Doosan DL450-3 Wheel Loader Service Repair Manual Instant Download

1
Shop Manual DL450-3 Wheel Loader
Serial Number 10001 and Up
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.
950106-00414E January 2012
Original Instructions
Copyright DOOSAN 2012
2
Table of Contents
Safety Wheel Loader Safety .......................
..................................................
... SP002397 Specifications Specification for
DL450-3 ..........................................
........................... SP002398 General
Maintenance General Maintenance
Instructions......................................
.................. SP002454 Standard
Torques...........................................
......................................
SP002404 Engine Engine...........................
..................................................
...................... SP002399 Engine Coolant
Heater (Option) ..................................
......................... SP002328 Drivetrain Tra
nsmission and Torque Converter (ZF
4WG-260-4)......................... SP002400
Transmission and Torque Converter (ZF 5WG-260)
(Option) .............. SP002401 Transmission
Error Codes (ZF) .................................
........................... SP002423 Axle ZF -
Multitrac (MT-L 3105 II)..........................
............................... SP002402
Driveshaft........................................
..................................................
.... SP002424 Brake Service Brake
..................................................
.....................................
SP002426 Supply Valve.............................
..................................................
.......... SP002427 Charging Block
..................................................
...................................
SP002428 Parking Brake ...........................
..................................................
.......... SP002429 Brake Pedal Valve
..................................................
.............................. SP002430 Accumulato
r.................................................
......................................... SP002431
Table of Contents Page I
3
Steering Power Steering System ...................
..................................................
... SP002432 Steering Unit .......................
..................................................
................ SP002425 Steering
Pump..............................................
........................................
SP002433 Flow Amplifier ..........................
..................................................
........... SP002434 Jerk Softener and
Accumulator ......................................
...................... SP002435 Emergency
Steering .........................................
....................................
SP002436 Frame Articulation Center
..................................................
.............................. SP001678 Counterwei
ght...............................................
........................................
SP002437 Tank Oil Tank ..........................
..................................................
.................... SP002438 Fuel
Tank..............................................
................................................
SP002439 Hydraulics Main Pump....................
..................................................
...................... SP002440 Main Control
Valve ............................................
................................... SP002441 3rd
Control Valve (Option)............................
........................................
SP002442 Load Isolation System ...................
..................................................
..... SP002443 Cooling System.....................
..................................................
.............. SP002444 Pilot System..............
..................................................
.......................... SP002445 Hydraulic
Schematic (DL450-3)...............................
............................. SP002446 Electrical
System Air Conditioner...........................
..................................................
......... SP002447 Electrical System
..................................................
................................
SP002448 Electrical Schematic (DL450-3)
..................................................
.......... SP002449
Table of Contents Page II
4
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Wheel Loader
Safety
SP002397
Edition 1
Wheel Loader Safety
SP002397 Page 1
6
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
Wheel Loader Safety
SP002397 Page 3
7
SAFETY INSTRUCTIONS 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.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DL200-3 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
SP002397 Page 5
Wheel Loader Safety
8
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.
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 should be
alert to the potential for personal injury or
accidents. Always observe safety precautions and
follow recommended procedures. 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.
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.
Wheel Loader Safety Page 6
SP002397
9
Engine
SP002399
Edition 1
Engine
SP002399 Page 1
10
SAFETY INSTRUCTIONS 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.
APPLICABLE MODELS The contents of this section
apply to the following models and serial number
ranges.
MODEL SERIAL NUMBER RANGE
DL350-3 10001 and Up
DL420-3 10001 and Up
DL450-3 10001 and Up

SP002399 Page 5
Engine
11
DC13 ENGINE
Figure 1
Engine Page 6
SP002399
12
ENGINE IDENTIFICATION
Engine Data Plate Applies to engines with
cylinder block generation 2.
Reference Number Description
A Smoke Value
B Engine type
C Engine serial number
A
B
C
FG020225
Figure 3
FG020227
Figure 4
Engine data on plate, on 9 and 13 liter engines
with XPI
2 123 44XX
1 Typ/Type DC 13 06
Variant Motor/Engine No
Reference Number Description
1 Engine Type and Engine Serial Number
2 Engine Serial Number, Stamped
3 Smoke Data
4 Valve Clearance
3
4

FG020228
Figure 5
SP002399 Page 17
Engine
13

• Mounting the Engine in a Universal Stand
• Preparations before commencing work
• Remove engine from the machine.

