service repair manual

1. Original InstructionsCopyright DOOSAN 2012
Serial Number 10001 and Up
Shop Manual
DL550-3 Wheel Loader
950106-00434E
June 2012
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

2. Table of Contents
Page I
1Table of Contents
Safety
Wheel Loader Safety ............................................................................ SP002397
Specifications
Specification for DL550-3 ..................................................................... SP002593
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Engine
Engine................................................................................................... SP002399
Engine Coolant Heater (Option) ........................................................... SP002328
Drivetrain
Transmission and Torque Converter (ZF 4WG-310)............................ SP000786
Transmission and Torque Converter (ZF 5WG) ................................... SP002401
Axle ZF - Multitrac (MT - L 3115 II / 3125 II)......................................... SP002657
Transmission Error Codes (ZF) ............................................................ SP002423
Driveshaft.............................................................................................. SP002424
Brake
Service Brake ....................................................................................... SP002426
Supply Valve......................................................................................... SP002427
Charging Block ..................................................................................... SP002428
Parking Brake ....................................................................................... SP002429
Brake Pedal Valve ................................................................................ SP002430
Accumulator.......................................................................................... SP002431

3. Table of Contents
Page II
Steering
Power Steering System ........................................................................ SP002465
Steering Unit......................................................................................... SP002425
Steering Pump...................................................................................... SP002480
Flow Amplifier ....................................................................................... SP002434
Jerk Softener and Accumulator ............................................................ SP002658
Emergency Steering ............................................................................. SP002436
Frame
Articulation Center ................................................................................ SP002542
Counterweight....................................................................................... SP002437
Tank
Oil Tank ................................................................................................ SP002725
Fuel Tank.............................................................................................. SP002439
Hydraulics
Main Pump............................................................................................ SP002486
Main Control Valve ............................................................................... SP002441
3rd Control Valve (Option).................................................................... SP002442
Load Isolation System .......................................................................... SP002443
Cooling System..................................................................................... SP002444
Pilot System.......................................................................................... SP002445
Hydraulic Schematic (DL550-3)............................................................ SP002659
Electrical System
Air Conditioner...................................................................................... SP002447
Electrical System .................................................................................. SP002448
Electrical Schematic (DL450-3 / DL550-3) ........................................... SP002449

4. 1Safety

5. SP002397
Page 1
Wheel Loader Safety
SP002397
WHEEL LOADER SAFETYSP002397
Wheel Loader
Safety
Edition 3

6. SP002397
Page 3
Wheel Loader Safety
Table of Contents
Wheel Loader Safety
Safety Instructions ................................................ 5
Applicable Models ................................................ 5
Safety Messages .................................................. 6
Safety Decals ....................................................... 7
General................................................................. 7
Transportation .................................................... 18
Operation............................................................ 20
Maintenance ....................................................... 38
Environment and Circumstances........................ 53

7. SP002397
Page 5
Wheel Loader Safety
SAFETY INSTRUCTIONS
APPLICABLE MODELS
The contents of this section apply to the following models and
serial number ranges.
WARNING
AVOID DEATH OR SERIOUS INJURY
Instructions are necessary before operating or servicing
machine. Read and understand the Operation and
Maintenance Manual and signs (decals) on machine. Follow
warnings and instructions in the manuals when making
repairs, adjustments or servicing. Check for correct
function after adjustments repairs or service. Untrained
operators and failure to follow instructions can cause death
or serious injury.
MODEL SERIAL NUMBER RANGE
DL200-3 10001 and Up
DL220-3 10001 and Up
DL250-3 10001 and Up
DL300-3 10001 and Up
DL350-3 10001 and Up
DL420-3 10001 and Up
DL450-3 10001 and Up
DL550-3 10001 and Up

