PDF Shop Manual Daewoo Doosan Wheel Loader with QSM11 Cummins Engine - 958 KB
This specialized shop manual is an essential resource for technicians working on Daewoo and Doosan wheel loaders equipped with the Cummins QSM11 engine.
It provides extremely detailed, engine-specific information that is not found in a standard machine service manual.
The guide covers everything from fuel system diagnostics and electronic troubleshooting to complete engine overhaul procedures.
With precise specifications and step-by-step instructions, this manual is vital for any major engine repair.
Ensure your Cummins-powered loader is serviced correctly with this expert-level document.
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QSM11 Cummins
Shop Manual
P/N QSM11CUMMINSENG
DOOSAN reserves the right to improve its products continuously, delivering the best possible product to
the marketplace. These improvements can be implemented at any time with no obligation to change
materials previously sold. It is recommended that consumers periodically contact their distributors for most
recent documentation on purchased equipment.
This documentation may include attachments and optional equipment not available in your machine's
package. Please call your distributor for additional items that you may require.
Illustrations used throughout this manual are used only as a representation of the actual piece of
equipment, and may vary from the actual item.
P/N QSM11CUMMINSENG Shop Manual
Copyright DOOSAN 2006
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Important Reference Numbers
Fill in the part name and number in the blank spaces provided
below. This will give you a reference whenever service or
maintenance is required.
Part Name Part Number
Engine Model QSM11
Engine Serial Number (ESN)
Control Parts List (CPL)
Fuel Pump Part Number
Electronic Control Module (ECM)
Electronic Control Module Serial Numbers (ECM)
Filter Part Numbers
Outer 474-00038
Air Cleaner Element
Inner 474-00037
DOOSAN 474-00034B
Lubricating Oil Filter Cummins 3101869 and 3101868
Fleetguard LF9001 or LF9000
DOOSAN 474-00033B
Main Fuel Filter Cummins 3329289
Fleetguard FS1000
DOOSAN K1006519
Pre-Fuel Filter with Fuel-Water Separator
Mann-Hummel 66 606 62 200
DOOSAN 474-00020B
Coolant Filter Cummins 3100308
Fleetguard WF2075
QSM11 Cummins Engine QSM11CUMMINSENG
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If particles that are smaller than the clearance between the
parts while they are at rest (engine stopped), but larger than
the running clearance then damage will occur when the
parts move relative to each other (engine started). While the
engine is running and there is oil pressure, particles that are
smaller than the bearing clearance are likely to pass
between the parts without damage and be trapped in the oil
filter. However, particles larger than the bearing clearance will
remove material from one part and can become embedded in
one of the parts. Once embedded in one part it will abrade the
other part until contact is no longer being made between the two
parts. If the damage sufficiently degrades the oil film, the two
parts will come into contact resulting in early wear out or failure
from lack of effective lubrication.
Abrasive particles can fly about during cleaning it is very
important to block these particles from entering the engine
as much as possible. This is particularly true of lubricating
oil ports and oil drilling holes, especially those located
downstream of the lubricating oil filters. Plug the holes
instead of trying to blow the abrasive particles and debris
with compressed air because the debris is often simply
blown further into the oil drilling.
All old gasket material must be removed from the parts
gasket surfaces. However, it is not necessary to clean and
polish the gasket surface until the machining marks are
erased. Excessive sanding or buffing can damage the
gasket surface. Many newer gaskets are of the edge molded
type (a steel carrier with a sealing member bonded to the
steel). What little sealing material that can adhere is best
removed with a blunt-edged scraper or putty knife. Cleaning
gasket surfaces where an edge-molded gasket is used with
abrasive pads or paper is usually a waste of time.
WARNING!
Excessive sanding or grinding the carbon ring from the
top of the cylinder liners can damage the liner beyond
reuse. The surface finish will be damaged and abrasive
particles can be forced into the liner material which can
cause early cylinder wear out or piston ring failures.
Tape off or plug all openings to any component interior
before using abrasive pads or wire brushes. If really
necessary because of time to use a power tool with
abrasive pads, tape the oil drillings closed or use plug and
clean as much of the surface as possible with the tool but
clean around the oil hole/opening by hand so as to prevent
contamination of the drilling.
