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Daewoo Doosan ADT DA30-5 Shop Manual MX533347-1 – PDF DOWNLOAD
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Daewoo Doosan ADT DA30-5 Shop Manual MX533347-1 – PDF DOWNLOAD
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Description
Daewoo Doosan ADT DA30-5 Shop Manual MX533347-1 – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan ADT DA30-5 Shop Manual MX533347-1 – PDF DOWNLOAD
Foreword
The Shop Manual is prepared as an aid to performing quality repairs by giving the service personnel an understanding of the dump truck, and showing the correct way perform repairs and make judgements. Make sure that you understand the manual and use it at every available opportunity. The manual will also serve as a useful guide to office personnel and other persons who are involved with the dump truck in one way or another.
How to use the SHOP MANUAL:
The main index give an view of the chapters index page no.
0 General
1 Engine XPI/PDE
2 Transmission
3 Driveline
4 Lubrication
5 Hydraulic
6 Electrical system
7 Front frame
8 Rear frame
9 Option
10 Error codes list
- In the chapters index you will find the page no. for the description of each part. Each part will describe: Structure and function: This section explains how the components are built and how they work. Testing and adjusting: This section explains checks to be made before and after performing repairs, as well as adjustments to be done at the completion of the checks and repairs. Disassembly and assembly: This section describes how to remove
- install, disassemble, repair and assemble components, and the work order. Special tools are listed at the end of each chapter. The special tools are an excellent aid in the work shop. By using special tools, the job will be easier to perform and in some cases a special tool is required to carry out the work. List of all special tools for the complete truck are listed in the “Special Tool Guide”. Maintenance standard: This section gives the judgement standards when inspecting disassembled parts
- .Troubleshooting: When a fault is detected, this section is used as before the practical fault finding starts. A skilled and trained mechanic together with the Shop Manual is the best combination for troubleshooting when repair instruction is needed. At the end of each chapters are the main Troubleshooting This manual is valid for the serial nos. listed on the first page. Distributing and updating: Subscribed Shop Manuals will automatically be updated at revisions.
- This manual is originally produced by Doosan Infracore Norway AS, 6440 Elnesvågen, Norway, and must not be reproduced, translated or made available to a third party, fully or partly, without our written permission
TABLE OF CONTENTS:
Daewoo Doosan ADT DA30-5 Shop Manual MX533347-1 – PDF DOWNLOAD
Chapter 00 - General......................................................................... 0 Foreword................................................................................. 11 Torque limit table....................................................................... 12 Types of sealing-/locking compounds and lubricants....................................... 13 Safety in workshop....................................................................... 14 Working on machine....................................................................... 15 Personal Protective Equipment (PPE)...................................................... 18 Vibration................................................................................ 19 Injurious noise.......................................................................... 20 Organic solvent.......................................................................... 21 Fueling.................................................................................. 22 Fire and Explosion Prevention............................................................ 22 Fire and explosion risks................................................................. 24 In case of Fire.......................................................................... 25 Coolant.................................................................................. 26 Refrigerant.............................................................................. 27 Air pollution............................................................................ 28 Operation in extreme conditions.......................................................... 29 Liquid or gas under high pressure........................................................ 33 Asbestos................................................................................. 34 Lead..................................................................................... 34 Battery hazard prevention................................................................ 35 Disposal of hazardous materials.......................................................... 37 Jacked up vehicle or bodywork............................................................ 38 Crushing and Cutting Danger.............................................................. 38 Heavy units.............................................................................. 39 More than one person working with the same object........................................ 40 Involuntary start of electric motors etc................................................. 40 Rotating parts........................................................................... 41 Splinters, flying object When using certain tools........................................ 42 Springs under load....................................................................... 43 Precautions for disassembly and assembly................................................. 44 Chapter 01 - Engine PDE...................................................................... 53 Engine identification.................................................................... 60 Removal of engine assembly............................................................... 64 Lifting the engine....................................................................... 70 Starting the engine...................................................................... 71 Important information about the fuel.................................................... 72 Fuel system Tier2 (PDE)................................................................. 73 Schematic diagram of the fuel system Tier2............................................... 73 Overflow valve........................................................................... 73 General.................................................................................. 74 FUEL..................................................................................... 74 Temperature Dependency of the Fuel....................................................... 75 Fuel filter.............................................................................. 76 Changing the fuel filter................................................................. 76 Water separating prefilter PDE.......................................................... 77 changing the water separating fuel filter................................................ 77 Bleeding the fuel system................................................................. 78 Feed pump................................................................................ 80 Renewing the control unit................................................................ 81 Removing the ECU wiring Tier2.......................................................... 82 Cylinder head - PDE System Tier2........................................................ 86 Cylinder head, parts view. PDE Tier2.................................................... 86 Special tools............................................................................ 87 Valve mechanism.......................................................................... 88 Dismantling ............................................................................. 93 Renewing the valve stem seal............................................................. 93 Replacement of valve seats............................................................... 94 Machining the valve seats insert......................................................... 95 Renewing the valve guides................................................................ 97 Renewing PDE unit injector sleeves....................................................... 98 Assembly ................................................................................ 99 Fitting.................................................................................. 99 Unit injector and flywheel............................................................... 101 Valve and unit injector adjustment with PDE.............................................. 101 Order of adjustment for valve clearance and PDE unit injectors........................... 103 Flywheel readings (DA40)................................................................. 103 Flywheel readings (DA30)................................................................. 103 Adjusting the valve clearance and unit injectors......................................... 103 Turbocharger............................................................................. 105 Measuring radial clearance and axial clearance .......................................... 