8. SP002397Wheel Loader Safety
Page 6
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.

9. SP002397
Page 7
Wheel Loader Safety
SAFETY DECALS
Location of safety labels (decals) can vary from unit to unit.
Refer to appropriate Operation and Maintenance Manual, and
parts manual for your unit.
Always replace damaged or faded decals.
GENERAL
Safe Operation is Operator's
Responsibility
Only trained and authorized personnel should operate and
maintain the machine.
Follow all safety rules, regulations and instructions when
operating or performing maintenance on machine.
• Do not operate machine if you are under the
influence of drugs or alcohol. An operator who is
taking prescription drugs must get medical advice to
determine if he or she can safely operate the
machine.
• When working with other personnel on a work site, be
sure that all personnel know the nature of work and
understand all hand signals that are to be used.
• Be sure that all guards and shields are installed in
their proper location. Have guards and shields
repaired or replaced immediately if damaged.
• Be sure that you understand the use and
maintenance of all safety features such as pilot cutoff
switch and seat belt. Use them at all times.
• Never remove, modify or disable any safety features.
Always keep them in good operating condition.
• Always check for and know the location of
underground and overhead utility lines before working.
• Failure to use and maintain safety features according
to instructions in this manual, Safety Manual and
Shop Manual can result in death or serious injury.
Know Your Machine
Know how to operate your machine. Know the purpose of all
controls, gauges, signals, indicators and monitor displays. Know
the rated load capacity, speed range, braking and steering
characteristics, turning radius and operating clearances. Keep in
mind that rain, snow, ice, loose gravel, soft ground, slopes etc.,
can change operating capabilities of your machine.

10. SP002397Wheel Loader Safety
Page 8
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. Because DOOSAN cannot anticipate, identify or
test all attachments that owners may want to install on their
machines, contact DOOSAN for written authorization and
approval of attachments, and their compatibility with optional
kits.
Attachments and attachment control systems that are
compatible with the machine are required for safe and reliable
machine operation. Do not exceed maximum operating weight
(machine weight plus attachment) that is listed on ROPS
certification plate.
Make sure that all guards and shields are in place on machine
and on work tool. Depending on type or combination of work
equipment, there is a potential that work equipment could
interfere with the cabin or other parts of machine. Before using
unfamiliar work equipment, check if there is any potential of
interference, and operate with caution.
While you are performing any maintenance, testing, or
adjustments to attachments, stay clear of the following areas:
cutting edges, pinch points, and crushing surfaces.
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.
Pressurized Fluids
Pressurized air or fluids can cause debris and/or fluids to be
blown out. This could result in death or serious injury.
Immediately after operations are stopped, coolant, engine oil,
and hydraulic oil are at their highest temperatures and the
radiator and hydraulic tank are still under pressure. Always wait
for temperature to cool down. Follow specified procedures when
attempting to remove caps, drain oil or coolant, or replacing
filters. Always wait for temperature to cool down, and follow
specified procedures when performing these operations. Failure
to do so can result in death or serious injury.
When pressurized air and/or pressurized water is used for
cleaning, wear protective clothing, protective shoes, and eye
protection. Eye protection includes goggles or a protective face
shield.
Pressure can be trapped in a hydraulic system and must be
relieved before maintenance is started.
Releasing trapped pressure can cause sudden machine
movement or attachment movement. Use caution if you
disconnect hydraulic lines or fittings.
FG018457
Figure 1

11. 1Engine

12. SP002399
Page 3
Engine
Table of Contents
Engine
Safety Instructions ................................................5
Applicable Models.................................................5
DC13 Engine ........................................................6
Inspection .............................................................7
Cleaning the Engine ........................................................ 7
Special Tools ........................................................7
Engine Identification ...........................................18
Engine Data Plate.......................................................... 18
Mounting the Engine in a Universal Stand..................... 19
Engine Specification ...........................................20
Motor...................................................................21
Removal and Installation of Motor ................................. 21
Installing Engine ............................................................ 21
Tightening Torques.............................................23
Normal Tightening Torque ............................................. 23
Cylinder...............................................................32
Cylinder Head ................................................................ 32
Valve Mechanism .......................................................... 45
Cylinder Block................................................................ 48
Cylinder Liner................................................................. 63
Flywheel Housing .......................................................... 67
Front Cover.................................................................... 70
Oil Mist Separator.......................................................... 72
Camshaft ....................................................................... 78
Crankshaft ..................................................................... 86
Flywheel Housing .......................................................... 89
Piston.............................................................................90
Belt Circuit ..................................................................... 95
Gear Wheel Transmission ........................................... 103
Lubrication System ...........................................108
Centrifugal Oil Cleaner ................................................ 108

