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.

Foreword
0-3
DL550-5
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
NOTE: The word "NOTE" identifies information for effective
use.
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.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.
Figure 1

DL550-5Foreword
0-4
PRODUCT INFORMATION
Intended Use
The machine is intended to be used under normal conditions for
applications described in this manual. If it is used for other
purposes, or in potentially hazardous environments, special
precautions must be followed and the machine must be
equipped for such use. Examples include, but are not limited:
falling object guards, work lights, etc. Do not engage in
prohibited uses as described in this manual. Contact your
DOOSAN distributor for further information.
Machine Capacity
Do not exceed machine capacity by modifying machine or using
unapproved attachments.
Exceeding machine capacity can adversely affect machine
performance characteristics such as: stability, system
certifications such as brakes and steering, the 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. This
includes proper inspection and maintenance of the machine's
emission control system. This could include machine and engine
components, such as an EGR (Exhaust Gas Recirculation)
system, fuel system, turbocharger, electrical system, air intake
system and/or cooling system.
As a heavy-duty off-road diesel engine owner, you are
responsible for performing required maintenance. The required
maintenance procedures are outlined in this Operation &
Maintenance Manual, or Shop Manual. Do not remove, alter, or
render inoperative, any emission control system.

Foreword
0-5
DL550-5
PRODUCT IDENTIFICATION
With the aid of the product plates, shown below, it is possible to
identify the machine and its components. The Product
Identification Number (PIN) indicates the model designation,
engine code and serial number of the machine. The Component
Identification Number (CIN) indicates the serial number of the
component. Make a note of the identification numbers.
When ordering spare parts, and in all telephone inquiries or
correspondence, the PIN and CIN, of the machine, must always
be referenced.
567
1324
WL1300045
Figure 2
Reference
Number Description
1 Product Plate
The manufacturer's name and address, machine PIN.
Operating weight, year of manufacture, year of delivery and position of CE
mark (EU/EEA countries only) (stamped into right side).
2 Specification
Label operating weight, overall length, overall width, overall height, ground
clearance engine output, tire, turning radius, bucket capacity, dumping
reach, dumping clearance (only available for some regions).
3Cabin
The manufacturer's name and address, cabin part number, machine model
designation, operating weight, cabin serial number, ROPS/FOPS standard
number.
4 Engine The engine type designation and number.
5 Front Axle The manufacturer's name and address and front drive axle CIN.
6 Transmission The manufacturer's name and address and transmission CIN.
7 Rear Axle The manufacturer's name and address and rear drive axle CIN.

DL550-5Foreword
0-6
FEDERAL EMISSION CONTROL
SYSTEMS
Emission Control System Warranty
Statement
General Warranty Provisions
The emission control systems of your new Scania Engines
"Scania" industrial diesel engine were designed, built and tested
using genuine parts, and were certified as being in conformity
with federal emission control regulations. Scania warrants to the
original owner, and to each subsequent owner, of a new Scania
industrial diesel engine.
1. Was designed, built and equipped so as to conform at the
time of sale with all applicable regulations under Section
213 of the Clean Air Act, 42 U.S.C. section 7547, for their
full useful life and designed, built and equipped so as to
conform with all applicable regulations adopted by the
California Air Resources Board pursuant to its authority
under Chapters 1 and 2, Part 5, Division 26 of the
California Health and Safety Code, and:
2. Is free from defects in material and workmanship which
would cause such engine to fail to conform to applicable
regulations for its warranty period or otherwise cause the
failure of a warranted part to be identical in all material
respects to the part as described in the engine
manufacturer's application for certification.
Where a warrantable condition exists, Scania will repair your
heavy-duty off-road engine at no cost to you including diagnosis,
parts, and labor.
Warranty Period
This warranty shall apply for one of the following periods,
whichever occurs first:
• 3,000 hours of operation as determined by a device to
measure hours of use, or
• Five years
Each engine is equipped with a device to measure hours of use.
If that device fails to account for hours of use because of defects
in materials or workmanship, the engine shall be warranted for a
period of five years. 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
0-7
DL550-5
The Warranty on Emission-related Parts Shall be
Interpreted as Follows:
1. Any warranted part which is not scheduled for replacement
as required maintenance in Scania's written instructions for
maintenance and use of the engine by owner shall be
warranted for the warranty period defined above. If any
such part fails during the period of warranty coverage, it
shall be repaired or replaced by the engine manufacturer
according to Subsection (4) below. Any such part repaired
or replaced under the warranty shall be warranted for the
remaining warranty period.
2. Any warranted part which is scheduled only for regular
inspection in Scania's written instructions for maintenance
and use of the engine by owner shall be warranted for the
warranty period defined above. A statement in such written
instructions to the effect of "repair or replace as necessary"
shall not reduce the period of warranty coverage. Any such
part repaired or replaced under warranty shall be
warranted for the remaining warranty period.
3. Any warranted part which is scheduled for replacement as
required maintenance in Scania's written instructions for
maintenance and use of the engine by owner shall be
warranted for the period of time before the first scheduled
replacement point for that part. If the part fails before the
first scheduled replacement, the part shall be repaired or
replaced by the engine manufacturer according to
Subsection below. Any such part repaired or replaced
under warranty shall be warranted for the remainder of the
period before the first scheduled replacement point for the
part.
4. Repair or replacement of any warranted part under the
warranty provisions of this article shall be performed at no
charge to the owner at a warranty station.
5. Notwithstanding the provisions of Subsection (4) above,
warranty services or repairs shall be provided at all
manufacturer distribution centers that are franchised to
serve the subject engines.
6. The owner shall not be charged for diagnostic labor that
leads to the determination that a warranted part is in fact
defective provided that such diagnostic work is performed
at a warranty station.
7. The engine manufacturer shall be liable for damages to
other engine components proximately caused by a failure
under warranty of any warranted part.
8. Throughout the engine's warranty period defined above,
the engine manufacturer shall maintain a supply of
warranted parts sufficient to meet the expected demand for
such parts.
9. 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.

