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Daewoo Doosan MT36MT40B Trouble Shooting Manual – PDF DOWNLOAD
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Description
Daewoo Doosan MT36MT40B Trouble Shooting Manual – PDF DOWNLOAD
SAMPLE PAGE:
Daewoo Doosan MT36MT40B Trouble Shooting Manual – PDF DOWNLOAD
Injection Pump
Testing and reconditioning Reonditioning and testing should be carried out only at workshops having experienced personnel and the requiste equipment. In regard to repair instructions for the pump and governor, contact the pump manufactures and their organizations. Pumps and governors should be set in accoerdance with MOXY’s test tables. These list the settings and test equipment required for each type of pump
Injection timing
1. Remove the cover in the timing gear housing in front of the injection pump. The cover is fitted in the flywheel housing.
2. Set the prescribed injection pump timing on the flywheel. The injection timing is given on the plate on one of the rocker covers. If the setting is correct (at the right engine speed), the No. 1 cylinder should be at the end of its compression stroke, i.e. both inlet and exhaust valves should be closed (there should be a clearance between valve and rocker arm).
3. Insert the injection timing lock pin 8422 (alpha) through the hole in the driver and into the hole in the pump housing end plate. The holes are in line at about 9 o’clock
4. If the lock pin fits, the injection timing is set correctly. If the pin does not fit, adjust the pump drive as described in points 5-13
5. Undo the pump drive bolts. Leave the bolts in place
NOTE!
Point 6 must be carried out with care. The pump shaft can only be turned a degree or two either way.
If it in not possible to insert the lock pin through the elongated hole in the drive, it may be because the drive is incorrectly fitted.
6. Use a NV46 spanner to turn the pump shaft so that the lock pin can be pushed throught the hole in the driver and into the hole in the pump housing end plate. Leave the lock pin in place. Tighten the bolts in three stages as decribed below.
7. Tighten the two accessible pump drive bolts to 20 Nm (15 Ftlb)
8. Remove the lock pin.
NOTE!
If the lock pin is left in position when the bolts are tightened harder, the pump setting may be altered. The pump will then have to be reset on a test bench.
9. Titghten the two accessible botls to 80 Nm(59FtLb).
10. Carefully turn the engine until the third bolt becomes accessible and tighten it to 20 Nm (15 FtLb) and to 80Nm (59 FtLb) in two stages.
11. Turn the engine round one revolution and tighten the remaining bolts to 20 Nm (15 FtLb), 80 Nm (59 FtLb)and 110 Nm (81 FtLb) in three stages.
12. Turn the engine round revolution and tighten the remaining bolts.
13. Check that the lock pin can be pushed through the driver and into the pump end plate. Check on the flywheel that the timing is correct.
TABLE OF CONTENTS:
Daewoo Doosan MT36MT40B Trouble Shooting Manual – PDF DOWNLOAD
MT36/MT40B Training Guide.................................................. 1 MT36 General Information................................................... 2 New Body Design........................................................ 3 Tilting Cab............................................................ 4 Cab Interior........................................................... 5 Controls............................................................... 6 Switches............................................................... 7 Engine................................................................. 8 Electronic Control................................................. 9 Transmission........................................................... 10 Technical Data......................................................... 11 Engine............................................................. 12 Transmission....................................................... 12 Hydraulic System................................................... 13 Electrical System.................................................. 14 Relays & Fuses..................................................... 15 Meteric Conversion................................................. 16 Performance Chart.................................................. 17 Torque Limits...................................................... 18 Serial Number Locations............................................ 19 Scania DSI12 Engine ....................................................... 20 Cylinder Head.......................................................... 20 Valve Adjustment................................................... 21 Cylinder Block......................................................... 22 Cylinder Block & Liners............................................ 23 Crankshaft............................................................. 24 Camshaft............................................................... 25 Injection Pump......................................................... 0 Removal............................................................ 26 Fitting ........................................................... 28 Timing Pg. 1....................................................... 30 Timing Pg. 2....................................................... 31 Scania DEC2 Control System................................................. 32 Control Unit........................................................... 33 Basic Info............................................................. 34 DEC2-MT36.............................................................. 35 DEC2-MT40B............................................................. 36 LED fuctions-Normal Operation.......................................... 37 Sensors................................................................ 38 Sensors (cont'd)....................................................... 39 Control Rack Solenoid and Sensor....................................... 40 Fuel Shut-off, Throttle Position Sensor................................ 41 Electrical Warning..................................................... 42 Engine Protection/Diagnostics.......................................... 43 Fault Finding.......................................................... 44 Procedure.......................................................... 45 Critical Faults/Actions............................................ 46 Shutdown/Actions................................................... 