Doosan dl550 wheeled loader service repair manual

Page 1

Fig. 011 CYLINDER HEAD

DL550

Fig. 011 CYLINDER HEAD Key No

Part No

Description

Qty S.C

1

150113-00403

HEAD,CYLINDER

6

2

110949-00376

SLEEVE

1

3

430221-00582

PLUG,CORE

2

4

120407-00033

RIVET

3

5

110922-00468

GUIDE,VALVE

4

6

401003-00429

RING;VALVE SEAT

2

6

401003-00430

RING;VALVE SEAT

2

7

401003-00431

RING;VALVE SEAT,EXHAUST

2

7

401107-01317

RING;VALVE SEAT

2

8

120501-02353

PIN

2

9

401107-01142

SEAL,VALVE;STEM

4

10

410112-00047

VALVE,INTAKE

2

11

111601-00429

SPRING,VALVE;INTAKE

2

12

110917-00291

COLLAR,SPRING;VALVE

2

13

410112-00064

VALVE,EXHAUST

2

14

111601-00431

SPRING,VALVE;EX(OUTER)

2

15

111601-00430

SPRING,VALVE;EX(INNER)

2

16

110917-00292

COLLAR,SPRING;VALVE

2

17

410201-00032

COTTER,VALVE;COLLET

8

18

120501-02043

PIN

2

19

400602-00510

GASKET

1

20

111501-00040

YOKE

2

21

120705-00708

SCREW

6

22

110406-02240

BRACKET;BEARING

1

23

130712-00952

SHAFT

1

24

430221-00592

PLUG;RIVET

1

25

120705-00852

SCREW

4

26

150101-00045

ARM,ROCKER

1

27

120702-00040

SCREW,ADJUSTING

1

28

120312-00388

NUT

1

29

150101-00046

ARM,ROCKER

1

30

120702-00040

SCREW,ADJUSTING

1

31

120312-00388

NUT

1

32

150101-00047

ARM,ROCKER

1

33

120702-00041

SCREW,ADJUSTING

1

34

120312-00391

NUT

1

DL550

1

OS

OS

Serial No

ICA

Replacable

Qty

Key No

Part No

Description

Qty S.C

35

430221-00593

PLUG;RIVET

1

36

430221-00708

PLUG

1

37

401107-01256

SEAL

1

DL550

2

Serial No

ICA

Replacable

Qty

Fig. 012 ROCKER COVER

DL550

Fig. 012 ROCKER COVER Key No

Part No

Description

Qty S.C

1

110508-11422

COVER,VALVE

6

2

110508-13728

COVER,VALVE

4

3

110508-11500

COVER,VALVE

2

7

400602-00511

GASKET

6

8

120705-00748

SCREW;FLANGE

18

9

400602-00512

GASKET

6

10

120705-00734

SCREW;FLANGE

24

DL550

1

L1

Serial No

ICA

Replacable

Qty

Fig. 013 CYLINDER BLOCK

DL550

Fig. 013 CYLINDER BLOCK Key No

Part No

Description

Qty S.C

1

150102-00455

BLOCK,CYLINDER

1

2

-

CAP

6

D

3

-

CAP

1

D

4

110949-00316

SLEEVE,GUIDE

14

5

120705-00835

SCREW

14

6

131002-00381

BUSHING,BEARING

7

7

430221-00582

PLUG,CORE

2

8

430221-00583

PLUG,CORE

5

9

150117-00026

LINER,CYLINDER

6

10

401003-00356

RING

6

11

401002-00701

RING,O

6

12

401002-00699

RING,O

6

13

140111-00016

METAL,MAIN;CRANK

7

13

140111-00017

METAL,MAIN;CRANK(0.25)

7

US

13

140111-00018

METAL,MAIN;CRANK(0.5)

7

US

13

140111-00052

METAL,MAIN;CRANK(0.75)

7

US

13

140111-00053

METAL,MAIN;CRANK(1.00)

7

US

15

120816-00097

WASHER,THRUST;CRANK

4

15

120816-00099

WASHER,THRUST(0.16)

4

OS

15

120816-00100

WASHER,THRUST(0.26)

4

OS

15

120816-00119

WASHER,THRUS;(0.52)

4

OS

15

120816-00120

WASHER,THRUST(1.02)

