Daewoo Doosan ADT DA30-5 DA40-5 Operation & Maintenance Manual MX533497 – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan ADT DA30-5 DA40-5 Operation & Maintenance Manual MX533497 – PDF DOWNLOAD
Foreword
- This manual provides rules and guidelines which will help you use this dump truck safely and effectively. This manual describes procedures for operating, handling, lubricating, maintenance, checking and adjustment. It will help the operator to achieve peak performance through effective, economical and safe dump truck operation and maintenance. • Keep this manual in the dump truck at all times and ensure that all personnel read it carefully before operating the dump truck.
- Continue studying the manual until proper operating procedures are completely adopted as personal habit. • This manual describes the basic techniques. The operator’s skill will increase with correct knowledge of dump truck operation. • Operation, inspection and maintenance should be carefully carried out, and safety must be given first priority. If this manual has been lost or has become dirty and cannot be read, request a replacement manual from your local Doosan Dealer.
- If you sell the dump truck, be sure to give this manual to the new owners. Doosan Infracore Norway AS cannot be held responsible for damage or injury caused through use of improper spare parts not specified by Doosan Infracore Norway AS, improper handling, operation and utilisation of the dump truck in other ways than those described in this manual. Doosan Infracore Norway AS cannot be held responsible for unauthorised modifications or the non-adherence to local, national government or international regulations. This Operation & Maintenance Manual may contain standard extra equipment and optional accessories that are not available in your area.
- Please consult your local Doosan Dealer for those items you may require. Doosan Infracore Norway AS aim to continuously improve the dump trucks and therefore retain the right to make design changes and improvements whenever we feel it will improve the efficiency of the dump truck. Doosan Infracore Norway AS also reserves the right to change data and equipment without prior notice, as well as amending instructions for maintenance and other service measures.
WARNING:
- This dump truck complies with EC directives 2006/42/EC (Machinery Directive) with amendments, 2000/14/EC (Noise Emission Directive) with amendments, 2004/108/EC (Electronic Compatibility) with amendments and 2004/26/EC (Exhaust Gas Emission) with amendments. Dump trucks complying with the directives display the CE mark. The dump truck must not be modified in such a way that it no longer complies with the EC – directive.
- Improper operation and maintenance of this dump truck can be hazardous and could result in serious injury or death. • Operators and maintenance personnel should read this manual thoroughly before operation or maintenance.
- Some actions involved in operation and maintenance of the dump truck can cause serious accidents, if they are not carried out in a manner described in this manual. • The procedures and precautions given in this manual apply only to intended uses of the dump truck. If you use your dump truck for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in the prohibited uses or actions which are described in this manual.
- Doosan Infracore Norway AS delivers dump trucks that comply with all applicable regulations and standards of the country to which it has been shipped. If this dump truck has been purchased in another country or purchase from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country.
- If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local Doosan Dealer before operating the dump truck. • Safety descriptions are given in SAFETY INFORMATION on page 12 and in SAFETY INSTRUCTION, chapter 2.
Product information
Machine capacity Do not exceed machine capacity by modifying machine or using unapproved attachments. Exceeding machine capacity can adversely affect machine performance characteristics such as: stability, system certifications such as brakes and steering, the Roll-over Protective Structure (ROPS) and can result in death or serious injury. Contact your DOOSAN distributor for further information.
Engine and emission control system maintenance
Proper inspection, maintenance and repair is essential to keeping engine and machine systems properly operating. This includes proper inspection and maintenance of the machine’s emission control system. This could include machine and engine components, such as an EGR (Exhaust Gas Recirculation) system, fuel system, turbocharger, electrical system, air intake system and or cooling system. As a heavy-duty off-road diesel engine owner, you are responsible for performing required maintenance. The required maintenance procedures are outlined in this Operation & Maintenance Manual, or Shop Manual. Do not remove, alter, or render inoperative, any emission control system.
Introduction
Intended use
This Doosan articulated dump truck is designed to be used mainly for earth moving at sites, both on and off road conditions. The basic machine is intended to be used under normal conditions, that is, outdoors, above ground, off road, for earth moving, and in an ambient temperature between -25°C and +45°C with maintained performance. Conditions that deviate from this are also described in this manual. For use on public roads, the machine must be adapted according to governing national legislation (only DA30). If it is used for other purposes or in potentially dangerous environments such as explosive atmosphere, areas with dust that contains asbestos, etc., precautions must be taken and the machine must be equipped for such use. Contact the Doosan Dealer for more information. The machine is designed for a maximum machine weight (includes equipment and attachments) of 51,400 kg for DA30 and 70,300 kg for DA40. If the maximum weight is exceeded, no warranties on the part of the manufacturer will apply. However, always pay attention to national regulations for travelling on public roads
General description
Doosan dump truck DA30, DA40 is an articulated, 6-wheel drive dump truck. The free-swinging rear tandem housing, and the special articulation system, provide excellent performance in soft and difficult terrain. The special body design ensures that a low centre of gravity is maintained and an even load distribution to front and rear wheels, for stability on uneven ground and for fast easy tipping of the load. The Doosan dump truck is designed and manufactured to work under difficult conditions. In addition, the wide range of optional equipment allows the dump truck to be used for several different applications.