47 DIP Switches....................................................... 48 Obtaining Fault Codes.............................................. 49 Dash Warning Light................................................. 50 Test/Fault Switch.................................................. 51 Chart Fault Codes.................................................. 52 Computer Codes - Pg 1.............................................. 53 Computer Codes - Pg 2.............................................. 54 Connecting Table................................................... 55 Actuator Solenoid-Fuel Pump.................................... 56 Control Rack Sensor-Fuel Pump.................................. 57 Fuel Shut Off Valve (EHAB)..................................... 58 Engine Control-Accelerator Pedal............................... 59 Location Engine Control........................................ 60 Measuring Potentiometer.................................... 61 Adjusting Potentiometer.................................... 62 Boost Temperature Sensor....................................... 63 Coolant Temperature Sensor..................................... 64 Oil Pressure Sensor............................................ 65 SPI 11/2000................................................ 66 SPI 11/2000 (Page 2)....................................... 67 SPI 11/2000 (Page3)........................................ 68 Engine Speed Sensor............................................ 69 Connector Identification & Pin No.s............................ 70 No. 270 Connector (LH Side Cab)................................ 71 Component Location on DSI12 Engine............................. 72 Component Locations on DSI14................................... 73 Component Locations in the Cab................................. 74 Relay Locations................................................ 75 Relay Indentification.......................................... 76 Electrical Connections......................................... 77 DEC2 Tuning & Calibration.................................................. 78 Laptop Start-up Procedure.............................................. 79 Main Menu.......................................................... 80 Engine Tuning...................................................... 81 Explanation of Parameters.......................................... 81 Explanation of Parameters - Page 2................................. 82 Explanation of Function Keys....................................... 83 Fault Log.......................................................... 84 F-6 Codes...................................................... 85 F-6 Codes - Page 2............................................. 86 DEC2 Configuration ........................................................ 87 DEC2 Governor Calibration.................................................. 88 Settings............................................................... 88 Procedures............................................................. 0 Multimeter Hook Up................................................. 88 Obtaining Readings................................................. 89 Rack Travel........................................................ 90 Adjusting Voltage.................................................. 90 Trim Pot 2..................................................... 91 Trim Pot 3..................................................... 92 Failed Calibration..................................................... 93 Possible Fault Messages............................................ 93 Additional Errors.................................................. 94 Calibration Passed..................................................... 94 Saving the Calibration............................................. 94 New Screens in 7.0/8.1................................................. 95 Engine Maintenance Data............................................ 95 PC Software Configuration.......................................... 96 COM Port Selection............................................. 96 OEM Information................................................ 97 Komatsu KT6140 Transmission................................................ 98 Hydraulic Retarder Valve...............................................120 Hydraulic Retarder Drain Valve.....................................121 Retarder Operation - Retarder OFF..................................122 Retarder Operation - Retarder ON...................................123 Hydraulic Circuit Diagram.............................................. 99 Torque Converter - External View.......................................100 Torque Converter - Internal Parts......................................101 Main Relief Valve......................................................102 Operation of Main Relief...........................................103 Torque Converter Main Relief...........................................104 Torque Converter Lock Up - ECMV........................................105 Converter Lock Up Operation............................................106 Driving in Direct Drive............................................107 Gear Shifting......................................................108 Transmission Valves - ECMV.............................................109 Breakdown of ECMV..................................................110 Outline of ECMV....................................................111 ECMV Actuation - Solenoid Energized................................112 ECMV Actuation - Start of Fill.....................................113 ECMV - Clutch Filling & Adjustment.................................114 High - Low and Diff Lock Solenoid Valve................................115 Operation of High - Low............................................116 High - Low Not Changing............................................117 Operation of Diff Lock ............................................118 Diff Lock Won't Engage.............................................119 Automatic Shift Control System.........................................124 Transmission Shift Controller......................................125 Controller Functions - Shift Pattern...............................126 Braking and High Power Modes.......................................127 Shift Lever Switch.................................................128 Sensors and Switches...............................................129 