4

OS

16

430218-00157

NOZZLE;PISTON COOLING

6

17

120705-00685

SCREW,BANJO CONNECTOR

1

18

110508-08924

COVER;CHAMBER

3

19

400602-00455

GASKET

3

20

120705-00747

SCREW;FLANGE

18

21

-

FLANGE

1

22

400602-00467

GASKET

1

23

120705-00735

SCREW;FLANGE

4

24

110508-11416

COVER

1

25

400602-00475

GASKET

1

26

120705-00731

SCREW;FLANGE

9

27

120705-00754

SCREW;FLANGE

2

28

110949-00319

SLEEVE,SPACER

2

29

110411-00138

BRACKET;LIFTING

1

DL550

1

D

Serial No

ICA

Replacable

Qty

Key No

Part No

Description

Qty S.C

30

120705-00703

SCREW

3

31

110949-00324

SLEEVE,SPACER

3

32

430221-00586

PLUG,SCREW

1

33

120808-00541

WASHER,SEAL

1

34

430208-00232

CONNECTER;HOSE

1

35

430221-00586

PLUG,SCREW

1

36

120808-00541

WASHER,SEAL

1

DL550

2

Serial No

ICA

Replacable

Qty

Fig. 014 TIMING GEAR COVER

DL550

Fig. 014 TIMING GEAR COVER Key No

Part No

Description

Qty S.C

1

110508-08925

COVER;FRONT

1

2

401107-01135

SEAL

1

3

120501-02046

PIN

2

4

910101-00014

SILICONE

1

5

120705-00732

SCREW;FLANGE

8

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 015 FLYWHEEL HOUSING

DL550

Fig. 015 FLYWHEEL HOUSING Key No

Part No

Description

Qty S.C

1

150114-00145

HOUSING,FLYWHEEL

1

2

110508-08909

COVER

2

3

401107-01137

SEAL

1

4

120705-00756

SCREW,HEX

9

5

120808-00533

WASHER

9

6

120705-00742

SCREW;FLANGE

12

7

120705-00893

SCREW;FLANGE

1

8

120705-00739

SCREW;FLANGE

6

9

120705-00740

SCREW;FLANGE

1

10

110508-08918

COVER

1

11

401002-00696

RING,O

1

12

120705-00739

SCREW;FLANGE

2

13

110508-08906

COVER

1

14

110508-08913

COVER

1

15

120705-00730

SCREW;FLANGE

4

16

250201-02113

PLATE;TIMING GEAR

1

17

120501-02046

PIN

2

18

120705-00746

SCREW;FLANGE

6

19

430221-00573

PLUG

1

20

120705-00730

SCREW;FLANGE

1

21

120808-00537

WASHER

1

22

110411-00115

BRACKET;LIFTING

2

23

120408-00079

STUD

12

24

120305-00030

NUT,FLANGE

12

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 016 OIL PAN

DL550

Fig. 016 OIL PAN Key No

Part No

Description

Qty S.C

1

150119-00269

SUMP,OIL

1

2

430221-00594

PLUG;INSERT

1

3

400604-00014

GASKET,OIL PAN

1

4

120705-00754

SCREW;FLANGE

18

5

430221-00576

PLUG

1

6

401002-00686

RING,O

1

7

120705-00725

SCREW;FLANGE

2

8

430221-00585

PLUG,MAGNETIC

1

9

120808-00545

WASHER,SEAL

1

10

160609-02757

FRAME

1

11

400602-00472

GASKET

1

12

120705-00750

SCREW;FLANGE

36

13

120705-00753

SCREW;FLANGE

6

DL550

1

L1

Serial No

ICA

Replacable

Qty

Fig. 017 CRANK MECHANISM

DL550

Fig. 017 CRANK MECHANISM Key No

Part No

Description

Qty S.C

1

150121-00172

ROD ASSY,CONNECTING

6

2

120705-00704

SCREW

2

4

140111-00013

METAL,CONNECTING ROD

12

4

140111-00014

METAL,CONNECTING ROD(0.25)

12

US

4

140111-00015

METAL,CONNECTING ROD(0.5)

12

US

4

140111-00050

METAL,CONNECTING ROD(0.75)

12

US

4

140111-00051

METAL,CONNECTING ROD(1.00)