QSM11 Cummins Engine QSM11CUMMINSENG
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Figure 10 Industrial Drive - Fuel Pump Side
Reference Reference
Description Description
Number Number
1 ECM cooling plate 12 CentinelTM (Optional)
2 ECM 13 Fuel Inlet to Pump
3 Compressor Air Inlet 14 Fuel Filter
(not Used)
15 Rail Pressure
4 Blowby Measurement
16 Power Steering Pump Mounting
5 Ambient Air Pressure Sensor Location (not Used)
6 Fuel Return to Tank 17 Oil Pressure and Temperature
7 Engine Data Tag Sensor
8 Engine Serial Number 18 Engine Position Sensor
9 Starter 19 Freon Compressor Mounting
10 Flywheel Ring Gear Speed Location
Sensor 20 Compressor Air Discharge
11 Side Oil Drain (not Used)
QSM11 Cummins Engine QSM11CUMMINSENG
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CAUTION!
Do not operate the engine beyond the maximum engine
speed. Operating the engine beyond the maximum
engine speed can cause severe engine damage. Use
proper operating techniques for the vehicle, vessel, or
equipment to prevent engine overspeed. The maximum
engine speed specification is listed in Maintenance
Specifications (Section V).
Engine Shutdown
For engines with shielded exhaust manifold and turbochargers,
allow the engine(s) to idle for 10 - 12 minutes before shutting off
after full load operation.
Otherwise, allow the engine(s) to idle 3 - 5 minutes before
shutting off after full load operation. This allows the cool down of
pistons, cylinders, bearings and turbocharger components.
If the engine does not shut down, refer to Troubleshooting
Symptom (Section TS).
Turn the starter switch to the "OFF" position.
Electronic Controlled Fuel System
General Information
The system is an electronically controlled fuel injection system
that optimizes fuel economy and reduces exhaust emissions. It
does this by controlling the torque and horsepower curve, AFC
function, engine high-speed, low idle, and road speed.
Figure 27
QSM11 Cummins Engine QSM11CUMMINSENG
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CAUTION!
Select the correct oil change interval for your
application. Cummins Engine Company, does not
recommend exceeding these published intervals and is
not responsible for damage sustained due to
overextended drain intervals.
The maintenance monitor automatic mode is easily adjusted to
accommodate severe-, normal-, or light-duty applications and Figure 55
Valvoline® Premium Blue 2000TM, engine oil. This is done by
using a CompulinkTM, or EchekTM, service tool to enter an
interval factor that corresponds to the appropriate duty cycle and
type of product used.
When selecting the correct interval factor for your application,
refer to 102-002 (Maintenance Schedule) in Section 2, to
determine which oil drain interval duty cycle fits your application:
Severe duty, normal duty, or light duty. Once the duty cycle is
chosen, use an interval factor of 1.00 for severe duty, 1.50 for
normal duty, and 2.00 for light duty.
NOTE: These interval factors must be adjusted accordingly if
Valvolive® Premium Blue® 2000 oil is used to extend
the oil drain interval. See the Valvolive® Premium
Blue® 2000 product literature to determine how much
your drain interval can be extended.
The time mode allows the customer to enter a desired time
interval. The maintenance monitor will then monitor the time the
engine has been operating and alert the operator when the
interval has been consumed.
Alerting the operator: The maintenance monitor will alert the
operator of the need to change oil by flashing the engine
maintenance indicator light for approximately 12 seconds after
key-on. The flashing sequence will be three quick flashes,
followed by a pause. This flash sequence will go through five
cycles in the 12-second period. This sequence will occur at
every key-on until the maintenance monitor has been reset.
NOTE: The diagnostic switch must be in the "OFF" position
for the flashing sequence to occur.
Figure 56
QSM11 Cummins Engine QSM11CUMMINSENG
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Fan, Cooling
Inspect for Reuse
A visual inspection of the cooling fan is required daily. Check for
cracks, loose rivets, and bent or loose blades. Check the fan to
make sure it is securely mounted. Tighten the cap screws, if
necessary.
Figure 65
WARNING!
Do not straighten a bent fan blade or continue to use a
damaged fan. A bent or damaged fan blade can fail
during operation and cause personal injury or property
damage.
Figure 66
Replace original equipment fan that is damaged with a fan of the
identical part number. Cummins Inc. must approve any other fan
changes to be covered under warranty.
Refer to the vehicle or equipment manufacturer's specifications
for cap screw torque.
Figure 67
QSM11 Cummins Engine QSM11CUMMINSENG
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Remove
WARNING!
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C (120F)
before removing the pressure cap. Heated coolant spray
or steam can cause personal injury.
Remove the cooling system pressure cap.
Figure 93
Turn the valve on the remote-mounted coolant filter head to the
"OFF" position.
Figure 94
Turn the valve on the coolant filter head to the "OFF" position.
Figure 95
WARNING!