Transmission Testing and Adjusting.....................................130 Standard Value Table - RPM.........................................131 Standard Value Table - Pressure....................................132 Standard Value Table - Electrical - Page 1.........................133 Standard Value Table - Electrical - Page 2.........................134 Standard Value Table - Electrical - Page 3.........................135 Table of Tools.....................................................136 Special Tool S.....................................................137 Pressure Testing Ports.............................................138 Testing Torque Converter Stall Speed...............................139 Procedure for Moving Machine w/Failed Transmission.................140 Adjusting Transmission and Engine Speed Sensors....................141 Transmission Troubleshooting...........................................142 Don'ts When Handling Connectors....................................142 Handling Control Unit..............................................143 Connector ID and Pin Numbers - X1 thru X3..........................144 Connector ID - 10, 11A, 11B, 46 and96A.............................145 Connector ID - 96B, 96C, 96E ......................................146 Connector ID - 140.................................................147 Transmission Controller Connections................................148 Connecting Table - T/M Controller..................................149 Self Diagnostic Display............................................150 Error Code Finding.................................................151 Judgement Table....................................................152 Explanation of Trouble Shooting Charts.............................153 Re-enacting Displayed Code.........................................154 Precedure for re-enacting..........................................155 Points to Remember in Testing......................................156 Index of Troubleshooting Codes.....................................157 Page 2 - Index Troubleshooting Codes...............................158 Error Codes 0.1 to 0.6.............................................159 Error Codes 0.7 to A-1.........................................161 Error Codes 1.5 to 2.4.........................................163 Error Codes 2.5 to 4._ (1-6,8).................................165 Error Codes 4.1 to 5._ (1-6,8).................................167 Error Codes 5.3 to 6.2.........................................169 Error Codes 6.3 to 7.8.........................................171 Error Codes 8.1 to 9.8.........................................173 Error Codes F.A to F.F.........................................175 Drawing Electrical Plug 140........................................177 Judgement Table........................................................179 Electrical Troubleshooting Charts......................................181 A-1 Abnormality....................................................181 A-2 Abnormality....................................................184 A-3 Abnormality....................................................185 A-4 Abnormality....................................................187 A-6 Abnormality....................................................188 A-7 Abnormality....................................................189 A-8 Abnormality....................................................193 A-9 Abnormality....................................................196 A-10 Abnormality...................................................197 Error Code 1.7.....................................................202 Potentiometer Adjustment.......................................203 A-12 Abnormality...................................................204 A-13 Abnormality...................................................205 A-14 Abnormality...................................................208 A-15 Abnormality...................................................209 A-16 Abnormality...................................................211 A-17 Abnormality...................................................213 A-18 Abnormality...................................................216 A-19 Abnormality...................................................219 Index Hydraulic Testing Charts.........................................222 H-1 Machine Won't Start............................................225 H-2 Machine Jerks..................................................227 H-3 Lock Up Clutch Sticks..........................................227 H-4 Excessive Shift Shock..........................................228 H-5 No Up Shift....................................................228 H-6 Lack of Power..................................................229 H-7 Excessive Time Lag.............................................235 H-8 High Converter Oil Temperature.................................237 H-9 Low Converter Oil Pressure.....................................238 H-10 High - Low Changeover.........................................239 H-11 Diff Lock ON/OFF Failure......................................240 H-12 Retarder ON/OFF Failure.......................................241 MT36 Air System............................................................242 Air Supply System -410080..............................................243 Air Supply System 410085-..............................................244 Brake System 1.........................................................245 Brake System 2.........................................................246 Parking Brake System...................................................247 Exhaust Brake System...................................................248 Cab Central Air........................................................249 Air Supply Driver's Seat...............................................250 Tilting System.........................................................251 Air Dryer..............................................................252 Four-Way Protection Valve..............................................253 Park Brake Valve.......................................................254 Pneumatic Valves.......................................................255 Tilt Servo Valve.......................................................256 Diaphragm Cylinder.....................................................257 Foot Brake Valve.......................................................258 