DL550-5Foreword
0-8
It is not necessary for replacement parts to be the same
brand or by the same manufacturer as the original part sold
with the engine. Such use shall not reduce the warranty
obligations of the engine manufacturer.
10. Add-on or modified parts, as defined in Section 1900 (b),
Title 13 of the California Code of Regulations, that are not
exempted by the California Air Resources Board may not
be used. The use of any nonexempt add-on or modified
parts shall be grounds for disallowing a warranty claim
made according to this article. The engine manufacturer
shall not be liable under this article to warrant failures of
warranted parts caused by the use of a nonexempt add-on
or modified part.
11. The Executive Officer of the California Air Resources
Board may request, and in such case, the engine
manufacturer shall provide, any documents which describe
that manufacturer's warranty procedures or policies.
Parts Covered by the Warranty
The following is a list of parts considered to be part of the
Emission Control Systems covered by the Emission Warranty
for Scania industrial engines which were built to conform to
federal and California emission control regulations:
1. Fuel injection system
2. Air Induction System:
3. Exhaust manifold system
4. Smoke puff limiter (included in ECU)
5. Oil fill cap
6. EGR system (when applicable):
A. Cooler
B. EGR valve
7. Exhaust brake (when applicable)
8. NOx sensors:
A. NOx sensor, engine out
B. NOx sensor, tail pipe
9. DOC (when applicable)
10. SCR System:
A. DEF (AdBlue) tank
B. DEF (AdBlue) tank level, temperature and quality
sensors
C. DEF (AdBlue) hose
D. DEF (AdBlue) injector
E. DEF (AdBlue) injector pressure and temperature
sensors

Foreword
0-9
DL550-5
F. Evaporator
G. SCR catalyst inlet temperature sensor
H. SCR catalyst including the ammonia-slip catalyst
I. SCR control unit (EEC3)
11. Miscellaneous items used in the above systems:
A. Electronic control unit (ECU), sensors, wiring
harnesses.
B. Hoses, belts, connectors, assemblies, clamps, fittings
tubing, sealing gaskets or devices and mounting
hardware.
C. Pulleys, belts and idlers.
D. Emission control information label
General Warranty Limitations
To retain the dependability of the exhaust emission control
originally built into your Scania industrial diesel engine, it is
essential that engine is installed according to Scania installation
instructions and emission certificates. Your engine is designed
to operate on diesel fuel only. Use of any other fuel can result in
your engine no longer operating in compliance with state or
federal emissions requirements. The use of alternative fuels
shall not void the warranties on any engine certified if the fuel is
approved for use.
In addition, as the engine owner, you are responsible for the
performance of all scheduled maintenance listed in your owner's
manual, and all necessary repairs, on your new Scania industrial
diesel engine. Scania may deny a warranty claim if the engine or
part has failed because of abuse, neglect, improper
maintenance or unapproved modifications.
Receipts covering the performance ofregular maintenance must
be retained in the event questions arise concerning
maintenance.
IMPORTANT
This list does not include all expendable maintenance
parts.
• Expendable emission related parts requiring
scheduled maintenance are warranted until their
first scheduled replacement point.
• Emission related parts scheduled for inspection
and replacement only as necessary are not
considered expendable and if repaired or
replaced under warranty shall be warranted for
the remaining warranty period.
See Specific Warranty Exclusions below.