A small amount of coolant can leak when servicing the
coolant filter with the shutoff valve in the "OFF" position. To
reduce the possibility of personal injury, avoid contact with
hot coolant.
Remove and discard the coolant filter.
Using a lint free cloth, clean the coolant filter head gasket's
surface. Figure 96
QSM11 Cummins Engine QSM11CUMMINSENG
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If the valve cover gasket was not been damaged, it can be used
again. If the gasket was damaged, it must be discarded and a
new one used.
Install the gasket on the cover.
Figure 122
Install the cover on the rocker lever housing.
install the 16 isolators, spacers, and cap screws in the cover.
Tighten the cap screws in the sequence shown.
Torque Value: 15 Nm [130 in lb]
Figure 123
QSM11 Cummins Engine QSM11CUMMINSENG
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Cooling System
General Information
Restore™, is a heavy-duty cooling system cleaner that removes
corrosion, silica gel, and other deposits. The performance of
Restore™, is dependent on time, temperature, and
concentration levels. An extremely scaled or flow-restricted
system, for example, can require higher concentrations of
cleaners, higher temperatures, or longer cleaning times, or the
use of Restore Plus™‚. Up to twice the recommended
concentration levels of Restore™, can be used safely. Restore Figure 149
Plus™, must be used only at its recommended concentration
level. Extremely scaled or fouled systems can require more than
one cleaning.
Clean
WARNING!
Do not remove the pressure cap from a hot engine.
Wait until the coolant temperature is below 50°C (120°F)
before removing the pressure cap. Heated coolant spray
or steam can cause personal injury.
Remove the radiator cap.
Figure 150
WARNING!
Coolant is toxic. Keep away from children and pets. If
not reused, dispose of in accordance with local
environmental regulations.
Drain the cooling system. Do not allow the cooling system to dry
out.
Do not remove the coolant filter.
Figure 151
QSM11 Cummins Engine QSM11CUMMINSENG
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Belt drive systems equipped with an automatic belt tensioner
cannot be adjusted. A belt tension gauge will not give an
accurate measure of the belt tension. The automatic belt
tensioner is designed to maintain proper belt tension over the life
of the belt. Only inspection of the tensioner is required.
The belt tensioner is designed to operate within the limit of arm
movement provided by the cast stops when the belt length and
geometry are correct.
If the tensioner is hitting either of the limits during operation,
check the mounting brackets and the belt length. Loose
brackets, bracket failure, alternator movement, incorrect belt
Figure 181
length, or belt failure can cause the tensioner to hit the limits.
NOTE: If the engine is equipped with a secondary alternator,
reference to the vehicle manufacturer for the
secondary alternator belt adjustment procedure.
QSM11 Cummins Engine QSM11CUMMINSENG
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Install the thermostat in the housing.
Install a new seal in the groove on the thermostat housing
mounting surface.
Figure 214
Install the hose on the thermostat housing bypass outlet.
Install the thermostat housing and four mounting cap screws.
Torque Value: 54 Nm [40 ft lb]
Figure 215
Equally space the bypass hose over the water pump connection
and thermostat housing connection, and tighten the bypass
hose clamps.
Torque Value: 3 Nm [27 in lb]
Install the upper and lower coolant hoses. Refer to the OEM's
specifications for the correct torque value.
Figure 216
The oil seal must be installed with the lip of the seal and the
shaft clean and dry. Do not lubricate. The yellow dust lip must be
facing out.
Install the new gasket and oil seal. Use the installation sleeve
provided with the new seal to install the seal.
The cap screw threads must be coated with thread sealant, Part
No. 3823494, or equivalent, to prevent oil leakage.
Torque Value: Step1 7 Nm [62 in lb]
Step2 20 Nm [177 in lb]
Figure 217
QSM11 Cummins Engine QSM11CUMMINSENG
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SYSTEM DIAGRAMS
System Diagrams - Overview
General Information
The following drawings show the flow through the engine
systems. Although parts can change between different
applications and installations, the flow remains the same. The
systems shown are:
• Fuel System
• Lubricating Oil System
• Coolant System
• Intake Air System
• Exhaust System
Knowledge of the engine systems can help you in
troubleshooting, service, and general maintenance of your
engine.
QSM11 Cummins Engine QSM11CUMMINSENG
Page 119
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Information we need to take your Customized Parts Catalog
Order. This information drives the cover content of the CPC.
• Customer Name
• Street Address
• Company Name (optional)
• Telephone no.
• Credit Card No.