Hydraulics-Structure & Function............................................260 Schematic Diagram......................................................261 Circuit Function.......................................................262 Hydraulic Pumps........................................................263 Tilting System.........................................................265 Tilt Cylinder - Closed End.............................................267 Tilt Cylinder - Oil Ports..............................................268 Steering System........................................................269 Steering Cylinder......................................................270 Breakdown - Steering Cylinder..........................................271 MT36 - Tip System w/Hydraulic, Pneumaticand Electric Switches..........272 MT40B Tip System with Hydraulic, Pneumatic and Electrical Functions....278 Explanation of Tip Circuit.............................................280 Tilting Positions......................................................282 Location of Float Valve & Switches.....................................286 SPI 21/2000 - Protection For Float Valve...............................287 Location 'S' Switch....................................................288 Safety Relief Valve....................................................289 Tilt Cylinder - Disassembled...........................................290 'S' Port - Tilt Cylnder................................................291 Tilt Valve - Exploded View.............................................292 SPI 18/2000 - Plugs for Valve..........................................293 Tilt Valve - Cut Away..................................................294 Shock Valve & Relief Valve.............................................295 Hydraulic Tank.........................................................296 Hydraulic Pump (Double Pump)...........................................297 Hydraulic System-Testing & Adjusting...................................298 Measurement of Tip Pressures.......................................299 Adjusting Pressure-MT36.......................................300 Access to Tilt Valve.......................................301 Up Pressure................................................302 Down Pressure..............................................304 Two Position Relief Valve..................................305 Adjusting Lift Pressure-MT40B..................................299 Adjusting Lowering Pressure....................................307 Adjustment of the 'S' Sensor...................................308 Adjustment of 'S' Relief Valve.................................309 MT36 Electrical Schematics.................................................311 Circuit 1 - Power Supply...............................................311 Circuit 2 - Instrument Panel...........................................313 Circuit 3 - Cab........................................................315 Circuit 4 - Fuses and Relays...........................................317 Circuit 5 - Engine Sensors.............................................319 Circuit 6 - Transmission Sensors.......................................321 Circuit 7 - Front Frame................................................323 Circuit 8 - Rear Frame.................................................325 Circuit 9 - Switchboards...............................................327 Lock-Up Circuit........................................................330 Exhaust Brake Circuit..................................................331 Retarder Circuit.......................................................332 Inter Axle Lock Circuit................................................333 High/Low Range Circuit.................................................334 AC Circuit.............................................................335 Auto Lube Circuit......................................................336 MT40B General Information..................................................337 MT40B .................................................................337 Technical Data.........................................................338 Measurements.......................................................338 Engine Specs.......................................................339 Hydraulic System...................................................340 Electrical System..................................................341 Performance Chart..................................................344 Exhaust Brake & Retarder Capacity..................................345 Torque Limits for Bolts............................................346 Serial Number Plates...............................................347 MT40B Weight&Volume....................................................348 MT40B Engine...........................................................349 MT40B Transmission.....................................................350 MT40B Body.............................................................351 MT40B Cab..............................................................352 Scania DSI14 Engine........................................................355 Individual Cylinder Heads..............................................355 Engine Block...........................................................356 Crankshaft.............................................................357 Piston.................................................................358 Timing Gears/Camshaft..................................................359 Oil Pump...............................................................360 Intake Manifold........................................................361 6WG310 Transmission........................................................363 Measuring Points.......................................................363 Code Chart - MT40B.....................................................364 EST37 Control Unit..................................................... 0 Digital Display....................................................365 Explanation of Codes...............................................366 Display During AEB.................................................367 Operating Modes....................................................368 Table of Fault Codes............................................... 