Hyundai HA30 / HA30A HA45 / HA45A Articulated Dump Truck Shop Manual 2023 PDF

Description

Hyundai HA30 / HA30A HA45 / HA45A Articulated Dump Truck Shop Manual 2023 – PDF DOWNLOAD

The Hyundai HA30/HA30A and HA45/HA45A Articulated Dump Truck Shop Manual (PDF) is a comprehensive guide for maintenance and repair, providing detailed instructions for servicing these trucks to ensure optimal performance and longevity.

FILE DETAILS:

Hyundai HA30 / HA30A HA45 / HA45A Articulated Dump Truck Shop Manual 2023 – PDF DOWNLOAD

Language : English
Pages : 1133
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Hyundai HA30 / HA30A HA45 / HA45A Articulated Dump Truck Shop Manual 2023 – PDF DOWNLOAD

Cover Shop Manual HA 1
HA30 – HA45 Final S2 – 0 – General (VERKST-BOK – 1132468 – 1 – A) – 1 2
Foreword 5
Doosan ADT Payload Policy 6
Torque limit table 7
Types of sealing-/locking compounds and lubricants 11
Safety in workshop 12
Working on machine 13
Personal Protective Equipment (PPE) 16
Vibration 17
Injurious noise 18
Organic solvent 19
Fueling 20
Fire and Explosion Prevention 20
Fire and explosion risks 22
In case of Fire 23
Coolant 24
Refrigerant 25
Air pollution 26
Operation in extreme conditions 27
Liquid or gas under high pressure 31
Asbestos 32
Lead 32
Battery hazard prevention 33
Disposal of hazardous materials 35
Jacked up vehicle or bodywork 36
Crushing and Cutting Danger 36
Heavy units 37
More than one person working with the same object 38
Involuntary start of electric motors etc 38
Rotating parts 39
Splinters, flying object When using certain tools 40
Springs under load 41
Precautions for disassembly and assembly 42
HA30 – HA45 Final S2 – 1 Engine PDE (VERKST-BOK – 1132510 – 1 – A) – 1 50
Engine identification 56
Removal of engine assembly 60
Lifting the engine 66
Starting the engine 67
Important information about the fuel 68
Fuel system Tier2 (PDE) 69
Schematic diagram of the fuel system Tier2 69
Overflow valve 69
General 70
Fuel 70
Temperature dependency of the fuel 71
Fuel filter 72
Changing the fuel filter 72
Water separating prefilter PDE 73
Changing the water separating fuel filter 73
Bleeding the fuel system 74
Feed pump 76
Renewing the control unit 77
Cylinder head – PDE System Tier2 78
Cylinder head, parts view PDE Tier2 78
Special tools 79
Valve mechanism 80
Dismantling 85
Renewing the valve stem seal 85
Replacement of valve seats 86
Machining the valve seats insert 87
Renewing the valve guides 89
Renewing PDE unit injector sleeves 90
Assembly 91
Fitting 91
Valve adjustment DC9 / DC13 with XPI 93
Adjustment tables DC9 / DC13 94
Checking and adjusting the unit injectors 96
Turbocharger 97
Measuring radial clearance and axial clearance 98
Renewing the turbocharger 100
General 101
Changing oil filter 102
Oil analysis 103
Checking oil level 103
Changing the oil 104
Special tools 105
Pistons and cylinder liners 106
Special tools 107
Connecting rods 108
Removing and dismantling connecting rods and pistons 109
Renewal of bearing bushing in connecting rod 111
Pistons 113
Assembling piston and connecting rod 115
Cylinderblock 116
Cylinder liner 116
Removing the cylinder liners 118
Measuring the cylinder liner height 119
Measuring the cylinder wear ridge and cylinder bore 119
Fitting the cylinder liners 120
Fitting the piston and connecting rod 121
Flywheel and flywheel housing 123
Special tools 124
Removing the flywheel 124
Renewing the rear crankshaft seal 126
Removing the flywheel housing 126
Fitting flywheel housing 127
Fitting the flywheel 129
Flexible coupling 130
Safety instructions 130
Functional description 130
Disassembly and dismantling the coupling 131
Assembling the coupling →7×1126;→8×1128 131
Installation instructions 131
Friction disk, friction ring 132
Timing gear – 13 and 9 liter 133
Gear drive 133
Belt drive collant pump, generator and AC compressor 134
Checking the drive belt 135
Check for leaks 136
