This document provides instructions for servicing components of a DOOSAN DL450-3 wheel loader engine, including removing and installing the engine, cylinder head, intake and exhaust manifolds, fuel system components, and other parts. Safety warnings indicate potential hazards and precautions are required when servicing the engine. Tables provide engine specifications and tightening torques for screws, nuts and other fasteners. Detailed steps and diagrams illustrate the service procedures.

1. Original InstructionsCopyright DOOSAN 2012
Serial Number 10001 and Up
Shop Manual
DL450-3 Wheel Loader
950106-00414E
January 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 DL450-3 ..................................................................... SP002398
General Maintenance
General Maintenance Instructions........................................................ SP002454
Standard Torques................................................................................. SP002404
Engine
Engine................................................................................................... SP002399
Engine Coolant Heater (Option) ........................................................... SP002328
Drivetrain
Transmission 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
Accumulator.......................................................................................... SP002431

3. Table of Contents
Page II
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
Counterweight....................................................................................... 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

4. SP002397
Page 1
Wheel Loader Safety
SP002397
WHEEL LOADER SAFETYSP002397
Wheel Loader
Safety
Edition 1

5. 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

6. 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
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

7. 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 should 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.

8. SP002399
Page 1
Engine
SP002399
ENGINE SP002399
Engine
Edition 1

9. SP002399
Page 5
Engine
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
DL350-3 10001 and Up
DL420-3 10001 and Up
DL450-3 10001 and Up

10. SP002399Engine
Page 6
DC13 ENGINE
Figure 1

11. SP002399
Page 17
Engine
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

12. SP002399Engine
Page 18
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)

13. SP002399
Page 19
Engine
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 DC 13
Injection System Extra high-pressure fuel injection system, XPI
Rated Net Power 256 kW (339 HP) @ 1,800 rpm (SAE J1349)
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 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 17.3:1
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
Coolant Temperature 80 - 90
Number of Thermostats 1
Thermostat, Opening
Temperature
2,100 ±50
Electrical System Type 1-pin, 24V, DC
Starter Motor (Standard
Equipment)
1-pin, 24V, 5.5 kW
Alternator
(Standard Equipment)
1-pin, 28V, 100 A

14. SP002399Engine
Page 20
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

15. SP002399
Page 21
Engine
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.

16. SP002399Engine
Page 22
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.

17. SP002399
Page 31
Engine
CYLINDER
Cylinder Head
Removal
1. 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.
2. 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.
3. Remove cooling system bleeder hose, separate the quick
release coupling at the front lifting eye.
4. Remove cable duct from the intake.
5. Remove cable ties for the cable harness from the engine
control unit.
6. Depressurize the fuel system and detach the fuel pipe
running between the accumulator and fuel manifold.
7. Detach the fuel manifold and remove bolts on the relevant
cylinder.
8. Detach the intake manifold and remove bolts on the
relevant cylinder.
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.
IMPORTANT
The fuel system components are extremely sensitive
to dirt. Clean thoroughly before dismantling and plug
all connections with lint-free rags and tape.
897
FG020250
Figure 11
IMPORTANT
All parts in the fuel injection system and valve
mechanism should be marked.
Everything must be reinstalled in the same position.

18. SP002399Engine
Page 32
10. Remove upper rocker cover and then the rocker arm
housing, valve bridges and pushrods.
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.
12. Work on the adjacent cylinders. Remove upper rocker
cover, release the cable harness and the lower rocker
cover so it can be moved.
13. Remove relevant cylinder head. Be careful with the
adjacent rocker covers.
NOTE: Mark the cylinder heads if more than one is
being removed at the same time.
NOTE: If all cylinder heads are removed at the same
time, the turbocharger must be removed or
supported against the frame.
Installing
1. Check the liner height as described in the work description
for Checking the liner height.
2. Clean the cylinder head and cylinder block. Lubricate the
threads and below the heads of the cylinder head bolts.
3. Install a new cylinder head gasket.
4. Install the cylinder head.
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.
FG020251
Figure 12
FG020252
Figure 13

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20. SP002399
Page 33
Engine
5. Tighten the cylinder head as shown in the illustration and
according to specification.
Cylinder 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.
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.
7. Tighten the intake manifold and the exhaust manifold. Use
new gaskets.
8. Install the cable bracket bolt in the lower rocker cover and
install the following parts:
• Lower rocker cover.
• Pushrods.
• Valve bridge.
• Rocker arm housing.
1
2
3
4
5
6
FG020253
Figure 14
FG020254
1 2 3 4
Figure 15
1 3 5 7 9 11 13 15 17 19
2 4 6 8 10 12 14 16 18 20
FG020255
Figure 16
2
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.

21. SP002399Engine
Page 34
9. Install the injector, high-pressure pipe connection and
high-pressure pipe as instructed in the work description.
10. Reset adjacent cylinders.
11. Adjust the valve clearance.
12. Install the upper rocker covers.
13. Install the cooling system vent
14. 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
1. Removing Valves
A. 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.
B. Place the valves in a stand so they can be reinstalled
in the same position in the cylinder head.
2. Installing Valves
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.
A. Lubricate all parts well with engine oil before
assembly.
B. Insert the valve in the guide.
C. Install the valve springs and the valve spring collar.
D. Press together the springs in a press with tool 99 322
and install the collets. Ensure that collets are installed
in their correct positions.
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear protective goggles for eye protection.
99 322
FG020258
Figure 18
FG020259
99 322
Figure 19

22. SP002399
Page 35
Engine
Replacing a Valve Stem Seal
1. Remove valve according to the work description for
Removing valves.
2. Remove valve stem seal with a pair of pliers.
3. Install the valve.
4. Carefully tap a new valve stem seal into place using tool 99
323 and a hammer.
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.
FG020261
Figure 20
99 323
FG020262
Figure 21
2
1
FG020266
Figure 22
WARNING
AVOID DEATH OR SERIOUS INJURY
Wear protective goggles for eye protection from flying
metal parts.