0 Fault Codes 11-26..............................................369 Fault Codes 27-35..............................................370 Fault Codes 36-65..............................................371 Fault Codes 66-76..............................................372 Fault Codes 77-84..............................................373 Fault Codes 85-92..............................................374 Fault Codes 93-6F..............................................375 Fault Codes 9A-A4..............................................376 Fault Codes A5-B5..............................................377 Fault Codes B6-BF..............................................378 Fault Codes D3-F6..............................................379 Measuring Resistance of Sensors....................................380 Location Senders on Transmission...................................381 Electrical Schematic...............................................383 VTS-3 Gear Selector-Testing........................................384 Tandem Bearings............................................................389 MT40B Air System...........................................................393 Air Supply System......................................................394 Moisture Drain System..................................................395 Brake Circuit 1........................................................396 Rear Brake Circuit, Front Vehicle......................................397 Rear Brake Circuit.....................................................398 Parking Brake System, Front Vehicle....................................399 Rear Parking Brake System..............................................400 Tilting System.........................................................401 Air Pressure System - Front............................................402 Hydraulic Retarder.....................................................403 Four-Way Protection Valve..............................................404 Diaphragm, Main Brakes.................................................405 Parking Brake Servo Valve..............................................406 Air Governor...........................................................407 Pneumatic Valves.......................................................408 Relay Valve............................................................409 Air Dryer..............................................................410 Air Cylinder - Park Brake..............................................411 Tilt Servo Valve.......................................................412 Foot Brake Valve.......................................................413 Retarder Valves........................................................414 MT40B Electrical System.................................................... 0 MT40B Index - Electrical System........................................415 Welding Warning........................................................416 How Index Works........................................................417 Description of Electrical Symbols......................................418 Specifications - Engine Components.....................................419 Specifications - DEC2 Components.......................................420 Specifications (cont'd)................................................421 Specifications - Transmission..........................................422 Specifications - General...............................................423 Specifications - General...............................................424 Cross Reference List - 1...............................................425 Cross Reference List - 2...............................................426 Cross Reference List - 3...............................................427 Cross Reference List - 4...............................................428 Cross Reference List - 5...............................................429 Cross Reference List - 6...............................................430 Cross Reference List -7................................................431 Map 01 - Starting and Charging.........................................432 Map 02 - Front Frame...................................................433 Map 03 - Rear Frame....................................................434 Map 04 - Engine........................................................435 Map 05 - DEC2..........................................................436 Map 06 - Transmission..................................................437 Map 07 - Cab Outside, Front............................................438 Map 07 - Cab Outside, Rear.............................................439 Map 10 - Instrument Panel..............................................440 Map 12 - Cab Inside Lower Left Side....................................441 Map 12 - Cab Inside Lower Right Side...................................442 Map 13 - Cab Inside....................................................443 Map 14 - Fuse Box and Relays...........................................444 Map 15 - Fuse and Relay Indentification................................445 Circuit 01 - Compartment and Cab Light.................................446 Circuit 02 - Brake Light...............................................447 Circuit 03 - Power Supply, Starting....................................448 Circuit 04 - Extra High Beam...........................................449 Circuit 05 - Heated Seat, Mirrors, & Air Dryer.........................450 Circuit 06 - Fan and A/C...............................................451 Circuit 07 - Flame Start...............................................452 Circuit 08 - Working Light.............................................453 Circuit 09 - Reverse and Work Light....................................454 Circuit 10 - Instrument Light..........................................455 Circuit 11 - Lighter...................................................456 Circuit 12 - Rotating Beacon...........................................457 Circuit 13 - Radio.....................................................458 Circuit 14 - Wiper, Washer and Horn....................................459 Circuit 18 - Engine Wiring Diagram.....................................460 Circuit 19 - Transmission Wiring Diagram...............................461 VTS-3 Gear Selector-Testing........................................462 Circuit 20 - Brake Warning.............................................464 Circuit 21 - Headlight.................................................465 Circuit 22 - Tilting