Renewing the seal in the front cover 137
Crankshaft damper 138
Timing gear, exploded view 139
Special tools 140
Intermediate gear 141
Renewal of bearing in intermediate gear for the camshaft 142
Camshaft gear 144
Crankshaft gear 145
Camshaft 146
Replacement of camshaft bearing 147
Crankshaft 154
Removal 155
Fitting 158
Adjust – Machining the crankshaft 159
Lubrication system 160
General 160
Oil pump 162
Lubrication oilways 163
Oil pressure 164
Oil cooler, engine 165
Oil cooler view See 010009 166
Renewing seals and leakage testing 167
Oil filter 168
Centrifugal oil cleaner 169
Dismantling and assembly 170
Operational testing of the centrifugal oil cleaner 173
Oil mist separator 174
General 174
High levels of oil carryover 174
Crankcase pressure measurement 176
Oil mist separator exploded view 177
Oil mist separator disassemble 178
Check – Rotational speed on oil mist separator 180
Alternator 100 A 181
Check 181
Output test 182
Renewal – Bearing and carbon brushes 185
Oil pump, brake cooling 189
Exploded view 189
Disassemble and overhaul the oil pump 190
Checking and renewing parts 192
Oil circulate pump assemble 193
Renewing the gasket 196
Cooling fan 197
View of the radiator system 197
Cooling system 198
Principal view of the cooling system 198
Circulation 199
Coolant 200
Checking coolant level 201
External leakage 202
Internal leakage 202
Checking the antifreeze level 203
Changing coolant 203
Filling coolant 204
Cleaning the cooling system 205
Disassemble the cooling unit 206
Disassemble the cooling unit 208
Thermostat and thermostat housing 209
Thermostat 210
Coolant pump 211
External cleaning 215
Internal cleaning 215
Technical data DC13 with PDE 216
General data 216
Technical data DC9 with PDE 218
General data 218
Troubleshooting SDP3 / Canbus 220
To do: 220
Troubleshooting – basic info 220
Diagnostic procedure 221
Use of diagnostic kit 221
Connection point Canpc + OBDII conector 221
Can bus overview 221
SDP3 Scania dagnostic 222
Troubleshooting Manual 223
White smoke 224
White smoke, water vapour 224
Black smoke on starting 225
Blue smoke 226
Fuel in the oil 226
Oil in coolant 227
Coolant/water in oil 227
Low oil pressure 228
High oil pressure (engine warmed up) 230
Abnormal wear (liner, piston rings, etc ) 230
Vibration, no driven components engaged 231
Vibration when the clutch or reverse gear is engaged 232
Vibration when alternator is in operation 232
Engine speed hunting – single-speed engines with RQ governor 233
Engine speed hunting – single-speed engines with RSV governor 233
Delivery pipe fractures 234
External corrosion on cylinder liner 234
Engine difficult to start 235
Fluid stroke 236
Knocking/noise 237
High oil consumption 238
High fuel consumption 239
Low compression 239
Low engine output 240
Hot engine 241
Cold engine 242
Coolant loss 242
Polluted coolant 242
High oil temperature 243
High exhaust temperature 243
Low charge air pressure 244
Low fuel pressure 244
Low system voltage 244
High system voltage 245
External oil leakage 245
External fuel leakage 245
External coolant leakage 246
Oil pressed out via crankcase ventilation 246
Turbocharger breakdown 246
Compressed air system 247
HA30 – HA45 Final S2 – 1 Engine XPI (VERKST-BOK – 1132587 – 1 – A) – 1 250
Engine identification 256
Removal of engine assembly 260
Lifting the engine 265
Starting the engine 266
XPI Fuel system DA30/45 267
Route of the fuel on 9 and 13 liter engines 268
Fuel filter and water separation filter 269
Changing the fuel filter 270
Water separating prefilter 271
Changing the water separating fuel filter 271
Bleeding the fuel system using a hand pump 271
Overflow valve 272
Fuel system components 273
Schematic diagram of the fuel system: 273
Important information about the fuel 274
Exhaust system XPI T4F 275
Introduction system overview 275
Overview – Control system for exhaust gas aftertreatment 276
Control unit EEC3 282