12

US

5

150107-00394

CRANKSHAFT

1

6

180313-00157

DAMPER;TORTION

1

7

130418-00362

GEAR;CRANK SHAFT

1

8

120501-02045

PIN

1

9

150111-00143

FLYWHEEL

1

10

130422-00050

GEAR,RING

1

11

120705-00712

SCREW

10

12

120408-00082

STUD

8

13

120311-00110

NUT,LOCK

8

14

120808-00536

WASHER

8

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 018 PISTON

DL550

Fig. 018 PISTON Key No

Part No

Description

Qty S.C

-

101529-00298

KIT,REPAIR;PISTON

6

1

-

PISTON

1

2

401003-00357

RING,COMPRESSOR

1

3

401003-00358

RING,COMPRESSOR

1

4

401003-00428

RING

1

5

111104-00236

RING,RETAINING

2

6

120501-02340

PIN

1

DL550

1

D

Serial No

ICA

Replacable

Qty

Fig. 019 CAM SHAFT DRIVE

DL550

Fig. 019 CAM SHAFT DRIVE Key No

Part No

Description

Qty S.C

1

150103-00086

CAMSHAFT

1

2

120501-02044

PIN 10x25

1

3

150125-00009

TAPPET,VALVE

3

4

130112-00055

TAPPET;ROLLER

4

5

130112-00056

TAPPET;ROLLER

2

6

111104-00239

RING,RETAINING

4

7

110949-00317

SLEEVE,GUIDE

2

8

120705-00747

SCREW;FLANGE

6

9

120705-00707

SCREW

3

10

150123-00083

PUSHROD

12

11

150123-00096

PUSHROD

6

13

130418-00413

GEAR

1

14

120705-00755

SCREW,HEX

5

15

430215-00521

FLANGE,GUIDE

1

16

120816-00098

WASHER,THRUST;CAM SHAFT

1

17

120705-00746

SCREW;FLANGE

2

18

130418-00362

GEAR;CRANK SHAFT

1

19

130418-00365

GEAR ASSY;INTERMEDIATE

1

20

130418-00360

GEAR

1

21

130712-00768

SHAFT

1

22

140105-00303

BEARING

1

23

111104-00240

RING,SNAP

1

24

110949-00325

SLEEVE,SPACER

1

25

120705-00700

SCREW

1

27

130418-00364

GEAR;INTERMEDIATE

1

28

130712-00768

SHAFT

1

29

140105-00303

BEARING

1

30

111104-00240

RING,SNAP

1

31

110949-00325

SLEEVE,SPACER

1

32

120705-00700

SCREW

1

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 020 OIL FILLER

DL550

Fig. 020 OIL FILLER Key No

Part No

Description

Qty S.C

1

430215-00720

PIPE,FLANGE

1

8

400602-00456

GASKET

1

9

120705-00731

SCREW;FLANGE

4

10

110411-00173

BRACKET

1

11

120705-00730

SCREW;FLANGE

2

12

420210-01388

PIPE

1

13

420210-01389

PIPE

1

14

120705-00732

SCREW;FLANGE

2

16

110910-00451

CAP

1

17

110928-00174

HOLDER

1

18

420108-00853

HOSE

1

19

120202-00144

CLAMP,HOSE

2

20

800103-00034

DIPSTICK,OIL

1

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 021 TURBO CHARGER PLUMBING

DL550

Fig. 021 TURBO CHARGER PLUMBING Key No

Part No

Description

Qty S.C

1

420210-00852

PIPE;LUBRICATION

1

6

430208-00227

CONNECTER

1

7

400602-00452

GASKET

1

8

420210-01195

PIPE

1

9

400602-00470

GASKET

1

10

120705-00730

SCREW;FLANGE

1

11

420108-00571

HOSE

1

12

120202-00147

CLAMP,HOSE

2

13

120203-00291

CLAMP

1

14

120705-00687

SCREW

2

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 022 OIL FILTER

DL550

Fig. 022 OIL FILTER Key No

Part No

Description

Qty S.C

1

400405-00088

FILTER ASSY,OIL

1

2

430208-00227

CONNECTER

1

3

120808-00540

WASHER,SEAL

1

4

401002-00700

RING,O

1

5

401002-00693

RING,O

1

6

401002-00692

RING,O

1

7

400405-00092

FILTER,OIL

1

8

101529-00223

KIT,REPAIR

1

9

101529-00225

KIT,REPAIR;BY-PASS V/V

1

11

400602-00469

GASKET

1

12

120705-00732

SCREW;FLANGE

7

13

120705-00736

SCREW;FLANGE

2

14

120705-00737

SCREW;FLANGE

1

15

500203-00047

CLEANER;OIL

1

16

130712-00769

SHAFT

1

17

120808-00538

WASHER

1

18

120705-00719

SCREW,PLUG

1

19

430221-00579