System............................................466 Circuit 23 - Tachometer, Fuel Gauge, Voltmeter.........................467 Circuit 24 - Direction and Hazard Light................................468 Electric Circuit Auto Lube.............................................469 Location of Senders - Instrument Panel ................................470 Contact Arrangements...................................................471 Groeneveld Single System...................................................472 Outline of System......................................................473 Pneumatic Pump.........................................................474 Filling Reservoir......................................................475 Timer..................................................................476 Solenoid Valve.........................................................477 Pressure Switch........................................................478 Distribution Blocks....................................................479 Metering Units.........................................................480 Test 1.................................................................481 Test 2.................................................................482 Test 3.................................................................483 Timer Display Unit.....................................................484 Hook Up TDU........................................................485 Read Timer.........................................................486 Twin GINA Software User's Manual 2003......................................492 Table of contents......................................................494 Introduction...........................................................498 1.1 Introduction...................................................499 1.2 Groeneveld Transport Efficiency B.V............................499 1.3 Twin GINA Programming Software.................................500 Installation...........................................................502 2.1 System requirements............................................503 2.2 Installing the software........................................503 2.3 Changing the serial port (COM-port) setting....................505 2.4 Removing the software..........................................506 Starting the program...................................................508 3.1 Starting the program...........................................509 3.2 Validating the program.........................................509 3.3 Making a connection............................................510 3.4 Working offline................................................511 3.5 Closing the program............................................511 Functions..............................................................512 4.1 Introduction...................................................513 4.2 File menu......................................................513 4.3 Reports menu...................................................514 4.4 Twin menu......................................................515 4.5 Language.......................................................516 4.6 About..........................................................516 Parameters.............................................................518 5.1 Parameter settings and read-outs...............................519 5.2 The Main (F9) tab..............................................519 5.3 The Parameters (F10) tab.......................................522 5.4 The Errors (F11) tab...........................................526 5.5 The Diagnosis (F12) tab........................................528 Reports................................................................534 6.1 Introduction...................................................535 6.2 Entering data of pump unit currently connected.................535 6.3 Viewing a report...............................................537 6.4 Printing a report..............................................538 6.5 Editing a report...............................................538 6.6 Importing a report.............................................539 6.7 Exporting a report.............................................539 Shop Manual............................................................542 Table of Contents..................................................543 Introduction.......................................................548 Using Manual.......................................................549 Safety Precautions.................................................550 Evironmental Considerations........................................551 Composition........................................................552 Operating Principle................................................553 Operation..........................................................556 The Twin Pump Unit.................................................557 5/2 Solenoid Valve.............................................559 Dosers and Doser Blocks............................................560 Principle of Operation.........................................561 Grease Pressure Switch.........................................562 Signal Light...................................................563 Test Button....................................................564 Filing Grease Reservoir........................................566 Maintenance........................................................568 Fault Finding Charts...........................................570 Grease Reservoir...............................................575 Filler Coupling & Filter.......................................580 Test Push Button...............................................586 Control Unit...................................................587 Minimum-Level Switch...........................................589 Solenoid Valve.................................................590 Pump Assembly..................................................595 Electric Pump Motor............................................599 Testing the Pump...............................................603 Installation...................................................605 Electrical Connections.....................................606 Technical Data.................................................607
DAEWOO DOOSAN MT36MT40B TROUBLE SHOOTING MANUAL – PDF DOWNLOAD:
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