• Cummins Engine Serial Number (located on the
engine data plate)
• Please identify the required media: Printed Catalog,
CD-ROM, or PDF File
Unfortunately not all Cummins Engines can be supported by this
parts catalog. Engines older than 1984 or newer than 3 months
may not have the necessary parts information to compile a
catalog. We will contact you if this occurs and explain why we
are unable to fill your order.
Customized Parts Catalogs are produced specifically for a single
customer. This means they are not returnable for a refund. If we
make an error and your catalog is not usable, we will correct that
error by sending you a new catalog.
QSM11 Cummins Engine QSM11CUMMINSENG
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California Fresno Branch Cummins West, Inc.
2740 Church Avenue Fresno, CA 93706
Telephone: (209) 495-4745
FAX: (209) 486-7402
California Redding Branch Cummins West, Inc.
20247 Charlanne Drive Redding, CA 96001
Telephone: (916) 222-4070
FAX: (916) 224-4075
California Stockton Branch Cummins West, Inc.
41 West Yokuts Avenue Suite 131
Stockton, CA 95207
Telephone: (209) 473-0386
FAX: (209) 478-2454
California West Sacramento Cummins West, Inc.
Branch 2661 Evergreen Avenue
West Sacramento, CA 95691
Telephone: (916) 371-0630
FAX: (916) 371-2849
California Los Angeles Distributor Cummins Cal Pacific Inc.
1939 Deere Avenue (Irvine) Irvine, CA 92606
Telephone: (949) 253-6000
FAX: (949) 253-6080
California Montebello Branch Cummins Cal Pacific Inc.
1105 South Greenwood Avenue
Montebello, CA 90640
Telephone: (323) 728-8111
FAX: (323) 889-7422
California Bloomington Branch Cummins Cal Pacific Inc.
3061 S. Riverside Avenue Bloomington, CA 92377
Telephone: (909) 877-0433
FAX: (909) 877-3787
California San Diego Branch Cummins Cal Pacific Inc.
310 N. Johnson Avenue El Cajon, CA 92020
Telephone: (619) 593-3093
FAX: (619) 593-0600
California Ventura Branch Cummins Cal-Pacific Inc.
3958 Transport St. Ventura, CA 93003
Telephone: (805) 644-7281
FAX: (805) 644-7284
Colorado Denver Distributor Cummins Rocky Mountain, Inc.
5100 East 58th Avenue Commerce City, CO 80022
Telephone: (303) 287-0201
FAX: (303) 288-7080
Colorado Denver Onan/Industrial Cummins Rocky Mountain, Inc.
5100 East 58th Ave. Commerce City, CO 80022
Branch
Telephone: (303) 286-7697
FAX: (303) 287-4837
Colorado Durango Branch Cummins Rocky Mountain, Inc.
13595 County Road 213 Durango, CO 81301
Telephone: (970) 259-7470
FAX: (970) 259-7482
QSM11 Cummins Engine QSM11CUMMINSENG
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Pennsylvania Pittsburgh Branch Cummins Power Systems, Inc.
3 Alpha Drive Pittsburgh, PA 15238-2901
Telephone: (412) 820-8300
FAX: (412) 820-8308
Pennsylvania Harrisburg Branch Cummins Power Systems, Inc.
4499 Lewis Road Harrisburg, PA 17111-2541
Telephone: (717) 564-1344
FAX: (717) 558-8217
Puerto Rico Puerto Nuevo - (Branch Cummins Diesel Power, Inc.
of Tampa) #31 Calle "C" El Matadero
Puerto Nuevo, Puerto Rico 00920
Telephone: (787) 793-0300
FAX: (787) 793-1072
South Carolina Charleston - (Branch of Cummins Atlantic, Inc.
Charlotte) 3028 West Montague Avenue
Charleston, SC 29418-5593
Telephone: (843) 554-5112
FAX: (843) 745-0745
South Carolina Charleston - (Branch of Cummins Atlantic Inc.
Charlotte) 231 Farmington Road Charleston, SC 29483
Telephone: (843) 851-9819
FAX: (843) 875-4338
South Carolina Columbia - (Branch of Cummins Atlantic, Inc.
Charlotte) 1233 Bluff Road (29201) P.O. Box 13543
Columbia, SC 29201-3543
Telephone: (803) 799-2410
FAX: (803) 779-3427
South Dakota Sioux Falls - (Branch of Cummins Great Plains Diesel, Inc.