DL550-5Foreword
0-10
The receipts must be transferred to each subsequent owner of
the engine with the emission warranted engine. Scania cannot,
however, deny warranty solely for the lack of receipts or for your
failure to ensure the performance of all scheduled maintenance.
The Warranty covers the cost of diagnosis, repair and
replacement parts and services of warranted components and
systems performed by an authorized Scania distributor or dealer
using genuine Scania parts. You may elect to have
maintenance, replacement or repair of these components and
systems performed by any repair establishment or individual
without invalidating the Warranty.
The use of other than Scania replacement parts also does not
invalidate the warranty on other components unless such parts
cause damage to warranted parts. However, the cost of such
services or parts will not be covered by the Warranty.
You are responsible for initiating the warranty process. The
California Air Resources Board suggests that you present your
heavy-duty off-road engine to an authorized Scania dealer as
soon as a problem exists. The warranty repairs must be
completed by the dealer as expeditiously as possible.
Specific Warranty Exclusions
This warranty does not cover:
1. Malfunctions in any part causedby any of the following:
misuse, abuse, improper adjustments, modifications,
alteration, tampering, disconnection, improper or
inadequate maintenance, or use of fuels not recommended
for the engine as described in the Operator's Manual.
2. Engine installation, including cooling system, intake
system and exhaust system installation, that is not
completed according to the Scania installation instructions
and emissions certificate for this engine type.
3. Damage resulting from accidents, acts of nature or other
events beyond the control of Scania.
WARNING
AVOID DEATH OR SERIOUS INJURY
Use of replacement parts which are not of equivalent
quality may impair the effectiveness of emission control
systems. Accordingly, it is recommended that only Scania
repair or replacement parts be used for maintenance, repair
or replacement of emission control systems.
If other than Scania parts are used for maintenance, repair
or replacement, the owner should obtain assurance that
such parts are warranted by their manufacturer to be
equivalent to genuine Scania parts.

Foreword
0-11
DL550-5
4. The replacement of expendable maintenance items such
as filters, hoses, belts, oil, thermostat, exhaust system and
coolant made about scheduled maintenance services once
these parts have been replaced.
5. Replacement items which are not genuine Scania parts or
not authorized by Scania.
6. Inconvenience, loss of use of the engine or commercial
loss.
7. Any engine on which the actual use cannot be accurately
determined because of a failure of the device to track
hours of use unrelated to defects in materials or
workmanship.
8. Any engine operating outside the United States.
Customer Support
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
The SCR converter is fitted in the silencer and does not
constitute a health hazard during normal use and handling.
When performing work on the SCR catalytic converter which can
result in exposure to dust, safety precautions must be taken.
Such work includes, for example, opening the silencer
machining and scrapping the catalytic converter.
Safety precautions when working on the SCR-system.
• Inhalation: If dust is inhaled, the person must be provided
with fresh air immediately. Then seek immediate medical
attention.
• Eye contact: Rinse eyes with water immediately. If irritation
persists, seek immediate medical attention.
• Skin contact: Wash with water and soap. Remove
contaminated clothes.
• Ingestion: If large amounts have been ingested, drink
plenty of water and induce vomiting. Then seek immediate
medical attention.
WARNING
AVOID DEATH OR SERIOUS INJURY
The SCR catalytic converter contains vanadium pentoxide,
a chemical known to the State of California to cause cancer.

DL550-5Foreword
0-12
Environmental hazards
• Vanadium pentoxide is toxic to water organisms and can
cause detrimental long term effects to water environment.
Environmental protection measures
• The SCR catalytic converter is a manufactured article that
contains vanadium pentoxide, a hazardous substance.
Before disposing of, or scrapping, a used SCR catalytic
converter, it must be tested for any hazardous
characteristics (ignitability, corrosiveness, reactivity, acute
hazardousness, and toxicity), as those categories are
described in 22 CCR 66261.30. If the spent SCR catalytic
converter exhibits hazardous characteristics and is being
disposed of, it will be considered by the State of California
to be a hazardous waste subject to Title 22, California
Code of Regulations. Before disposing of hazardous
waste, review and follow all pertinent federal and California
requirements.
• Vanadium pentoxide is a listed commercial chemical
product - P120 - pursuant to 22 CCR 66261.33 (e).
According to the State of California, commercial chemical
products that are discarded or intended to be discarded
are hazardous wastes and are subject to all provisions of
Title 22, California Code of Regulations. Before disposing
of vanadium pentoxide, review and follow all pertinent
federal and California requirements.
• If the SCR catalytic converteris opened for maintenance,
any dust spillages from the catalyst must be collected and
tested for the presence of vanadium pentoxide before
proper disposal. Dust spillages should also be tested for
any hazardous characteristics (ignitability, corrosiveness,
reactivity, acute hazardousness, and toxicity), as those
categories are described in 22 CCR 66261.30, before
proper disposal. If the dust contains either vanadium
pentoxide or exhibits hazardous characteristics and is
being disposed of, it will be considered by the State of
California to be a hazardous waste subject to Title 22,
California Code of Regulations. Before disposing of
hazardous waste, review and follow all pertinent federal
and California requirements.
• Do not dispose of the used SCR catalytic converter or its
constituent parts into any waterways, storm drains or
sanitary sewers.
Additional considerations when working on the SCR-system
• Perform work on the SCR catalytic converter in a well
ventilated area. Use protective goggles and gloves to
protect you from splashing or spraying of reductant or
coolant.
• 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.