106 Renewing the turbocharger................................................................ 108 General ................................................................................. 109 Changing oil filter...................................................................... 110 Oil analysis............................................................................. 111 Checking oil level....................................................................... 111 Changing the oil......................................................................... 112 Special tools............................................................................ 113 Pistons and cylinder liners.............................................................. 114 Special tools............................................................................ 115 Connecting rods.......................................................................... 116 Removing and dismantling connecting rods and pistons..................................... 117 Renewal of bearing bushing in connecting rod............................................. 119 Pistons.................................................................................. 121 Assembling piston and connecting rod..................................................... 123 Cylinderblock............................................................................ 124 Cylinder liner........................................................................... 124 Removing the cylinder liners............................................................. 126 Measuring the cylinder liner height...................................................... 127 Measuring the cylinder wear ridge and cylinder bore...................................... 127 Fitting the cylinder liners.............................................................. 128 Fitting the piston and connecting rod.................................................... 129 Flywheel and flywheel housing............................................................ 131 Special tools............................................................................ 132 Removing the flywheel.................................................................... 132 Renewing the rear crankshaft seal........................................................ 134 Removing the flywheel housing............................................................ 134 Fitting flywheel housing................................................................. 135 Fitting the flywheel..................................................................... 137 Timing gear - 13 and 9 liter............................................................. 141 Gear drive............................................................................... 141 Belt drive collant pump, generator and AC compressor..................................... 142 Checking the Drive Belt.................................................................. 143 Check for leaks.......................................................................... 144 Renewing the seal in the front cover..................................................... 145 Crankshaft damper........................................................................ 146 Timing gear, view exploded............................................................... 147 Special tools............................................................................ 148 Intermediate gear ....................................................................... 149 Camshaft gear ........................................................................... 152 Crankshaft gear ......................................................................... 153 Camshaft ................................................................................ 154 Replacement of camshaft bearing.......................................................... 155 Crankshaft .............................................................................. 162 Removal.................................................................................. 163 Fitting.................................................................................. 166 Adjust - Machining the crankshaft........................................................ 167 Lubrication system....................................................................... 168 Oil pump................................................................................. 168 Lubrication oilways .................................................................... 169 Oil pressure............................................................................. 170 Oil cooler, engine ...................................................................... 171 Oil cooler view Se 010009 ............................................................. 172 Renewing seals and leakage testing....................................................... 173 Oil filter............................................................................... 174 Centrifugal oil cleaner ................................................................. 175 Dismantling and assembly................................................................. 176 Oil mist separator....................................................................... 180 General.................................................................................. 180 High levels of oil carryover............................................................. 180 Crankcase pressure measurement........................................................... 182 Oil mist separator exploded view......................................................... 183 Oil mist separator disassemble........................................................... 184 Check - Rotational speed on oil mist separator........................................... 186 Alternator 100 A......................................................................... 187 Check.................................................................................... 187 Output test.............................................................................. 188 Renewal - Bearing and carbon brushes..................................................... 191 Oil pump, brake cooling circulate (DA40)................................................. 195 Exploded view............................................................................ 195 Disassemble and overhaul the oil pump.................................................... 196 Checking and renewing parts.............................................................. 198 Oil circulate pump assemble.............................................................. 199 Renewing the gasket...................................................................... 202 Cooling fan.............................................................................. 203 View of the radiator system DA40........................................................ 203 Cooling system........................................................................... 204 Principal view of the cooling system..................................................... 204 Circulation.............................................................................. 205 Coolant.................................................................................. 206 Checking Coolant Level................................................................... 207 Checking the Antifreeze Level............................................................ 209 Changing Coolant......................................................................... 209 Filling Coolant.......................................................................... 210 Cleaning the Cooling System.............................................................. 211 Removing oil cooler...................................................................... 212 Disassemble the cooling unit............................................................. 213 Thermostat and thermostat housing........................................................ 215 Thermostat............................................................................... 216 Coolant pump............................................................................. 217 External cleaning........................................................................ 221 Internal cleaning........................................................................ 221 Technical data DC13 with PDE............................................................. 222 General data............................................................................. 222 Technical data DC9 with PDE.............................................................. 224 General data............................................................................. 224 Troubleshooting ECOM / Canbus........................................................... 226 To do: .................................................................................. 226 Troubleshooting, -basic info............................................................. 226 Troubleshooting fuel system.............................................................. 227 Troubleshooting Guide.................................................................... 227 Diagnostic prosedure..................................................................... 