System overview for mechanics 283
System overview for electronics 284
Ad blue filter change 285
Reductant doser 286
Start-up instruction for new SCR Pump 288
Reductant pump, function 289
EGR valve and actuator removal 293
Checking the control cylinder 294
Leak testing the EGR cooler 294
Renewing the control unit 296
Common rail injectors Tier4/XPI 297
Cylinder head – XPI system Tier4 298
Cylinder head, parts view XPI system Tier4 298
Injector Scania XPI 299
Valve adjustment DC9 / DC13 with XPI 301
Adjustment tables DC9 / DC13 302
Turbocharger 304
Measuring radial clearance and axial clearance 305
VGT (Variable geometry turbo) 307
VGT Removal 307
VGT fitting 308
General 309
Changing oil filter 310
Oil analysis 311
Checking oil level 311
Changing the oil 312
Special tools 313
Pistons and cylinder liners 314
Special tools 315
Connecting rods 316
Removing and dismantling connecting rods and pistons 317
Renewal of bearing bushing in connecting rod 319
Pistons 321
Assembling piston and connecting rod 323
Cylinderblock 324
Cylinder liner 324
Removing the cylinder liners 326
Measuring the cylinder liner height 327
Measuring the cylinder wear ridge and cylinder bore 327
Fitting the cylinder liners 328
Fitting the piston and connecting rod 329
Flywheel and flywheel housing 331
Special tools 332
Removing the flywheel 332
Renewing the rear crankshaft seal 334
Removing the flywheel housing 334
Fitting flywheel housing 335
Fitting the flywheel 337
Flexible coupling 338
Safety instructions 338
Functional description 338
Disassembly and dismantling the coupling 339
Assembling the coupling →7×1126;→8×1128 339
Installation instructions 339
Friction disk, friction ring 340
Timing gear – 13 and 9 liter with XPI 341
Gear drive 341
Belt drive collant pump, generator and AC compressor 342
Checking the drive belt 343
Check for leaks 344
Renewing the seal in the front cover 345
Crankshaft damper 346
Timing gear, exploded view 347
Special tools 348
Intermediate gear 349
Camshaft gear 352
Crankshaft gear 353
Camshaft 354
Replacement of camshaft bearing 355
Crankshaft 362
Removal 363
Fitting 366
Adjust – Machining the crankshaft 367
Lubrication system 368
General 368
Oil pump 370
Lubrication oil-ways 371
Oil pressure 372
Oil cooler, engine 373
Oil cooler view 374
Renewing seals and leakage testing 375
Oil filter 376
Centrifugal oil cleaner 377
Dismantling and assembly 378
Operational testing of the centrifugal oil cleaner 381
Oil mist separator 382
General 382
High levels of oil carryover 382
Crankcase pressure measurement 384
Oil mist separator exploded view 385
Oil mist separator disassemble 386
Check – rotational speed on oil mist separator 388
Alternator 100 A 389
Check 389
Output test 390
Renewal – bearing and carbon brushes 393
Oil pump, brake cooling circulate 397
Exploded view 397
Disassemble and overhaul the oil pump 398
Checking and renewing parts 400
Oil circulate pump assemble 401
Renewing the gasket 404
Cooling fan 405
View of the radiator system 405
Cooling system 406
Principal view of the cooling system 406
Circulation 407
Coolant 408
Checking coolant Level 409
External leakage 410
Internal leakage 410
Checking the antifreeze level 411
Changing coolant 411
Filling coolant 412
Cleaning the cooling system 413
Disassemble the cooling unit 414
Disassemble the cooling unit 416
Thermostat and thermostat housing 417
Removing and fitting thermostat 418
Coolant pump 419
External cleaning 423
Internal cleaning 423
Technical data DC13 with XPI 424
General data 424
Technical data DC9 with XPI 426
General data 426
Troubleshooting SDP3 / Canbus 428
To do: 428
Troubleshooting – basic info 428
Troubleshooting fuel system 429
Troubleshooting guide 429
Diagnostic procedure 446
Use of diagnostic kit 446
Connection point Canpc + Testman 446
Can bus overview 446
SDP3 Scania diagnostic 447
Troubleshooting Manual 448
White smoke 449
White smoke, water vapour 449