PLUG

1

20

130602-00780

PISTON

1

21

111601-00428

SPRING

1

22

400602-00450

GASKET

1

23

210206-00090

ROTOR ASSY

1

24

-

BEARING

1

D

25

-

BEARING

1

D

26

-

NOZZLE

2

D

27

110508-08910

COVER

1

28

401002-00703

RING,O

1

29

120312-00345

NUT

1

30

400411-00039

STRAINER

1

31

110508-08908

COVER

1

32

120311-00108

NUT,LOCK

1

33

120808-00534

WASHER

1

34

401002-00690

RING,O

1

35

111104-00241

RING,SNAP

1

36

401002-00702

RING,O

1

37

400602-00471

GASKET

1

DL550

1

L1

L1

Serial No

ICA

Replacable

Qty

Key No 38

DL550

Part No 120705-00737

Description

Qty S.C

SCREW;FLANGE

4

2

Serial No

ICA

Replacable

Qty

Fig. 023 OIL COOLER

DL550

Fig. 023 OIL COOLER Key No

Part No

Description

Qty S.C

1

110508-08923

COVER ASSY

1

2

110508-08907

COVER

1

3

400602-00451

GASKET

1

4

120705-00724

SCREW;FLANGE

5

5

430208-00227

CONNECTER

1

6

120808-00540

WASHER,SEAL

1

7

430201-00587

ADAPTER

1

8

120808-00542

WASHER,SEAL

1

9

110949-00318

SLEEVE;PROTECTION

1

10

430221-00572

PLUG

2

11

120501-02047

PIN

1

12

130602-00780

PISTON

1

13

111601-00427

SPRING

1

14

400602-00450

GASKET

1

15

430221-00587

PLUG,SCREW

1

16

400206-00361

COOLER,OIL

1

17

400602-00453

GASKET

2

18

400602-00454

GASKET

2

19

120705-00894

SCREW;FLANGE

4

20

120501-02050

PIN,DOWEL

2

21

400602-00474

GASKET

1

22

120705-00753

SCREW;FLANGE

11

23

120705-00750

SCREW;FLANGE

1

24

110949-00319

SLEEVE,SPACER

1

25

430221-00580

PLUG

1

26

401002-00695

RING,O

1

27

120705-00730

SCREW;FLANGE

1

28

430221-00578

PLUG

2

29

401002-00691

RING,O

2

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 024 OIL PUMP

DL550

Fig. 024 OIL PUMP Key No

Part No

Description

Qty S.C

1

400915-00150

PUMP,OIL

1

2

120705-00733

SCREW;FLANGE

6

3

110949-00317

SLEEVE,GUIDE

4

4

120705-00750

SCREW;FLANGE

4

5

420210-00868

PIPE;SUCTION

1

6

120705-00731

SCREW;FLANGE

3

7

420210-00864

PIPE

1

8

401002-00686

RING,O

2

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 025 EXHAUST MANIFOLD

DL550

Fig. 025 EXHAUST MANIFOLD Key No

Part No

Description

Qty S.C

1

240102-00167

MANIFOLD,EXHAUST

1

2

240102-00255

MANIFOLD,EXHAUST

1

3

401109-00101

SEALRING

8

4

240102-00256

MANIFOLD,EXHAUST

1

5

430221-00589

PLUG,SCREW

1

6

400602-00458

GASKET

6

7

120705-00751

SCREW;FLANGE

12

8

110949-00320

SLEEVE,SPACER

1

9

400602-00468

GASKET

1

10

120705-00752

SCREW;FLANGE

2

11

110949-00322

SLEEVE,SPACER

2

12

120408-00081

STUD

2

13

120305-00032

NUT,FLANGE

2

14

150105-00320

CHARGER,TURBO

1

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 026 TURBO CHARGER PLUMBING

DL550

Fig. 026 TURBO CHARGER PLUMBING Key No

Part No

Description

Qty S.C

1

410135-00286

VALVE,SOLENOID

1

2

120705-00702

SCREW

2

3

420108-00741

HOSE

1

4

120202-00143

CLAMP,HOSE

4

5

430201-00586

ADAPTER ASS'Y

1

6

110406-02232

BRACKET

1

7

120705-00729

SCREW;FLANGE

2

8

120203-00288

CLAMP

7

9

120705-00729

SCREW;FLANGE

7

10

420108-00742

HOSE

1

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 027 INTAKE MANIFOLD

DL550

Fig. 027 INTAKE MANIFOLD Key No

Part No

Description

Qty S.C

1

240203-00116

MANIFOLD,INTAKE

1

2

400602-00457

GASKET

6

3

120705-00737

SCREW;FLANGE

24

4

401109-00076

SEALRING

1

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 028 POWER TAKE OFF(1)