244 Use of diagnostic kit, Tier 2........................................................... 244 Connection point Can pc VCU + Testman ................................................... 244 Can bus overview........................................................................ 244 Connection point SDP3 Scania dagnostic................................................... 245 Troubleshooting Manual................................................................... 246 White smoke.............................................................................. 247 White smoke, water vapour................................................................ 247 White smoke, water vapour................................................................ 248 Black smoke on starting.................................................................. 248 Blue smoke............................................................................... 249 Fuel in the oil.......................................................................... 249 Oil in coolant........................................................................... 250 Coolant/water in oil..................................................................... 250 Low oil pressure......................................................................... 251 High oil pressure (engine warmed up)..................................................... 253 Abnormal wear (liner, piston rings, etc.) ............................................... 253 Vibration, no driven components engaged ................................................. 254 Vibration when the clutch or reverse gear is engaged .................................... 255 Vibration when alternator is in operation ............................................... 255 Engine speed hunting - single-speed engines with RQ governor ............................ 256 Engine speed hunting - single-speed engines with RSV governor............................ 256 Delivery pipe fractures ................................................................. 257 External corrosion on cylinder liner..................................................... 257 Engine difficult to start ............................................................ 258 Fluid stroke............................................................................. 259 Knocking/noise........................................................................... 260 High oil consumption..................................................................... 261 High fuel consumption.................................................................... 262 Low compression.......................................................................... 262 Low engine output........................................................................ 263 Hot engine............................................................................... 264 Cold engine ............................................................................. 265 Coolant loss............................................................................. 265 Polluted coolant......................................................................... 265 Polluted coolant......................................................................... 266 High oil temperature..................................................................... 266 High exhaust temperature................................................................. 266 Low charge air pressure.................................................................. 267 Low fuel pressure........................................................................ 267 Low system voltage....................................................................... 267 High system voltage...................................................................... 268 External oil leakage .................................................................... 268 External fuel leakage.................................................................... 268 External coolant leakage ................................................................ 269 Oil pressed out via crankcase ventilation................................................ 269 Turbocharger breakdown................................................................... 269 Compressed air system.................................................................... 270 Chapter 01 - Engine XPI...................................................................... 275 Engine identification.................................................................... 282 Removal of engine assembly............................................................... 286 Lifting the engine....................................................................... 292 Starting the engine...................................................................... 293 XPI Fuel system DA30/40................................................................. 294 Route of the fuel on 9 and 13 liter engines.............................................. 295 Fuel filter and water separation......................................................... 296 Changing the fuel filter................................................................. 297 Overflow valve........................................................................... 298 Fuel system components................................................................... 299 Schematic diagram of the fuel system:.................................................... 299 Important information about the fuel.................................................... 300 Exhaust system XPI....................................................................... 301 Introduction System overview............................................................. 301 Control system for exhaust gas aftertreatment............................................ 302 Control unit EEC3........................................................................ 310 System overview for mechanics............................................................ 311 System overview for electronics.......................................................... 312 Ad blue filter change.................................................................... 313 Reductant doser.......................................................................... 314 Start-up instruction for new SCR Pump.................................................... 316 Reductant pump, function................................................................. 317 Renewing the control unit................................................................ 324 Removing the ECU wiring Tier2.......................................................... 325 Common rail Injectors Tier4/XPI.......................................................... 329 Cylinder head - XPI system Tier4......................................................... 330 Cylinder head, parts view. XPI system Tier4.............................................. 330 Injector Scania XPI...................................................................... 331 Order of adjustment for 13 liter engines................................................. 333 Valve adjustment DC13 with XPI........................................................... 333 Cylinder configuration, 6 cylinder engines............................................... 334 Valve adjustment DC9 with XPI............................................................ 335 Cylinder configuration, 5 cylinder engines............................................... 336 Turbocharger............................................................................. 337 Measuring radial clearance and axial clearance .......................................... 338 Renewing the turbocharger................................................................ 340 General ................................................................................. 341 Changing oil filter...................................................................... 342 Oil analysis............................................................................. 343 Checking oil level....................................................................... 343 Changing the oil......................................................................... 344 Special tools............................................................................ 345 Pistons and cylinder liners.............................................................. 346 Special tools............................................................................ 347 Connecting rods.......................................................................... 348 Removing and dismantling connecting rods and pistons..................................... 349 Renewal of bearing bushing in connecting rod............................................. 351 Pistons.................................................................................. 353 Assembling piston and connecting rod..................................................... 355 Cylinderblock............................................................................ 356 Cylinder liner........................................................................... 356 Removing the cylinder liners............................................................. 358 Measuring the cylinder liner height...................................................... 