Part of the Doosan Repair Manuals.
Setting valve lash on the Cummins QSM11 calls for 0.36 mm intake and 0.69 mm exhaust. The feeler gauge goes between the top of the crosshead and the rocker lever pad. This Doosan DL450 shop manual (serial 5001 and up) gives you both the torque wrench method and the touch method.
It also covers the ZF 4WG-260-4 power shift transmission and its TCU fault table, the ZF MT-L 3105 axles and the wet multi-disc brakes. Steering, the main control valve, the load isolation system and the articulation center are in there too. If the engine belts look glazed, the belt section tells you whether to adjust them or order a new set.
The book runs in twelve system sections, from Safety to Electrical. When the spanner symbol lights up, you can go straight to the ZF code table without paging through the engine chapters.
What's Inside This Doosan DL450 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 9-54 | Wheel Loader Safety Precautions, Operation, Maintenance, Battery, Towing and Transport Warnings |
| Specifications | 55-72 | Component Locations, General Specifications, Working Range and Dimensions for the DL450 |
| General Maintenance | 73-110 | General Maintenance Procedures, Standard Torques |
| Engine | 111-350 | Cummins QSM11 Engine Service |
| Transmission and Torque Converter | 351-498 | ZF 4WG-260-4 Power Shift Transmission with Torque Converter |
| Transmission Error Codes (ZF) | 499-552 | TCU Display, Table of ZF Fault Codes with Meaning, TCU Reaction and Possible Steps to Repair |
| Axles and Drive Shaft | 553-642 | ZF MT-L 3105 Axles, Drive Shaft |
| Brake | 643-694 | Service Brake, Brake Supply Valve, Parking Brake, Brake Pedal Valve, Accumulator |
| Steering | 695-776 | Steering Unit, Flow Amplifier, Cushion Valve, Emergency Steering |
| Frame and Tanks | 777-812 | Articulation Center, Counterweight, Oil Tank, Fuel Tank |
| Hydraulics | 813-903 | Main Control Valve, Load Isolation System, Cooling System, Pilot System, Hydraulic Schematic |
| Electrical System | 904-1016 | Air Conditioner, Engine Fault Codes, Electrical Schematic |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| DL450 | ||
| Standard bucket capacity (BOT / BOC) | 4.5 m3 (5.9 yd3) / 4.8 m3 (6.3 yd3) | p. 62 |
| Vehicle weight | 25,500 kg (56,218 lb) | p. 62 |
| Engine maker and model | Cummins QSM 11 | p. 62 |
| Engine emission | U.S EPA Tier3 (EU Stage IIIA) | p. 62 |
| Injection system | Unit Injection Controlled by Electronic ECM | p. 62 |
| Max. horse power | 324 ps (238 kw) / 1600 rpm | p. 62 |
| Rated horse power | 305 ps (224 kw) / 1900 rpm | p. 62 |
| Max. torque | 161 kg•m (1,578 N.m) / 1400 rpm | p. 62 |
| Transmission | Full Automatic Power Shift, 4 Forward, 3 Reverse | p. 62 |
| Service brakes | 4 Wheel, Wet Multi Disks, Dual Pedal | p. 62 |
| Parking brake | SAHR, Dry Disk Type | p. 62 |
| Travel speed (1 / 2 / 3 / 4) | 6.5 (4.0) / 12.4 (7.7) / 19.0 (11.8) / 38 (23.6) km/h (MPH) | p. 62 |
| Steering angle | ±40° | p. 62 |
| Safe operating load | 8,100 kg (17,857 lb) | p. 62 |
| Max. breakout force | 23,900 kg (53,797 lb) | p. 62 |
| Maximum gradeability | 30° (58%) | p. 62 |
| Wheel base | 3,550 mm (11' 8") | p. 62 |
| Cummins QSM11 | ||
| Valve lash (intake / exhaust) | 0.36 mm (0.014 in) / 0.69 mm (0.027 in) | p. 187 |
Doosan DL450 Common Problems This Manual Covers
Spanner symbol lit on the transmission display but no fault code shown
Put the transmission in neutral. The TCU only shows the active code in neutral. Look the code up in the ZF table, which gives its meaning, how the TCU reacts and the repair steps. Some faults clear after the TCU powers up again.
Manual Section: Transmission Error Codes (ZF) p. 506Transmission shifts to neutral with a clutch K1 slippage fault
The TCU sees too much speed difference across K1 while it is closed, so it decides the clutch is slipping. Measure the clutch pressure and main pressure first, because the manual names low readings at either one as a cause. Then follow the repair steps listed for that code.
Manual Section: Transmission Error Codes (ZF) p. 538Engine will not start, yellow light on, Cummins code 554 logged
Code 554 (SPN 157 FMI 2) means the ECM sees a fuel pressure signal on injector metering rail 1 that never changes. The engine fault code pages explain the fault and warn about losing starter lockout protection. Use the electrical schematic to trace the sensor circuit.
Manual Section: Electrical System p. 988Engine belts glazed, shiny, cracked or frayed
A glazed or shiny belt surface means the belt has been slipping, so adjust the tension. Replace any belt that is cracked, frayed or missing chunks, and order the new belts before you tear down. The Engine section covers the inspection and adjustment for the QSM11.
Manual Section: Engine p. 170Frequently Asked Questions
What does the spanner symbol on the DL450 transmission display mean?
At least one transmission fault is active. Put the shifter in neutral and the TCU shows the fault code. The ZF table gives the meaning of each code, what the TCU does about it and the repair steps. Some faults clear once the TCU powers back up. p. 506
Why does my loader drop into neutral and show a K1 clutch slippage fault?
With clutch K1 closed, the TCU compares input and output speed. If the difference is out of range, it treats K1 as slipping and shifts to neutral. The manual lists low clutch pressure and low main pressure as causes, so check those pressures before you open the transmission. p. 538
What causes Cummins fault code 554 with the yellow light on?
Code 554 is SPN 157 FMI 2: the pressure reading from injector metering rail 1 is erratic, intermittent or wrong. The ECM sees that the fuel pressure signal never changes. The engine may not start or may lose starter lockout protection. You'll find it in the engine fault code section under Electrical System. p. 988
What are the valve lash settings for the QSM11 in the DL450?
Intake is 0.36 mm (0.014 in) and exhaust is 0.69 mm (0.027 in). The gauge goes between the top of the crosshead and the rocker lever pad. The Engine section describes both the torque wrench method and the touch method, so use whichever one your tools allow. p. 187
Which DL450 machines does this manual fit?
It's Doosan publication K1039661E from 2008, covering DL450 wheel loaders from serial 5001 up. These machines have the Cummins QSM11 Tier 3 / Stage IIIA engine with ECM-controlled unit injection. The Specifications section lists the 8,100 kg safe operating load, the 23,900 kg breakout force and the working range dimensions. p. 62