13. SP002399Engine
Page 4
Oil Cooler .................................................................... 116
Oil Filter ....................................................................... 118
Oil Pump...................................................................... 119
Oil Sump...................................................................... 120
Oil Pressure Sensor .................................................... 121
Turbocharger............................................................... 122
Solenoid Valve for Wastegate Valve ........................... 126
Wastegate Valve ......................................................... 127
Cooling System ................................................ 128
Thermostat .................................................................. 129
Coolant Pump.............................................................. 131
Coolant Temperature Sensor ...................................... 132
Accumulator ................................................................ 132
Calculating the Fuel Consumption Factor ................... 133
Fuel System......................................................136
General Information on the XPI Fuel System.............. 136
Overflow Valve ............................................................ 156
Feed Pump.................................................................. 156
Injector Scania XPI...................................................... 158
Fuel Filter .................................................................... 161
Fuel Heater.................................................................. 164
Exhaust Temperature Sensor Before Catalytic Converter
164
Electrical System .............................................. 165
E44, Control Unit Ems S8 ........................................... 165
Alternator..................................................................... 180
Starter Motor ............................................................... 184
Installing ...................................................................... 185
EMS, Engine Management System S8 ....................... 186
DEF Tank ......................................................... 191
General........................................................................ 191
Reductant .................................................................... 191
System Overview, Mechanics ..................................... 192
System Overview, Electric........................................... 193

14. SP002399
Page 5
Engine
Reductant Unit .............................................................194
Placement and Fitting ..................................................195
Installation....................................................................195
Connection of Reductant Unit......................................196
Fuel System Troubleshooting........................... 197
M - Metal Shavings in the Engine ................................199
L - Low-pressure Check...............................................201
L - Descriptions, Low-pressure Check.........................202
H - High-pressure Check .............................................204
H - Descriptions, High-pressure Check........................206

15. SP002399Engine
Page 18
ENGINE IDENTIFICATION
Engine Data Plate
Applies to engines with cylinder block generation 2.
Engine data on plate, on 9 and 13 liter engines with XPI
A
B
C FG020225
Figure 3
Reference
Number
Description
A Smoke Value
B Engine Type
C Engine Serial Number
FG020227
Figure 4
:
21
3 4
Typ/Type DC 13 06
Variant
Motor/Engine No
123 44XX
FG020228
Figure 5
Reference
Number
Description
1
Engine Type and Engine Serial
Number
2 Engine Serial Number, Stamped
3 Smoke Data
4 Valve Clearance

16. SP002399
Page 19
Engine
Mounting the Engine in a Universal Stand
Preparations before commencing work:
• Remove engine from the machine.
1. Mount the engine in the universal stand.
1 4
3
2
FG020231
Figure 6
Reference
Number
Description
1 Engine Control Unit
2 Fuel Filter
3
High-pressure Pump and Feed
Pump
4 Starter Motor
Reference
Number
Description
1
2 3
99 331
FG020232
Figure 7
Reference
Number
Description
1 Bolt M10x30 (8 off)
2 Nut M16 (4 off)
3 Bolt M16x50 (4 off)