Black smoke on starting 450
Blue smoke 451
Fuel in the oil 451
Oil in coolant 452
Coolant/water in oil 452
Low oil pressure 453
High oil pressure (engine warmed up) 455
Abnormal wear (liner, piston rings, etc ) 455
Vibration, no driven components engaged 456
Vibration when the clutch or reverse gear is engaged 457
Vibration when alternator is in operation 457
Engine speed hunting – single-speed engines with RQ governor 458
Engine speed hunting – single-speed engines with RSV governor 458
Delivery pipe fractures 459
External corrosion on cylinder liner 459
Engine difficult to start 460
Fluid stroke 461
Knocking/noise 462
High oil consumption 463
High fuel consumption 464
Low compression 464
Low engine output 465
Hot engine 466
Cold engine 467
Coolant loss 467
Polluted coolant 468
High oil temperature 468
High exhaust temperature 468
Low charge air pressure 469
Low fuel pressure 469
Low system voltage 469
High system voltage 470
External oil leakage 470
External fuel leakage 470
External coolant leakage 471
Oil pressed out via crankcase ventilation 471
Turbocharger breakdown 471
Compressed air system 472
HA30 – HA45 Final S2 – 2 Transmission (VERKST-BOK – 1132586 – 1 – A) – 1 474
General 478
Structure of the Repair Manual 479
Denomination of standard dimensions 480
Conversion table 480
Torque limits for screws 481
Table 481
Setting clutch 481
Labeling of type plate 482
Information on spare parts ordering 482
Type plate electronic control unit 482
Configuration of transmission 483
Transmission schematics and gear schematics 483
Gear schematics 483
Measuring points and connections 484
Table 484
Measuring points for pressure oil and temperature 484
Installation sheet 485
Special tools for disassembly and reassembly 486
Commercial tools for disassembly and reassembly 499
Removal of transmission, disassembly 504
Disassemble the structure bar 511
Disassemble the hydraulic hoses 511
Positioning for disassembly and reassembly 515
Removal and refitting various components 516
Transmission 516
LKV axle insert 516
Separate axle insert LKV assy from transmission 517
Removal inner components of Trasnsmission 518
Removal of speed sensor n4-output 518
Disassembly of shifting block I and speed sensors 519
Engine connection 523
Oil supply 527
Removal of shifting block II, valve block primary 527
pump and retarder 527
Retarder 530
Valve block 532
Shifting block II 533
Primary pump 535
Removing output flanges 536
Power take-off 537
Version with 1st PTO 537
Emergency steering pump 538
Planetary drive “F” 539
Separate planetary drive from housing II 539
Dismantling planetary drive 540
Removal input shaft and clutches 547
Separate housing I and housing II 547
Housing I 548
Differential “G” 551
Clutches “V”; “R”; “A”; “B”; “C”; “D”; “E” 551
Housing II 553
Clutches „V“; „R“; „A“; „B“; „C“; „D“; „E“ and Differential 556
Clutch “E” 557
Clutch “R” 562
Clutch “B“ 567
Clutch “V“ 572
Clutch “C“ 576
Clutch “D“ 581
Clutch “A“ 586
Dismantling differential ”G“ 591
Reassembly of Transmission inner parts 597
Clutches „V“; „R“; „A“; „B“; „C“; „D“; „E“ and Differential 597
Clutch ”E“ 597
Clutch “R“ 605
Clutch “B“ 612
Clutch “V“ 619
Clutch “C“ 626
Clutch “D“ 633
Clutch “A“ 640
Check of the disk clearance all clutches 647
Assembling differential ”G“ 648
Installation input shaft and clutches 655
Housing II 655
Clutches “V”;“R”;“A”;“B”;“C”;“D”;“E” 659
Housing I 662
Assemble housing I and housing II 665
Oil supply 666
Shifting block II 666
Valve block 668
Retarder 670
Primary pump 673
Installation retarder, primary pump, valve block and shifting block II 673
Engine connection 677
Planetary drive “F” 681
Mount planetary drive to housing II 688
Output to front and rear axle 690
Output to front axle with axle insert LKV 690
Power take-off 692
PTO-gear – 1st power take-off 693
PTO-input shaft 694
Emergency steering pump 696
Reassembly of shifting block I and speed sensors: 697