359 Measuring the cylinder wear ridge and cylinder bore...................................... 359 Fitting the cylinder liners.............................................................. 360 Fitting the piston and connecting rod.................................................... 361 Flywheel and flywheel housing............................................................ 363 Special tools............................................................................ 364 Removing the flywheel.................................................................... 364 Renewing the rear crankshaft seal........................................................ 366 Removing the flywheel housing............................................................ 366 Fitting flywheel housing................................................................. 367 Fitting the flywheel..................................................................... 369 Flexible coupling........................................................................ 370 Safety instructions...................................................................... 370 Functional description................................................................... 370 Disassembly and dismantling the coupling................................................. 371 Assembling the coupling.................................................................. 371 Installation instructions................................................................ 371 Friction disk, Friction ring............................................................. 372 Timing gear - 13 and 9 liter with XPI ................................................... 373 Gear drive............................................................................... 373 Belt drive collant pump, generator and AC compressor..................................... 374 Checking the Drive Belt.................................................................. 375 Check for leaks.......................................................................... 376 Renewing the seal in the front cover..................................................... 377 Crankshaft damper........................................................................ 378 Timing gear, view exploded............................................................... 379 Special tools............................................................................ 380 Intermediate gear ....................................................................... 381 Camshaft gear ........................................................................... 384 Crankshaft gear ......................................................................... 385 Camshaft ................................................................................ 386 Replacement of camshaft bearing.......................................................... 387 Crankshaft .............................................................................. 394 Removal.................................................................................. 395 Fitting.................................................................................. 398 Adjust - Machining the crankshaft........................................................ 399 Lubrication system....................................................................... 400 Oil pump................................................................................. 400 Lubrication oil-ways ................................................................... 401 Oil pressure............................................................................. 402 Oil cooler, engine ...................................................................... 403 Oil cooler view Se 010009 ............................................................. 404 Renewing seals and leakage testing....................................................... 405 Oil filter............................................................................... 406 Centrifugal oil cleaner ................................................................. 407 Dismantling and assembly................................................................. 408 Oil mist separator....................................................................... 412 General.................................................................................. 412 High levels of oil carryover............................................................. 412 Crankcase pressure measurement........................................................... 414 Oil mist separator exploded view......................................................... 415 Oil mist separator disassemble........................................................... 416 Check - Rotational speed on oil mist separator........................................... 418 Alternator 100 A......................................................................... 419 Check.................................................................................... 419 Output test.............................................................................. 420 Renewal - Bearing and carbon brushes..................................................... 423 Oil pump, brake cooling circulate (DA40)................................................. 427 Exploded view............................................................................ 427 Disassemble and overhaul the oil pump.................................................... 428 Checking and renewing parts.............................................................. 430 Oil circulate pump assemble.............................................................. 431 Renewing the gasket...................................................................... 434 Cooling fan.............................................................................. 435 View of the radiator system DA40........................................................ 435 Cooling system........................................................................... 436 Principal view of the cooling system..................................................... 436 Circulation.............................................................................. 437 Coolant.................................................................................. 438 Checking Coolant Level................................................................... 439 Pressure testing the cooling system XPI.................................................. 440 Delivery valve........................................................................... 440 External leakage......................................................................... 440 Internal leakage......................................................................... 440 Checking the Antifreeze Level............................................................ 441 Changing Coolant......................................................................... 441 Filling Coolant.......................................................................... 442 Cleaning the Cooling System.............................................................. 443 Removing oil cooler...................................................................... 444 Disassemble the cooling unit............................................................. 445 Thermostat and thermostat housing........................................................ 447 Thermostat............................................................................... 448 Coolant pump............................................................................. 449 External cleaning........................................................................ 453 Internal cleaning........................................................................ 453 Technical data DC13 with XPI............................................................. 454 General data............................................................................. 454 Technical data DC9 with XPI.............................................................. 456 General data............................................................................. 456 Troubleshooting ECOM / Canbus........................................................... 458 To do: .................................................................................. 458 Troubleshooting, -basic info............................................................. 458 Troubleshooting fuel system.............................................................. 459 Troubleshooting Guide.................................................................... 459 Diagnostic prosedure..................................................................... 476 Use of diagnostic kit, Tier 2........................................................... 476 Connection point Can pc VCU + Testman ................................................... 476 Can bus overview........................................................................ 476 Connection point SDP3 Scania dagnostic................................................... 477 Troubleshooting Manual................................................................... 479 White smoke.............................................................................. 480 White smoke, water vapour................................................................ 