17. SP002399Engine
Page 20
ENGINE SPECIFICATION
ITEMS SPECIFICATION
Engine
Type
4-Cycle Water Cooled, Waste Gate Turbocharge,
Air to Air Intercooled Direct Injection
Emission US EPA Tier 4i (EU Stage IIIB)
Maker and Model SCANIA / DC 13
Injection System Extra high-pressure fuel injection system, XPI
Rated Net Power 283 kW (390 HP) @ 1,800 rpm (SAE J1995)
Valve Clearance
Intake Valve 0.45 mm
Exhaust valve 0.70 mm
Number of cylinders and Configuration 6, Straight
Rotating Direction (from Flywheel) Counterclockwise
Oil Pressure (bar, kg/cm²)
Normal with the engine
at operating temperature,
operating speed
3 - 6
Min. permitted at idling
speed
0.7
Crankcase pressure with closed
crankcase ventilation
-55 - +20
Using Lubrication Oil
ACEA-E3, E4, E5 or E7
(for fuel with ultra low sulfur)
Oil Filter Paper filter form Scania
Interval between oil changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 130 mm
Piston Stroke 140 mm
Displacement 12.7 dm3
Compression Ratio 17.3:1
Number of teeth on the flywheel 158
Low Idle Speed 600 - 750 rpm
High Idle 2,180 rpm
Weight, without Coolant and Oil 1050 kg
Cooling System
Volume, excluding
radiator 16 dm3
Coolant Temperature 90 - 95
Number of Thermostats 1
Thermostat, Opening
Temperature
80/87
Electrical System Type 1-pin, 24V, DC
Starter Motor (Standard
Equipment)
1-pin, 24V, 6 kW
Alternator
(Standard Equipment)
1-pin, 28V, 100 A

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19. SP002399
Page 21
Engine
MOTOR
Removal and Installation of Motor
NOTE: Replace coolant hoses if there is clear damage to the
coolant hoses which were removed.
1. Drain the oil and coolant.
2. Remove air filter and inlet pipe between the turbocharger
and air filter. Cover the turbocharger inlet pipe.
3. Undo the connections for coolant, charge air pipes
between engine and charge air cooler, and bleed pipe for
the expansion tank.
4. Undo the cable harness with clamping.
NOTE: The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
5. Fasten the lifting chain 98 094 to the rear lifting eyes 99
637.
6. Fasten the lever block 587 308 to the front lifting eye.
NOTE: The lifting eyes 99 637 are designed to manage
a maximum inclination angle of 30° when lifting
an engine.
7. Undo the engine insulator bolts and lift away/out the
engine.
Installing Engine
1. Fasten the lifting chain 98 094 to the rear lifting eyes.
NOTE: The engine lifting eyes 99 637 are designed for
lifting the engine only, not the engine with
connected equipment (high voltage current
generator, gearbox, reverse gear, etc.) or
frame. All three lifting eyes must be used.
NOTE: The lifting eyes 99 637 are designed to manage
a maximum inclination angle of 30° when lifting
an engine.
2. Fasten the lever block 587 308 to the front lifting eye.
3. Lift the engine, position it on the engine insulators and
screw it into place.
FG020236
Figure 8
FG020237
max 30
max 20
Figure 9
FG020237
max 30
max 20
Figure 10

20. SP002399Engine
Page 22
4. Attach the cable harness with clamping.
5. Install the connections for coolant, charge air pipes
between engine and charge air cooler, and bleed pipe for
the expansion tank.
6. Install the air filter and inlet pipe between the turbocharger
and air filter.
7. Fill with oil and coolant as directed in booklet 00:03-01.
8. Test run the engine to check that no leakage occurs. Top
up with coolant if necessary.

21. SP002399
Page 23
Engine
TIGHTENING TORQUES
Normal Tightening Torque
The specifications in the tables below show the normal
tightening torque for screws, nuts and unions. The values are to
be used unless other values are specified in the inspection
information. Always check whether there are special tightening
torques given in the descriptions for the respective areas in the
inspection information before using the general values for
normal and special tightening torques respectively.
The following conditions apply:
• A tolerance of ±15 % applies to all values unless
otherwise specified.
• All contact surfaces are to be clean and free of paint.
• Bolts and nuts are normally not lubricated regardless
of surface treatment. All exceptions are specified in
the inspection information.
Union Assemblies
The specified values apply with a tolerance of ±5 %. The values
apply to tightening with a counterhold.
Thread Inserts
The specified tightening torques also apply to bolted joints with a
thread insert (Heli-Coil).
Thread inserts often provide greater strength compared to a
directly screwed thread. This generates a stronger bolted joint in
aluminium or the like. For this reason, thread inserts are used in
certain joints in Scania's production.
NOTE: When a damaged thread is repaired with a thread
insert, the normal screw and prescribed tightening
torque are to be maintained. Install the thread insert
as instructed in the inspection information.