Shifting block I 697
Refitting of speed sensor n4-output 702
Refitting breather, Oil sight level glass, Cover plate and screw plug 703
Disassembly of LKV Axle Insert 705
Disassembly 705
Dismantling multi-disk differential lock 709
Disassembling input 711
Assembling of LKV Axle Insert 713
Installing input 717
Adjusting differential bearing rolling torque and backlash 719
Checking backlash on the slotted nut 721
Checking contact pattern 721
Assembling output 722
Contact pattern examples of Gleason Tooth System 728
Field of application: 728
Ideal contact pattern: 728
Contact pattern setting: 728
Flank glossary: 728
EXAMPLE 1: DEDENDUM TOOTH POSITION 729
EXAMPLE 2: ADDENDUM TOOTH POSITION 730
EXAMPLE 3: “LINE” CONTACT PATTERN 731
Transmission assembly 732
Clutch calibration 740
Transmission oil check 743
HA30 – HA45 Final S2 – 3 Drive line (VERKST-BOK – 1132589 – 1 – A) – 1 747
Introduction 752
General 753
Structure of the repair manual 754
Denomination of standard dimensions 755
Conversion table 755
Kessler special tools for DA30 756
Driveline components 758
Hub assembly wheel gear front with brake 759
Hub assembly wheel gear 759
Assembly of the hub assembly 760
Overwiew of parts 760
Assembly of the thrust ring 761
Assembly of the spacer ring 761
Assembly hub assembly 761
Prepare and mount wheel hub 762
Prepare wheel hub 762
Assembly wheel hub 763
Adjustment of wheel bearings 764
Tightening torque of wheel safety nut 764
Assembly wheel bearing adjustment nut 764
Locking wheel bearing adjustment nut 764
Disassembly of planetary gear 765
Disassembly of sun gear 765
Loosening the wheel bearing adjustment nut 765
Checking the wheel bearing adjustment nut 765
Assembly of the face seal 766
Assembly of the ring gear and ring gear carrier 770
Prepare the ring gear and the ring gear carrier 770
Assembly of the ring gear carrier 770
Assembly wheel bearing adjustment nut 771
Locking wheel bearing adjustment nut 772
Preparation and assembly axle shaft 772
Assembly of the thrust ring 773
Assembly of the sun gear 773
Planetary gear drive 774
Assembly of planetary gear 775
Prepare planetary gear 775
Assembly of the planetary housing 776
Disassembly of planetary gear 777
Assembly / disassembly of cageless needle bearing 778
Assembly 778
Disassembly 778
Hub assembly wheel gear rear with brake 779
Hub assembly wheel gear 779
Overview of parts 780
Hub assembly wheel gear rear without brake 781
Hub assembly wheel gear 781
Overview of parts 782
Wet multiple disc brake 783
Connections wet multiple disc brake 784
Disassembly wet multiple disc brake 785
Assembly wet multiple disc brake 786
Air gap setting with piston adjustment 789
Assembly wet multiple disc brake on the axle 789
Test of the cooling oil chamber 790
Bleeding the wet multiple disc brake 790
Final assembly 791
Check the air gap (pressurized) 791
Alignment of the discs 791
Drive shafts 792
Front frame 792
Rear frame 793
Mounting the bearings on the intermediate shaft (B) 794
Front differential and transmission 803
Brakes 804
Service brake 804
Service brake description 805
Parking brake 806
Troubleshooting the park brake 807
Brake disc runout 808
Testing of parking brake 809
Removal of the linings 810
Removal of the park brake unit from dump truck 812
Disassembly of the park brake unit 812
Assembly of the park brake unit 813
Assembly of the park brake 814
Adjustment of the initial caliper clearance 817
Disc 819
Measure disc thickness 820
Lining wear measurement of wet multiple disk brake 821
Rear differential 822
Overview of parts 822
Exchange of the complete rear differential 823
Safety precautions 823
Disassembly 824
Complete removal of the differential 827
Disassembly of differential and carrier assembly 829
Assembly of differential and carrier assembly 830
Adjustment of drive pinion distance 830
Sample calculations ( dimensions in mm) 832
Assembly of the drive pinion bearing 833