480 White smoke, water vapour................................................................ 481 Black smoke on starting.................................................................. 481 Blue smoke............................................................................... 482 Fuel in the oil.......................................................................... 482 Oil in coolant........................................................................... 483 Coolant/water in oil..................................................................... 483 Low oil pressure......................................................................... 484 High oil pressure (engine warmed up)..................................................... 486 Abnormal wear (liner, piston rings, etc.) ............................................... 486 Vibration, no driven components engaged ................................................. 487 Vibration when the clutch or reverse gear is engaged .................................... 488 Vibration when alternator is in operation ............................................... 488 Engine speed hunting - single-speed engines with RQ governor ............................ 489 Engine speed hunting - single-speed engines with RSV governor............................ 489 Delivery pipe fractures ................................................................. 490 External corrosion on cylinder liner..................................................... 490 Engine difficult to start ............................................................ 491 Fluid stroke............................................................................. 492 Knocking/noise........................................................................... 493 High oil consumption..................................................................... 494 High fuel consumption.................................................................... 495 Low compression.......................................................................... 495 Low engine output........................................................................ 496 Hot engine............................................................................... 497 Cold engine ............................................................................. 498 Coolant loss............................................................................. 498 Polluted coolant......................................................................... 498 Polluted coolant......................................................................... 499 High oil temperature..................................................................... 499 High exhaust temperature................................................................. 499 Low charge air pressure.................................................................. 500 Low fuel pressure........................................................................ 500 Low system voltage....................................................................... 500 High system voltage...................................................................... 501 External oil leakage .................................................................... 501 External fuel leakage.................................................................... 501 External coolant leakage ................................................................ 502 Oil pressed out via crankcase ventilation................................................ 502 Turbocharger breakdown................................................................... 502 Compressed air system.................................................................... 503 Chapter 02 - Transmission.................................................................... 507 GENERAL.................................................................................. 511 Structure of the Repair Manual........................................................... 512 Denomination of standard dimensions...................................................... 513 Conversion table ........................................................................ 513 Torque limits for screws................................................................. 514 Table.................................................................................... 514 Labeling of type plate .................................................................. 515 Information on spare parts ordering...................................................... 515 Configuration of transmission............................................................ 516 Transmission schematics and gear schematics.............................................. 516 Measuring points and connections......................................................... 517 Table.................................................................................... 517 Clutch calibration....................................................................... 567 Installation sheet....................................................................... 518 Specjal tools for disassembly and reassembly............................................. 519 Commercial tools for disassembly and reassembly.......................................... 522 Removal of transmission, disass’y........................................................ 527 Disassemble the structure bar............................................................ 534 Disassemble the hydraulic hoses.......................................................... 534 Positioning for disassembly and reassembly............................................... 538 Removal and refitting various components................................................. 539 Transmission............................................................................. 539 LKV axle insert.......................................................................... 539 Removal and refitting of speed sensor n4-output.......................................... 540 Removal:................................................................................. 540 Retting:................................................................................. 540 Removal and refitting of solenoid valves of shifting block II and temperature sensors.... 542 Removal: ................................................................................ 542 Refitting: ............................................................................ 543 Disassembly and reassembly of shifting block I and speed sensors......................... 545 Disassembly: ........................................................................... 545 Reassembly: ............................................................................ 549 Removal and refitting of LKV axle insert................................................. 554 Separation of LKV axle insert from transmission: ........................................ 554 Attachment of LKV axle insert to transmission .......................................... 555 Sealing of outputs towards rear axle and LKV axle insert ............................... 557 Exchange of shaft seal ring towards LKV axle insert...................................... 557 Removal of shaft seal ring............................................................... 557 Fitting of shaft seal ring: ............................................................. 557 Exchange of shaft seal ring towards rear axle............................................ 557 Removal of shaft seal ring .............................................................. 557 Fitting of shaft seal ring............................................................... 558 Transmission assembly.................................................................... 560 Chapter 03 - Drive line...................................................................... 571 Introduction............................................................................. 575 General.................................................................................. 576 Structure of the Repair Manual........................................................... 577 Denomination of standard dimensions...................................................... 578 Conversion table ........................................................................ 578 Tightening torques for nuts and bolts.................................................... 579 Table.................................................................................... 579 Drive line components.................................................................... 580 Front reduction gear..................................................................... 581 Parts list............................................................................... 582 Front reduction gear cross section....................................................... 583 NAF special Tools for.................................................................... 584 Assembly................................................................................. 585 Drive shafts............................................................................. 598 Front frame.............................................................................. 598 Rear frame............................................................................... 