Daewoo Doosan ADT DA30-5 DA40-5 Operation & Maintenance Manual – PDF DOWNLOAD

Description

Daewoo Doosan ADT DA30-5 DA40-5 Operation & Maintenance Manual – PDF DOWNLOAD

DESCRIPTION:

Daewoo Doosan ADT DA30-5 DA40-5 Operation & Maintenance Manual – 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 utilization of the dump truck in other ways than those described in this manual.
• Doosan Infracore Norway AS cannot be held responsible for unauthorized 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 – directives. •
• 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 purchased 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 1-14 and in SAFETY INSTRUCTION, chapter 2. 1-6 Operation & Maintenance Manual 1. Foreword 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. 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 your 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.

TABLE OF CONTENTS:

Daewoo Doosan ADT DA30-5 DA40-5 Operation & Maintenance Manual – PDF DOWNLOAD

DA - 02 - Safety Instructions - English..................................................... 21
	Safety Instructions..................................................................... 21
		Safety decals....................................................................... 24
		Safe operation is operator's responsibility......................................... 36
		Know your machine................................................................... 36
		Pressurised fluids.................................................................. 37
		Flying or falling objects........................................................... 38
		Personal protective equipment....................................................... 38
		Correction of machine problems...................................................... 39
		Crushing and cutting................................................................ 39
		Hot coolant and oils - burn prevention.............................................. 40
		Fire and explosion prevention....................................................... 40
		Maintenance......................................................................... 41
		Operation........................................................................... 41
		Electrical.......................................................................... 41
		Hydraulic system.................................................................... 42
		Fuelling............................................................................ 42
		Never use starting gas.............................................................. 42
		Welding and grinding................................................................ 43
		If a fire occurs.................................................................... 43
		Fire Extinguisher, First-Aid Kit (Emergency Medical Kit) and Warning triangle....... 44
		Electrical System and Electrical Shock.............................................. 44
		Roll-over Protective Structure (ROPS)/Falling Object Protective Structure (FOPS).... 45
		ROPS Certification.................................................................. 45
		Emergency Exit from Operator’s Station.............................................. 46
		Before engine starting.............................................................. 47
		Work site........................................................................... 47
		Check tire pressure and condition................................................... 48
		Mounting/Dismounting................................................................ 48
		Cleaning............................................................................ 48
		Operator station.................................................................... 49
		Seat belt........................................................................... 49
		Visibility information.............................................................. 50
		Work site rules..................................................................... 51
		Boost starting or charging engine batteries......................................... 51
		Starting engine..................................................................... 52
		Travelling.......................................................................... 52
		Machine turning..................................................................... 53
		Operation on slopes................................................................. 54
		Operation of brakes................................................................. 54
		Engine and retarder brake operation................................................. 55
		Engine over speed................................................................... 55
		Vehicle over speed protection....................................................... 55
		Hauling hazardous loads............................................................. 56
		Top tailgate........................................................................ 57
		Equipment lowering with engine stopped.............................................. 58
		Engine stop......................................................................... 58
		Parking machine..................................................................... 58
		Maintenance......................................................................... 59
		Warning tag......................................................................... 61
		Wheel chocks........................................................................ 62
		Articulation lock................................................................... 62
		Lifting/Hoisting.................................................................... 62
		Engine bonnet....................................................................... 63
		Tiltable cab........................................................................ 63
		Body support........................................................................ 65
		Cleaning............................................................................ 66
		Proper tools and clothing........................................................... 66
		Disassembling precautions........................................................... 66
		Use of lighting..................................................................... 67
		Fire and explosion prevention....................................................... 67
		Burn prevention..................................................................... 68
		Rubber that contains fluorides...................................................... 69
		Rubber and plastics................................................................. 70
		Welding repairs..................................................................... 71
		Accumulators........................................................................ 72
		Compressed air...................................................................... 72
		Supports and blocking for equipment................................................. 73
		High pressure lines, tubes and hoses................................................ 73
		Battery............................................................................. 74
		Preservation/Storing machine........................................................ 76
		Transportation...................................................................... 78
		Environment and circumstances....................................................... 80
		High-voltage Cables................................................................. 82
		Working in water.................................................................... 83
		Exhaust Ventilation................................................................. 84
		Silica Dust Information............................................................. 85
		Disposal of Hazardous Materials..................................................... 85
