grease System (Optional) ....................................................... 3-36
Inspection, Maintenance and Adjustment...............................4-1
Maintenance Information ................................................................... 4-1
Machine Setup Position for Maintenance .......................................... 4-5
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
III
DL550-5
Fluid Capacities ............................................................................... 4-29
Lubrication and Service Chart.......................................................... 4-30
Maintenance Intervals...................................................................... 4-34
10 Hour / Daily Service .................................................................... 4-36
50 Hour / Weekly Service ................................................................ 4-46
250 Hour / Monthly Service.............................................................. 4-51
500 Hour / 3 Month Service ............................................................. 4-62
1,000 Hour / 6 Month Service .......................................................... 4-72
1,500 Hour / 9 Month Service .......................................................... 4-87
2,000 Hour / Yearly Service ............................................................. 4-89
12,000 Hour / 6 Year Service........................................................... 4-95
Standard Bolt Torque Chart ............................................................. 4-96
Electrical System ............................................................................. 4-97
Engine Cooling System.................................................................... 4-98
Handling of Accumulator................................................................ 4-101
Hydraulic Pressure Checks............................................................ 4-103
Long Term Storage ........................................................................ 4-108
Parking Brake Adjustment ............................................................. 4-109
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

DL550-5Table of Contents
IV
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

Foreword
0-1
DL550-5
1Foreword
This Operation & Maintenance Manual was written to give owner
or operator instructions on safe operation and maintenance of
DOOSAN equipment. READ AND UNDERSTAND THIS
OPERATION AND MAINTENANCE MANUAL BEFORE
OPERATING YOUR DOOSAN EQUIPMENT. Keep this manual
in the cabin so it is always available. 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.
Any modification made without written authorization or approval
from DOOSAN can create a safety hazard.
Always replace parts with genuine DOOSAN parts or DOOSAN
authorized replacement parts.

DL550-5Foreword
0-2
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.
Signal Words
The signal words "DANGER", "WARNING", "CAUTION" are
used throughout safety messages and safety decals in this
manual or on the machine. They indicate an existence of, and
the relative seriousness of, a hazard. All three indicate that a
safety risk is involved. Observe the precautions indicated
whenever a Safety Alert Symbol is present, no matter which
signal word appears next to it.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions.
This is a Safety Alert Symbol. Wherever it appears in this
manual or on safety decals on the machine, you must be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
DANGER
DANGER - This signal word is used on safety messages and
safety labels and indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING - This signal word is used on safety messages and
safety labels and indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION - This signal word is used on safety messages
and safety labels and indicates a potentially hazardous
situation which, if not avoided, could result in minor or
moderate injury.