Assembly radial seal ring on the drive flange 837
Assembly drive flange 838
Assembly lock nut 840
Securing of the lock nut 840
Limited-slip differential 841
Operating sequence 842
Assembly ring gear 843
Tightening torque for standard metric threads 844
Assembly tapered roller bearing onto differential housing 845
Installation of the pre-assembled differential 845
Fastening bearing caps 846
Dimension of backlash 846
Adjustment of backlash 847
Adjustment differential 848
Checking the contact pattern of the gear teeth 849
Locking the bearing adjustment rings 850
Assembly differential and axle house 851
Assembly wear ring axle house 852
Assembly bearingpacks axle house 853
Tandem 855
Bogie housing overview 855
Tandem section view 856
Assembly gearwheels 857
Installation of gearwheels “B” in tandem 858
Installation of gearwheels “A” in tandem 859
Installation of hub in tandem 860
Installation of gearwheels “C” in tandem 861
Checking clearance in the tandem bearing 863
View of the tandem bearing DA30 & DA45 (up to 8×1701) 864
View of the tandem bearing DA45 (8×1702 and beyond) 865
Assembly bogie – tandem to diff 866
Install rear axle to frame bearing 867
General information 868
Recommendation for repairs 868
Oil change for tandem housing and planetary drive(hubs) 869
General information 869
Differential + axle housing 869
Bogie housing 869
Oil change front and rear hubs with brakes 870
Oil change rear hubs without brakes 870
Note: 871
HA30 – HA45 Final S2 – 5 Hydraulic system (VERKST-BOK – 1132590 – 1 – A) – 1 873
Components, capacities and oil types 875
Hydraulic system main function 876
Hydraulic parts view DA30 877
Hydraulic System Description 877
Hydraulic System Components 878
Main Valve Circuit (Up to 7X1750 / 8X1718) 880
Main Valve Circuit (From 7X1751 / 8X1719) 881
Main Valve – List Of Components 882
Main Valve – Spare Parts & Torques 884
Hydraulic circuit DA30-45 (Up to 7X1836 / 8X1765) 891
Hydraulic circuit DA30-45 (From 7X1837 / 8X1766) 893
Startup test procedure 895
Main Pump 896
Pump description 896
Test block 897
Main pump pressure adjusting 898
Main pump pressure adjusting 899
Main pump circuit 900
Main pump parts list 900
Main pump exploded view 901
Steering system 903
Orbitrol 904
Steering valve 907
Steering circuit DA30 / DA40 908
Steering Cylinder 909
Steering cylinder, sectional drawing 911
Steering cylinder Repair Instructions 912
Emergency steering pump 914
Tilting system 917
Tilt Lever 917
View of the tilting system 918
Tilt cylinders: 919
Tilt cylinder, sectional drawing 921
Tilt cylinder Repair Instructions 922
Fan system 924
Fan Drive Motor 925
Disassemble the fan and fan motor 926
Brakes 927
Brake circuit view (Up to 7X1836 / 8X1765) 927
Brake circuit view (From 7X1837 / 8X1766) 928
General discription 929
Parking brake, description 929
Parking brake circuit view 930
Service brake, description 931
Accumulators 932
Description of the Accumulators 932
Filling table of Correction Factors 935
Main valve pressure adjustment: 936
Brake cooling system 937
HA30 – HA45 Final S2 – 6 Electrical system (VERKST-BOK – 1132591 – 1 – A) – 1 940
Safety instructions 943
Welding on the dump truck 943
Battery hazard prevention 944
Diagnostic 945
Overview tools 945
CanPc 945
CanPc setup 946
CIF2 interface 947
Software update 950
VCU software update procedure 950
Transmission software update With CANPC 951
Components 955
Front wagon 955
Rear wagon 956
Overview on the inside of the cabin 957
Overview on the outside of the cabin 958
Battery 959
Cabin 960
VCU3 960
HVAC 961
A/C compressor 961
Blower control 962
Water valve 962
Flap motor 963
Temperature sensors 963
Evaporator temperature sensor 963
Pressure sensors 963
Radio 964
Interior light 965
Cigarette lighter 965
Speakers 966
Doorswitch 966
Tip lever 967
Driver seat 967
Gear selector 968
Wiper motor 968
Throttle pedal 969
LCD Display 969
TMS 970
Electric mirrors (optional) 971