2
3
4
1
FG020231
Figure 6
Reference Number Description
1 Engine Control Unit
2 Fuel Filter
Reference Number Description
3 High-pressure Pump and Feed Pump
4 Starter Motor
1. Mount the engine in the universal stand.
Reference Number Description
1 Bolt M10x30 (8 off)
2 Nut M16 (4 off)
3 Bolt M16x50 (4 off)
2
3 99 331
1
FG020232
Figure 7
Engine Page 18
SP002399
14
ENGINE SPECIFICATION
ITEMS ITEMS SPECIFICATION
Engine Type 4-Cycle Water Cooled, Waste Gate Turbocharge, Air to Air Intercooled Direct Injection
Engine Emission US EPA Tier 4i (EU Stage IIIB)
Engine Maker and Model DC 13
Engine Injection System Extra high-pressure fuel injection system, XPI
Engine Rated Net Power 256 kW (339 HP) _at_ 1,800 rpm (SAE J1349)
Valve Clearance Intake Valve 0.45 mm
Valve Clearance Exhaust valve 0.70 mm
Number of cylinders and Configuration 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
Oil Pressure (bar, kg/cm²) 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 low sulfur content)
Oil Filter Paper filter form Scania
Interval between oil changes 500 h
Working Principle 4 Stoke Engine
Cylinder Diameter 130 mm
Piston Stroke 160 mm
Displacement 12.7 dm3
Compression Ratio 17.31
Number of teeth on the flywheel 158
Low Idle Speed 600 - 750 rpm
Max. full load speed 2100 rpm
Weight, without Coolant and Oil 1050 kg
Cooling System Volume, excluding radiator 16 dm3
Cooling System Coolant Temperature 80 - 90
Cooling System Number of Thermostats 1
Cooling System Thermostat, Opening Temperature 2,100 ? 50
Electrical System Type 1-pin, 24V, DC
Electrical System Starter Motor (Standard Equipment) 1-pin, 24V, 5.5 kW
Electrical System Alternator (Standard Equipment) 1-pin, 28V, 100 A
SP002399 Page 19
Engine
15
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.
FG020236
Figure 8

1. Fasten the lifting chain 98 094 to the rear
   lifting eyes 99 637.
2. 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.
max 30
7. Undo the engine insulator bolts and lift
away/out the engine.
max 20 FG020237
Figure 9
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. The
lifting eyes 99 637 are designed to manage a
maximum inclination angle of 30 when lifting an
engine.

max 30
NOTE
max 20

1. Fasten the lever block 587 308 to the front
   lifting eye.
2. Lift the engine, position it on the engine
   insulators and screw it into place.

FG020237
Figure 10
Engine Page 20
SP002399
16

1. Attach the cable harness with clamping.
2. Install the connections for coolant, charge air
   pipes between engine and charge air cooler, and
   bleed pipe for the expansion tank.
3. Install the air filter and inlet pipe between the
   turbocharger and air filter.
4. Fill with oil and coolant as directed in booklet
   0003-01.
5. Test run the engine to check that no leakage
   occurs. Top up with coolant if necessary.

SP002399 Page 21
Engine
17
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.
Engine Page 22
SP002399
18
CYLINDER Cylinder Head

• Removal
• If the engine has EGR
• Remove water-cooled EGR cooler as instructed in
  the work description for Removing the
  water-cooled EGR cooler.
• Remove brackets for the water-cooled EGR cooler.
• Remove bolts for the exhaust manifold on the
  relevant cylinder and slacken the bolts on the
  adjacent cylinders so the relevant part of the
  exhaust manifold comes loose.
• Remove cooling system bleeder hose, separate the
  quick release coupling at the front lifting eye.
• Remove cable duct from the intake.
• Remove cable ties for the cable harness from the
  engine control unit.

IMPORTANT
The fuel system components are extremely
sensitive to dirt. Clean thoroughly before
dismantling and plug all connections with
lint-free rags and tape.

1. Depressurize the fuel system and detach the fuel
   pipe running between the accumulator and fuel
   manifold.
2. Detach the fuel manifold and remove bolts on the
   relevant cylinder.
3. Detach the intake manifold and remove bolts on
   the relevant cylinder.