Omaha) 701 East 54th Street North Sioux Falls, SD 57104
Telephone: (605) 336-1715
FAX: (605) 336-1748
Tennessee Memphis Distributor Cummins Mid-South, Inc.
and Distribution Center 666 Riverside Drive Memphis, TN 38703
Telephone: (901) 577-0666
FAX: (901) 522-8758
Tennessee Chattanooga - (Branch Cummins South, Inc.
of Atlanta) 1509 East 26th Street Chattanooga, TN 37407-1095
Telephone: (615) 629-1447
FAX: (615) 629-1494
Tennessee Knoxville - (Branch of Cummins Cumberland, Inc.
Louisville) 1211 Ault Road Knoxville, TN 37914
Telephone: (423) 523-0446
FAX: (423) 523-0343
Tennessee Memphis Branch Cummins Mid-South, Inc.
1784 E. Brooks Road Memphis, TN 38116
Telephone:
Sales/Admin.: (901) 345-7424
Parts: (901) 345-1784
Service: (901) 345-6185
FAX: (901) 346-4735
QSM11 Cummins Engine QSM11CUMMINSENG
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Distributors and Branches - New Zealand
Auckland Cummins Engine Company, Pty. Ltd.
Private Bag 92804
Penrose, Auckland, New Zealand
Location:
440 Church Street Penrose
Telephone: (64-9) 579-0085
Branches: Auckland Cummins Engine Company, Pty. Ltd.
Private Bag 92804
Penrose, Auckland, New Zealand
Location:
440 Church Street Penrose
Telephone: (64-9) 579-0085
Branches: Christchurch Cummins Engine Company, Pty. Ltd.
P.O. Box 16-149
Hornby, Christchurch, New Zealand
Location:
35 Parkhouse Road Sockburn, Christchurch
Telephone: (64-3) 348-8170
Branches: Dunedin Cummins Engine Company, Pty. Ltd.
P.O. Box 2333 South Dunedin, New Zealand
Location:
8 Devon Street Dunedin
Telephone: (643) 477-8818
Branches: Palmerston North Cummins Engine Company, Pty. Ltd.
P.O. Box 9024 Palmerston North, New Zealand
Location:
852-860 Tremaine Avenue
Telephone: (64-6) 356-2209
Branches: Rotorua Cummins Engine Company, Pty. Ltd.
P.O. Box 934 Rotorua, New Zealand
Location:
328 Te Ngae Road Rotorua
Telephone: (647) 345-6699
QSM11 Cummins Engine QSM11CUMMINSENG
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BRAZIL Porto Alegre Distribuidora Cummins
Meridional S.A. Rua Dona Alzira, 98, Sarandi
91110-010 Porto Alegre, Rio Grande do Sul, Brazil
Telephone: (55-51) 340-8222
BRAZIL Rio de Janeiro Distribuidora Cummins
Leste Ltda. Rua Sariema, 138-Olaria
21030-550 Rio de Janeiro, Rio de Janeiro, Brazil
Telephone: (55-21) 290-7899
BRAZIL Sao Paulo Companhia Distribuidora de Motores Cummins
Rua Martin Burchard, 291 - Bras
03043-020 Sao Paulo, Sao Paulo, Brazil
Telephone: (55-11) 270-2311
BRITISH VIRGIN - See Puerto Rico
ISLANDS
BRUNEI - See Malaysia
BURKINA - FASO - See North/West/East and Central Africa Regional
Office - Daventry
BULGARIA -See Germany Regional Office - Gross-Gerau
BURMA Kuala Lumpur (Office In Contact: Scott and English (M) Sdn Bhd
Malaysia) P.O. Box 10324 50710 Kuala Lumpur
West Malaysia
Location:
16 Jalan Chan Sow Lin 55200 Kuala Lumpur
West Malaysia
Telephone: (60-3) 2211033
BURUNDI Brussels (Office in Bia, S.A.
Belgium) Rameistraat, 123
B-3090 - Overijse, Belgium
Telephone: (32-2) 6892811
CAMBODIA - See South and East Asia Regional Office -
Singapore
CANARY ISLANDS Madrid (Office in Spain) Cummins Ventas y
Servicio, S.A.
Torrelaquna, 56
28027 Madrid, Spain
Telephone: (34-91) 3672000/3672404
CAPE VERDE - See ECV Portugal
CENTRAL AFRICAN - See North/West Africa Regional Office - Daventry
REPUBLIC
CEYLON - See Sri Lanka
CHAD - See North/West/East and Central Africa Regional
Office - Daventry
CHILE Santiago Distribuidora Cummins Diesel S.A.C.I.
Casilla Postal 1230 Calle Bulnes 1203
Santiago, Chile
Corporate Office:
Av. Providencia 2653, Office 1901 Santiago,
Chile
Telephone: (56-2) 698-2113/4/5,
697-3566/7/8, 697-2709