DL550

Fig. 028 POWER TAKE OFF(1) Key No

Part No

Description

Qty S.C

1

401002-00696

RING,O

1

2

130418-00361

GEAR

1

3

111104-00238

RING,RETAINING

1

4

140107-00300

BEARING,ROLLER

1

5

111104-00237

RING,RETAINING

1

6

110931-00712

HOUSING

1

7

120705-00739

SCREW;FLANGE

5

8

401002-00688

RING,O

1

9

110508-08919

COVER

1

10

401002-00689

RING,O

1

11

120705-00744

SCREW;FLANGE

2

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 029 POWER TAKE OFF(2)

DL550

Fig. 029 POWER TAKE OFF(2) Key No

Part No

Description

Qty S.C

1

110508-08912

COVER

1

2

120408-00083

STUD

3

3

120305-00030

NUT,FLANGE

3

4

110949-00321

SLEEVE,SPACER

3

5

401002-00708

RING,O

1

6

401002-00707

RING,O

1

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 030 POWER TAKE OFF(3)

DL550

Fig. 030 POWER TAKE OFF(3) Key No

Part No

Description

Qty S.C

1

180313-00157

DAMPER;TORTION

1

2

850308-00170

DRIVER

1

3

120705-00899

SCREW

8

4

130707-00363

PULLEY

1

5

120808-00645

WASHER

1

6

120705-00900

SCREW,HEX

8

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 031 SEAL KIT - OIL MIST SEPARATOR

DL550

Fig. 031 SEAL KIT - OIL MIST SEPARATOR Key No

Part No

Description

Qty S.C

1

101529-00226

KIT,REPAIR;SEPARATOR

1

2

-

SCREW

3

D

3

-

SEALING RING

1

D

4

-

SEALING RING

1

D

5

101529-00378

KIT,REPAIR

1

6

-

SCREW

3

D

7

-

SEALING RING

1

D

8

-

SEALING RING

1

D

9

401107-01190

SEAL KIT

1

10

-

SEALING RING

1

11

101529-00379

KIT,REPAIR

1

12

-

SCREW

1

D

13

-

GASKET

1

D

14

101529-00380

KIT,REPAIR

1

15

-

SCREW

3

16

101529-00243

KIT,REPAIR

1

17

-

GASKET

1

D

18

-

HOUSING

1

D

19

-

SCREW

3

D

DL550

1

D

D

Serial No

ICA

Replacable

Qty

Fig. 032 GASKET KIT - CYLINDER HEAD

DL550

Fig. 032 GASKET KIT - CYLINDER HEAD Key No

Part No

Description

Qty S.C

-

400602-00657

GASKET ASSY;CYL HEAD

1

1

400602-00510

GASKET

1

2

400602-00511

GASKET

1

3

400602-00512

GASKET

1

4

400602-00458

GASKET

1

5

400602-00457

GASKET

1

6

400602-00521

GASKET

1

7

400602-00595

GASKET

1

DL550

1

Serial No

ICA

Replacable

Qty

Fig. 033 REPAIR KIT - PISTON AND LINER

DL550

Fig. 033 REPAIR KIT - PISTON AND LINER Key No

Part No

Description

Qty S.C

-

101529-00240

KIT,REPAIR

1

1

-

PISTON

1

2

401003-00357

RING,COMPRESSOR

1

3

401003-00358

RING,COMPRESSOR

1

4

401003-00428

RING

1

5

111104-00236

RING,RETAINING

2

6

120501-02340

PIN

1

7

150117-00026

LINER,CYLINDER

1

8

401002-00701

RING,O

1

9

401002-00699

RING,O

1

10

401003-00356

RING

1

DL550

1

D

Serial No

ICA

Replacable

Qty

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