599 Mounting the bearings on the intermediate shaft (B)...................................... 600 Front differential and transmission...................................................... 609 Brakes................................................................................... 610 Service brakes........................................................................... 610 Service brake description................................................................ 612 Testing of parking brake................................................................. 613 Remove the Linings....................................................................... 614 Disassembly the park brake unit.......................................................... 616 Assembly the park brake unit............................................................. 617 Adjust the Initial Caliper Clearance..................................................... 618 Park brake Maintenance................................................................... 619 Disc..................................................................................... 621 Troubleshooting Park brake............................................................... 623 Rear differential........................................................................ 624 Rear Differential........................................................................ 624 Exchange of the complete rear differential............................................... 625 Safety precautions....................................................................... 625 Repairs on the rear differential......................................................... 628 Exchange of crown gear / Pinion (7x1001-7x1020).......................................... 628 Exchange of crown gear / Pinion (7x1021 - up)............................................ 632 Determining thickness of the adjusting washer (44)....................................... 637 Determining thickness of the adjusting washer (45)....................................... 638 Pinion bearing adjustment................................................................ 639 Backlash and crown gear bearing adjustment............................................... 639 Checking contact pattern................................................................. 642 Exchange shaft seals..................................................................... 643 Exchange of differential cage (compensating gearbox)..................................... 644 Differential lock........................................................................ 645 Planetary drive.......................................................................... 646 Complete exchange of planetary cage...................................................... 648 Exchange of sun gear shaft............................................................... 649 Testing and Adjusting of Thrust Stud Adjustment.......................................... 650 Exchange of Planetary Studs and Gears.................................................... 651 Exchange of ring gear carrier............................................................ 651 Wheel bearings........................................................................... 652 Gear bearing exchange.................................................................... 652 Gear bearing adjustment.................................................................. 655 Brake.................................................................................... 657 Check disc’s wear........................................................................ 657 Exchange of the piston for the operating brake........................................... 658 Exchange of brake disks and pressure springs for the operating brake..................... 659 Tandem bearings.......................................................................... 662 Exchange of slewing ring................................................................. 662 Exchange of seal......................................................................... 666 Exchange of axle beam.................................................................... 666 Gear drive in tandem housing............................................................. 667 Exchange of bearing (84)................................................................. 667 Exchange of gear (43) and bearing (89) / (90)............................................ 668 Exchange of gears (86)................................................................... 669 Checking clearance in the Tandem bearing................................................. 670 View of the Tandem bearing............................................................... 671 Special Tools for Mox 08 axle (7x1001 - 7x1020).......................................... 672 Special Tools for Mox 17 axle (7x1021 - up).............................................. 673 Chapter 04 - Lubrication..................................................................... 677 Lubrication system parts................................................................. 681 Greasing cycles.......................................................................... 683 Lubrication Points on DA series.......................................................... 685 Grease pressure switch................................................................... 687 The 5/2 way valve........................................................................ 688 The relief valve......................................................................... 688 The minimum level switch................................................................. 689 System test.............................................................................. 689 Introduction............................................................................. 689 The single-test cycle.................................................................... 689 The continuous-test cycle................................................................ 691 Warning signal........................................................................... 691 Maintenance.............................................................................. 692 Regularly checks of the greasing system.................................................. 692 Bleeding the pump........................................................................ 692 Bleeding the system...................................................................... 693 Technical data........................................................................... 693 Dimensions of the Twin Pump.............................................................. 694 Central lubrication main unit, (overview)................................................ 695 Chapter 05 - Hydraulic system................................................................ 699 Components, capacities and oil types..................................................... 702 Hydraulic system main function....................................................... 703 Hydraulic System Description......................................................... 704 Hydraulic System Components.......................................................... 704 Hydraulic parts view DA30 / DA40..................................................... 705 Main Valve Circuit................................................................... 706 Main Valve - List Of Components...................................................... 707 Hydraulic System pressure............................................................ 707 Main Valve - Orifices................................................................ 708 Main Valve - Spare Parts & Torques................................................... 710 Tilt valve - Exploded................................................................ 714 Hydraulic circuit DA30............................................................... 717 Hydraulic circuit DA40............................................................... 719 Startup test procedure .................................................................. 721 Main Pump................................................................................ 722 Pump description..................................................................... 722 Test block........................................................................... 723 Main pump pressure adjusting......................................................... 724 Main pump pressure adjusting......................................................... 725 Main pump circuit.................................................................... 726 Main pump parts list................................................................. 727 Main pump exploded view.............................................................. 729 Main pump section drawing ........................................................... 731 Pump, disassemble - assemble the shaft............................................... 733 Steering system.......................................................................... 734 Steering Master Valve (Orbitrol)..................................................... 735 Steering Pressure Adjustment......................................................... 738 Steering valve....................................................................... 