Environmental requirements
Be aware of the environment when operating and during service and maintenance of the machine. Always follow local and national environmental legislation applicable to all handling of the machine
Engine
- DA30 and DA40 has a Scania DC9 (9,3 litre) and DC13 (12,7 litre) engines. DA30 T4F/Stage IV and DA40 T4F/Stage IV – These engines have an optimised cylinder block containing wet cylinder liners that can easily be exchanged. Individual cylinder heads with 4 valves per cylinder promotes repairability and fuel economy. The engine is equipped with a Scania developed Engine Management System, EMS, in order to ensure the control of all aspects related to engine performance. The injection system is Scania’s XPI (Extra High Pressure Injection), a common rail system that in combination with SCR (Selective Catalytic Reduction) gives low exhaust emissions with good fuel economy and a high torque.
- DA30 T2 and DA40 T2 – These engines have an optimised cylinder block containing wet cylinder liners that can easily be exchanged. Individual cylinder heads with 4 valves per cylinder promotes repairability and fuel economy. The engine is equipped with a Scania developed Engine Management System, EMS, in order to ensure the control of all aspects related to engine performance. The injection system is based on electronically controlled unit injectors that gives low exhaust emissions with good fuel economy and a high torque
TABLE OF CONTENTS:
Daewoo Doosan ADT DA30-5 DA40-5 Operation & Maintenance Manual MX533497 – PDF DOWNLOAD
Foreword 1-5
Introduction 1-6
Doosan ADT payload policy 1-13
Safety messages 1-14
California emission control warranty statement 1-15
2 Safety Instructions 2-1
1 Dump truck knowledge 2-3
2 General precautions 2-3
3 Precautions before starting the engine 2-8
4 When starting the engine 2-10
5 Do not go close to high-voltage cables 2-10
6 Battery hazard prevention 2-11
7 Air conditioning system hazard prevention 2-12
8 Rules to follow when filling fuel or oil 2-13
9 Expansion tank coolant level 2-13
10 Machine turning 2-13
11 Emergency steering 2-14
12 Travelling on slopes 2-14
13 Operation of brakes 2-14
14 Engine over speed (Emergency retarder) 2-15
15 Wading 2-15
16 Dangerous loads 2-16
17 Welding on the dump truck 2-17
18 Top tailgate 2-18
19 Engine bonnet 2-19
20 Tiltable cab 2-19
21 Body support 2-21
22 Service position 2-22
23 Wheel chocks 2-22
24 Articulation lock 2-23
25 Lifting / hoisting 2-23
26 Dump truck transportation 2-24
27 High pressure 2-24
28 Safety labels 2-25
3 Operating Controls 3-1
Overview of the instrument panels and controls 3-3
Instruments 3-5
Monitor warning / indicator symbols and lights 3-9
Groeneveld pump test 3-16
Keypad, buttons and switches 3-18
Cab ventilation 3-21
Controls 3-24
Other cab equipment 3-30
4 Running-in period 4-1
1 Running-in operation 4-3
2 Running-in services 4-4
5 Operating Instructions 5-1
Precautions on work sites 5-3
Some simple rules to be observed
prior to operation 5-6
1 Starting the engine 5-7
2 Operating the dump truck 5-9
3 Parking the dump truck 5-22
4 Stopping the engine 5-22
5 Checks after stopping the engine 5-23
6 Loading and tipping 5-23
7 Tyre handling 5-25
8 Cold weather 5-27
9 Long term storage 5-28
10 Battery power assistance 5-29
11 Towing the dump truck 5-30
12 Manual release of parking brake 5-30
13 Manual release of the ball valve on tilting
circuit 5-31
14 Troubleshooting 5-32
6 Lubricants 6-1
Lubrication schedule DA30 T2/T4/Stage 4 6-3
Overview of oil and lubrication points (DA30
T2/T4/Stage 4 6-4
Oil specification sheet (DA30 T2/T4/Stage 4 6-5
Filling capacities (DA30 T2/T4/Stage 4 6-6
Lubrication schedule (DA40 T2/T4/Stage 4 6-7
Overview of oil and lubrication points
(DA40 T2/T4/Stage 4 6-8
Oil specification sheet (DA40 T2/T4/Stage 4 6-9
Filling capacities (DA40 T2/T4/Stage 4 6-10
Transmission oil list 6-11
Axles oil list 6-14
Operation & Maintenance Manual 1-3
Table of contents 1 Foreword
7 Maintenance 7-1
Maintenance precautions 7-3
Maintenance table 7-5
Initial 100 Hours Service 7-8
Initial 500 Hours Service 7-12
8 Hours / Daily Service 7-17
40 Hours / Weekly Service 7-25
500 Hours Service 7-28
1000 Hours Service 7-43
2000 Hours Service 7-57
4000 Hours Service 7-65
Yearly recommended maintenance 7-69
8 Technical Data 8-1
Measurements 8-3
Engine 8-4
Transmission 8-4
Hydraulic system 8-5
Tyre pressures 8-5
Electrical system 8-6
Bulbs 8-7
Metering conversion table 8-7
Tool kit content (standard) 8-7
Tool kit content (optional) 8-7
Rimpull Performance 8-8
Graph of altitude power reduction
DA30 T2/T4/Stage 4 8-10
Graph of altitude power reduction
DA40 T2/T4/Stage 4 8-11
Engine and retarder brake capacity chart 8-12
Torque limits for bolts 8-13
Reference information 8-13
Consumable parts 8-13
Product signs 8-14
Periodic service 8-16
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