7 9 8
IMPORTANT
FG020250
All parts in the fuel injection system and valve
mechanism should be marked. Everything must be
reinstalled in the same position.
Figure 11
9. Remove injectors as instructed in the work
description for Removing the injectors. Also
remove high-pressure pipes and connection on the
cylinder head at the back viewed from the coolant
pump.
SP002399 Page 31
Engine
19
IMPORTANT
If work is done on the 6th cylinder of an engine
with an EGR system, the EGR valve control
cylinder must be detached at the damper and
removed. 10. Remove upper rocker cover and then
the rocker arm housing, valve bridges and
pushrods.
FG020251
Figure 12 11. Pull the cable harness out of the
lower rocker cover and remove it.
NOTE
Take care when pulling the cable harness out of
the rocker cover the cable terminals can be
damaged which can cause the nut securing the
cable harness to the injector to come loose.

1. Work on the adjacent cylinders. Remove upper
   rocker cover, release the cable harness and the
   lower rocker cover so it can be moved.
2. Remove relevant cylinder head. Be careful with
   the adjacent rocker covers.

FG020252
Figure 13
NOTE
Mark the cylinder heads if more than one is
being removed at the same time. If all cylinder
heads are removed at the same time, the
turbocharger must be removed or supported
against the frame.
NOTE

• Installing
• Check the liner height as described in the work
  description for Checking the liner height.
• Clean the cylinder head and cylinder block.
  Lubricate the threads and below the heads of the
  cylinder head bolts.
• Install a new cylinder head gasket.
• Install the cylinder head.

Engine Page 32
SP002399
20
5. Tighten the cylinder head as shown in the
illustration and according to specification. Cyli
nder head bolts can only be reused three times.
Make a mark with a center punch on the head of
the bolt. If any of the bolts already has three
marks, it must be replaced.
1
5
3
4
6
2
FG020253
Figure 14
1
2
3
4
FG020254
Figure 15 6. Tighten the intake manifold. Use a
new gasket. Tighten the bolts in the order 1-20
or 1-24 as illustrated. Tighten the bolts in the
same order again. 2 4 6 8 10 12 14 16 18 20
1
3 5
7 9 11 13 15 17 19
FG020255

• Figure 16
• Tighten the intake manifold and the exhaust
  manifold. Use new gaskets.
• Install the cable bracket bolt in the lower
  rocker cover and install the following parts

2

• Lower rocker cover.
• Pushrods.
• Valve bridge.
• Rocker arm housing.

4 6 8 10 12 14 16 18 20 22 24
1 3 5 7 9 11 13 15 17 19 21 23
FG020256
Figure 17
IMPORTANT
Lubricate the valve bridge and rocker arm
housing with engine oil.
SP002399 Page 33
Engine
21

• Install the injector, high-pressure pipe
  connection and high-pressure pipe as instructed
  in the work description.
• Reset adjacent cylinders.
• Adjust the valve clearance.
• Install the upper rocker covers.
• Install the cooling system vent
• If the engine has an EGR system
• Install the brackets for the water-cooled EGR
  cooler.
• Install the water-cooled EGR cooler as described
  in the work description for Installing the
  water-cooled EGR cooler.
• Removing and Installing Valves

WARNING
AVOID DEATH OR SERIOUS INJURY Wear protective
goggles for eye protection. 1. Removing Valves

1. Remove split collets, valve spring collars,
   springs and valves. Press down the spring using
   tool 99 322 in a press so the collets can be
   removed.
2. Place the valves in a stand so they can be
   reinstalled in the same position in the cylinder
   head.

99 322
FG020258
Figure 18
2. Installing Valves
99 322
NOTE
There are different versions of the combination
valve valve spring collar split collet. Parts
from the different versions must not be mixed
on the same valve.

• Lubricate all parts well with engine oil before
  assembly.
• Insert the valve in the guide. C.
• D.

Install the valve springs and the valve spring
collar. Press together the springs in a press
with tool 99 322 and install the collets. Ensure
that collets are installed in their correct
positions.
FG020259
Figure 19
Engine Page 34
SP002399
22
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• Replacing a Valve Stem Seal
• Remove valve according to the work description
  for Removing valves.
• Remove valve stem seal with a pair of pliers.
• Install the valve.

FG020261
Figure 20 4. Carefully tap a new valve stem seal
into place using tool 99 323 and a hammer.
99 323
FG020262
Figure 21
Replacing the Valve Seats
1. Remove valve seat inserts with an expanding
sleeve from the kit with puller 587 270 (1,
Figure 22). NOTE Insert, for example, an
aluminum sheet between the cylinder head and
counterhold to protect against damage.
1
2
WARNING
FG020266
AVOID DEATH OR SERIOUS INJURY Wear protective
goggles for eye protection from flying metal
parts.
Figure 22
SP002399 Page 35
Engine
24
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