Buzzer 971
DC – DC converter 972
USB charger 972
Park brake switch 973
Mirror adjustment switch 973
Steering column switch 973
Retarder lever 974
Diagnostic connector 974
Electrical parts involved in hydraulic control 975
Test block 975
Steering valve 976
Main valve 977
Parking brake sensor 978
Body float sensor 979
TPMS (optional) 980
Tire sensor 980
Heater (Optional Webasto) 981
Webasto Thermo Pro 90 981
Lubrication pump 982
PM1 983
Sensors 984
Clogged air filter sensor 984
Hydraulic level sensor 984
Level sensor 985
Proximity sensor 985
Temperature sensor 986
Rear view camera 986
Lights 987
Main lights 987
Rear lights 987
Beacon light 988
Direction/Marking Lights 988
Work lights 989
Marking light for mirrors 990
Electrical circuits 990
CAN bus 990
Wiring routing 991
Front frame 991
Rear frame 992
Cabin 993
Electrical diagrams 994
Cabin 994
Front and rear 995
Power, engine and options 996
HVAC unit VCU3 997
HA30 – HA45 Final S2 – 7 Front frame (VERKST-BOK – 1132592 – 1 – A) – 1 998
7 1 Introduction 999
7 2 Front Axle Suspension 1000
Hydraulic cylinder disassembly 1002
Hydraulic cylinder reassembly 1004
Suspension cylinder repair instructions (up to 7×1889 / 8×1804) 1007
Suspension cylinder repair instructions (from 7×1890 / 8×1805) 1008
Panhard Bar 1010
Suspension Bearing 1011
Cross Tube Bushings 1013
7 3 Articulation Hinge System 1016
Articulation Bearing 1017
Articulation Bearing assembly 1019
Bearing Clearance DA30 & DA45 (up to 7×1724 / 8×1701) 1022
Calculation of the Tandem bearing 1023
Bearing Clearance DA30 / DA45 (from 7×1725 / 8×1702) 1024
Articulation Hinge 1028
7 4 Fenders, Mudguards and Bonnet 1038
Fender RH 1039
Fender LH 1040
Mudguard 1041
Bonnet Lock 1042
Bonnet 1044
Bonnet adjustment and control 1045
7 5 Cooling system 1046
Disassembly of the cooling system 1046
Disassembly of the separate coolers 1048
Disassembly of the cooling systems hydraulic motor 1049
7 6 Cab 1051
Cab Removal 1051
Cab Ventilation Control Panel 1053
Cab Ventilation Unit 1054
Cab Door 1057
Door Damper Cylinder 1058
Door sensor 1059
Steering Column 1060
Removal/installation of hydraulic tank 1061
HA30 – HA45 Final S2 – 8 Rear frame (VERKST-BOK – 1132593 – 1 – A) – 1 1069
8 1 Introduction 1071
8 2 Dumper Body 1072
Dumper Body 1072
Tilt Bearing 1073
8 3 Remove rear axle from rear frame 1074
8 4 Body 1076
Overview of the dumper body 1076
HA30 – HA45 Final S2 – 9 Option (VERKST-BOK – 1132594 – 1 – A) – 1 1077
9 Optional Equipment 1078
Automatic Tail Gate 1078
View of the Exhaust Body Heating System for T4F 1081
View of the Exhaust Body Heating System for T2/T3/Stage V 1082
Assembly of The Exhaust Body Heating System 1083
View of the Engine heater 1086
Engine heater assembly 1087
Webasto 1090
Webasto Assembly (up to 7X1933/8X1788) 1091
Webasto Assembly (From 7X1934/8X1788) 1094
Telematic system installation 1098
Overview 1099
Installation procedure 1099
Checking functionality 1104
HA30 – HA45 Final S2 – 10 Error codes list (VERKST-BOK – 1132595 – 1 – A) – 1 1106
English 1107
Engine 1107
Transmission 1121
VCU2/VCU3 (Vehicle controller) 1126
TPMS (Tire Pressure Monitoring System) 1130
Main Display 1132
Lubrication 1132
Back Cover 2 Shop Manual HA 1133

DESCRIPTION:

Hyundai HA30 / HA30A HA45 / HA45A Articulated Dump Truck Shop Manual 2023 – PDF DOWNLOAD

HA30(T2;T4F) / HA30A(StageV)
HA45 (T2;T3;T4F) / HA45A (StageV)
Series:
HA30 – 7X1896 and up
HA45 – 8X1811 and up

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.
The manual is divided into the following chapters:

Chapter 1: Engine XPI/PDE
Chapter 2: Transmission
Chapter 3: Drive line
Chapter 4: Lubrication
Chapter 5: Hydraulic system
Chapter 6: Electric system
Chapter 7: Front frame
Chapter 8: Rear frame
Chapter 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.

Questions? Email us: [email protected]

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S.V 02/24