739 Steering circuit DA30 / DA40......................................................... 740 Steering Cylinder.................................................................... 741 Steering cylinder, sectional drawing................................................. 743 Emergency steering pump.............................................................. 744 Tilting system........................................................................... 747 Tilt Lever........................................................................... 747 View of the tilting system........................................................... 748 Tilt cylinders:...................................................................... 749 Tilt cylinder, sectional drawing..................................................... 751 Fan system............................................................................... 752 Fan Drive Motor...................................................................... 753 Disassemble the fan and fan motor.................................................... 754 Brakes................................................................................... 755 Brake circuit view................................................................... 755 Service brakes overview.............................................................. 757 Parking brake, description........................................................... 758 Parking brake circuit veiw........................................................... 759 Accumulators............................................................................. 760 Description of the Accumulators...................................................... 760 Filling table of Correction Factors.................................................. 763 Accumulator charging:................................................................ 764 Chapter 06 - Electrical system............................................................... 767 How to use the electrical documentation.................................................. 773 Troubleshooting, what to do.............................................................. 773 Description of the VCU2 functionality ................................................... 775 Doosan Moxy VCU 2........................................................................ 775 Find wiring contact on VCU2.............................................................. 776 LCD Instrumentation Unit................................................................. 778 Warning Lights Display................................................................... 778 LCD screen main menu..................................................................... 779 LCD use description .................................................................... 779 Pos reference list....................................................................... 780 Description of the main electrical system................................................ 784 General description...................................................................... 784 Welding on the dump truck................................................................ 784 Battery hazard prevention................................................................ 785 Component position....................................................................... 787 Electrical parts view.................................................................... 787 El.system, outside front and rear........................................................ 789 Electrical equipment inside cab.......................................................... 790 El.system, Cab inside.................................................................... 790 Switch panel............................................................................. 792 Heater unit exploded..................................................................... 793 Heater unit parts list................................................................... 794 Ignition key switch...................................................................... 794 Air conditioning system componenets...................................................... 795 Product final inspection................................................................. 796 Refrigerant charging..................................................................... 797 Regulation controll...................................................................... 798 Preassure reading and troubleshooting.................................................... 800 Use of the A.T.C......................................................................... 804 Rear frame .............................................................................. 807 DA series functions and parameters....................................................... 808 Brake/brake charge system (Accumulators) (7)........................................... 808 WDB Cooling (only on DA40) (7)........................................................... 808 Emergency Steering system (9)............................................................ 809 Park brake (6).......................................................................... 810 Low engine oil pressure (2).............................................................. 810 Low coolant level (3).................................................................... 810 Clogged air filter (4)................................................................... 810 Central lubrication pump (11)............................................................ 810 Charge lamp (12)......................................................................... 811 Body tip system (13)..................................................................... 811 Load weighing (32)....................................................................... 812 Differential lock (28).................................................................. 812 Cooling fan control...................................................................... 813 Quick warmup function.................................................................... 814 Cooldown function........................................................................ 814 Alternative engine speed................................................................. 815 Interior light........................................................................... 815 Retarder and Engine brake (24 - 25)...................................................... 815 Emergency Stop........................................................................... 815 Fuel Heater.............................................................................. 816 A/C compressor control................................................................... 816 To be implented.......................................................................... 817 Engine electrical components............................................................. 819 Engine EMS S6 / S8....................................................................... 824 Electrical cable routing................................................................. 826 EMS connection chart..................................................................... 827 EMS pin list............................................................................. 829 Engine Management System S8.............................................................. 832 Engine speed and camsghaft sensors....................................................... 836 Wastergate solenoid valve................................................................ 836 Control unit EMS S8...................................................................... 840 Fuel pressure sensor..................................................................... 840 Fuel inlet metering valve................................................................ 841 Solenoid valve for XPI injector.......................................................... 841 Transmission spesification of electrical components...................................... 842 Transmission speed sensors............................................................... 842 Transmission temperature sensors......................................................... 843 Transmission solenoid valves............................................................. 844 Transmission pressure switch............................................................. 845 Transmission electric switch............................................................. 845 Sensors hydraulic system................................................................. 846 Steering valve, el. connection........................................................... 847 Main valve el. connection................................................................ 848 Parking brake sensor..................................................................... 849 Body float sensor........................................................................ 850 Electrical chart and circuit............................................................. 852 Cab roof cable set....................................................................... 852 Cab floor cable set...................................................................... 853 Cab inside rear wall cable set .......................................................... 