		Sound............................................................................... 85
		Vibration........................................................................... 86
DA - 03 - Operating controls - English...................................................... 89
	Operating Controls...................................................................... 89
		Overview of the instrument panels and controls...................................... 91
		Instruments......................................................................... 93
		US units - Display settings......................................................... 93
		Monitor warning / indicator symbols and lights...................................... 96
		Groeneveld pump test................................................................103
		Keypad, buttons and switches........................................................104
		Cab ventilation.....................................................................107
		Controls............................................................................110
		Other cab equipment.................................................................116
		Operation of heater.................................................................123
		TMS (Telematic system)..............................................................126
DA - 04 - Running in period - English.......................................................129
	Running-in period.......................................................................129
		1.	Running-in operation.............................................................131
		2.	Running-in services..............................................................132
DA - 05 - Operating instructions - English..................................................135
	Operating Instructions..................................................................135
		Precautions on work sites...........................................................137
		Some simple rules to be observed prior to operation.................................141
		1.	Starting the engine.............................................................142
		2.	Operating the dump truck........................................................144
		3.	Parking the dump truck..........................................................157
		4.	Stopping the engine.............................................................157
		5.	Checks after stopping the engine................................................158
		6.	Loading and tipping.............................................................158
		7.	Tire handling...................................................................160
		9.	Long term storage...............................................................163
		10.	Battery power assistance.......................................................164
		11.	Towing the dump truck..........................................................165
		12.	Manual release of parking brake................................................165
		13.	Manual release of the ball valve on tilting circuit............................166
		14.	Troubleshooting................................................................167
DA - 06 - Lubricants - English..............................................................173
	Lubricants..............................................................................173
		Lubrication schedule DA30 T2/T4F/Stage IV...........................................175
		Overview of oil and lubrication points DA30 T2/T4F/Stage IV.........................176
		Oil specification sheet DA30 T2/T4F/Stage IV........................................177
		Filling capacities DA30 T2/T4F/Stage IV.............................................178
		Lubrication schedule DA40 T2/T4F/Stage IV ..........................................179
		Overview of oil and lubrication points DA40 T2/T4F/Stage IV.........................180
		Oil specification sheet DA40 T2/T4F/Stage IV........................................181
		Filling capacities DA40 T2/T4F/Stage IV.............................................182
		Composition of the fuel.............................................................183
		Transmission oil list...............................................................184
		Axles oil list......................................................................187
DA - 07a - 8 - 40 Hours maintenance - English...............................................193
	Maintenance.............................................................................193
		Maintenance precautions.............................................................195
		Maintenance table...................................................................197
		Initial 100 Hours Service ..........................................................200
		Initial 500 Hours Service...........................................................204
		8 Hours / Daily Service.............................................................209
		40 Hours / Weekly Service...........................................................217
DA - 07b - 500 - 1000 Hours maintenance - English...........................................220
	500 Hours Service.......................................................................220
		1000 Hours Service..................................................................235
DA - 07c - 2000 - 4000 Hours maintenance - English..........................................251
DA - 08 - Technical data - English..........................................................267
	Technical Data..........................................................................267
		Measurements........................................................................269
		Engine..............................................................................270
		Transmission........................................................................270
		Hydraulic system....................................................................271
		Tyre pressures......................................................................271
		Electrical system...................................................................272
		Bulbs  .............................................................................273
		Metering conversion table...........................................................273
		Tool kit content (standard).........................................................273
		Tool kit content (optional).........................................................273
		Rimpull Performance ................................................................274
		Graph of altitude power reduction DA30 T2/T4F/Stage IV..............................276
		Graph of altitude power reduction DA40 T2/T4F/Stage IV..............................277
		Engine and retarder brake capacity chart............................................278
		Torque limits for bolts.............................................................279
		Reference information...............................................................279
		Consumeable parts...................................................................279
		Product signs.......................................................................280
		Periodic service....................................................................282
DA - 09 - Index - English...................................................................285
Blank Page.................................................................................. 20
Blank Page..................................................................................128
Blank Page..................................................................................172
Blank Page..................................................................................192

DAEWOO DOOSAN ADT DA30-5 DA40-5 OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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