854 Wiring (cable set) S1 - S6.............................................................. 855 Cirquit chart cabine (No1)............................................................... 856 Junction box battery compartment......................................................... 858 Cirquit chart front and rear frame (No2)................................................. 859 Exhaust Emmission Control................................................................ 860 Wiring diagram for the exhaust emission control.......................................... 860 System overview for electrics............................................................ 861 Chapter 07 - Front wagon..................................................................... 865 7.1 Introduction......................................................................... 867 7.2 Front Axle Suspension............................................................ 868 Overview of the front axle suspension............................................ 868 View of the front axle suspension........................................................ 869 Disassemble of the front axle arm........................................................ 871 7.2.1 Shock Absorber..................................................................... 875 7.2.2 Chain Limiter...................................................................... 876 7.2.3 Rubber Cushion..................................................................... 877 7.2.4 Panhard Bar........................................................................ 878 7.2.5 Suspension Bearing................................................................. 879 7.2.6 Cross Tube Bushings................................................................ 881 7.3 Articulation Hinge System........................................................ 882 7.3.1 Articulation Bearing............................................................... 883 7.3.2 Articulation bearing assembly.................................................. 885 7.3.3 Articulation Hinge................................................................. 891 7.4 Fenders, Mudguards and Bonnet.................................................... 901 7.4.1 Fender RH.......................................................................... 902 7.4.2 Fender LH.......................................................................... 903 7.4.3 Mudguard........................................................................... 904 7.4.4 Bonnet Lock........................................................................ 905 7.4.5 Bonnet............................................................................. 907 7.4.6 Bonnet adjustment and control...................................................... 908 7.5 Cab.............................................................................. 910 7.5.1 Cab Removal........................................................................ 910 7.5.2 Cab Ventilation Control Panel...................................................... 912 7.5.3 Cab Ventilation Unit............................................................... 913 7.5.4 Cab Door........................................................................... 915 7.5.5 Door Damper Cylinder............................................................... 916 7.5.6 Steering Column.................................................................... 917 Chapter 08 - Rear frame...................................................................... 919 8.1 Introduction......................................................................... 921 8.2 Dumper Body...................................................................... 922 8.2.1 Dumper Body........................................................................ 922 8.2.2 Tilt Bearing....................................................................... 923 Chapter 09 - Option.......................................................................... 925 9 Optional Equipment..................................................................... 927 9.1 Automatic Tail Gate.................................................................. 927 9.2 Body heating system.................................................................. 930 9.2.1 View of the Exhaust Body Heating System............................................ 930 9.2.2 Assembly of The Exhaust Body Heating System........................................ 931 9.4 View of the Engine heater............................................................ 933 9.4.1 Engine heater assembly............................................................. 934 9.6 Webasto.............................................................................. 937 9.6.1 Webasto........................................................................ 937 9.6.2 Assembly Preparation....................................................... 938 9.6.3 Final assembly............................................................. 939 9.7 Telematic system installation........................................................ 940 9.7.1 Safety......................................................................... 940 9.7.2 Overview................................................................... 941 9.7.3 Installation procedure..................................................... 941 9.7.4 Checking functionality..................................................... 946 9.7.5 TMS software update........................................................ 947 Chapter 10 - Error codes list................................................................ 949 English.................................................................................. 951 Engine............................................................................... 951 Lubrication...................................................................... 955 Display internal................................................................. 956 VCU2............................................................................. 956 Transmission..................................................................... 959 Polish ...................................................................... 963 Silnik........................................................................... 963 Układ smarowania ................................................................ 969 Wyświetlacz główny............................................................... 969 VCU2............................................................................. 970 Skrzynia biegów.................................................................. 973 Spanish...................................................................... 977 Motor............................................................................ 977 Lubricación...................................................................... 981 Pantalla interna................................................................. 982 VCU2............................................................................. 982 Transmisión...................................................................... 985 French....................................................................... 990 Moteur........................................................................... 990 Lubrification.................................................................... 995 Afficher interne................................................................. 995 VCU2............................................................................. 996 Transmission..................................................................... 999 German.......................................................................1004 Motor............................................................................1004 Zentralschmierung ...............................................................1008 Bildschirm ......................................................................1009 VCU2.............................................................................1009 Getriebe.........................................................................1012 Blank Page................................................................................... 8 Blank Page................................................................................... 10 Blank Page................................................................................... 52 Blank Page................................................................................... 54 Blank Page................................................................................... 276 Blank Page................................................................................... 676 Blank Page................................................................................... 768 Blank Page................................................................................... 772 Blank Page................................................................................... 866 Blank Page................................................................................... 920 Blank Page................................................................................... 926 Blank Page................................................................................... 950
DAEWOO DOOSAN ADT DA30-5 SHOP MANUAL MX533347-1 – PDF DOWNLOAD:
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