Daewoo Doosan ADT DA30 DA40 Operation & Maintenance Manual MX532099-1 – PDF DOWNLOAD
DESCRIPTION:
Daewoo Doosan ADT DA30 DA40 Operation & Maintenance Manual MX532099-1 – PDF DOWNLOAD
Foreword
- This manual provides rules and guidelines which will help you use this dump truck safely and effectively. This manual describes procedures for operating, handling, lubricating, maintenance, checking and adjustment. It will help the operator to achieve peak performance through effective, economical and safe dump truck operation and maintenance. • Keep this manual in the dump truck at all times and ensure that all personnel read it carefully before operating the dump truck.
- Continue studying the manual until proper operating procedures are completely adopted as personal habit. • This manual describes the basic techniques. The operator’s skill will increase with correct knowledge of dump truck operation. • Operation, inspection and maintenance should be carefully carried out, and safety must be given first priority. If this manual has been lost or has become dirty and cannot be read, request a replacement manual from your local Doosan Dealer.
- If you sell the dump truck, be sure to give this manual to the new owners. Doosan Infracore Norway AS cannot be held responsible for damage or injury caused through use of improper spare parts not specified by Doosan Infracore Norway AS, improper handling, operation and utilisation of the dump truck in other ways than those described in this manual. Doosan Infracore Norway AS cannot be held responsible for unauthorised modifications or the non-adherence to local, national government or international regulations. This Operation & Maintenance Manual may contain standard extra equipment and optional accessories that are not available in your area.
- Please consult your local Doosan Dealer for those items you may require. Doosan Infracore Norway AS aim to continuously improve the dump trucks and therefore retain the right to make design changes and improvements whenever we feel it will improve the efficiency of the dump truck. Doosan Infracore Norway AS also reserves the right to change data and equipment without prior notice, as well as amending instructions for maintenance and other service measures.
WARNING
- This dump truck complies with EC directives 2006/42/EC (Machinery Directive) with amendments, 2000/14/EC (Noise Emission Directive) with amendments, 2004/108/EC (Electronic Compatibility) with amendments and 2004/26/EC (Exhaust Gas Emission) with amendments.
- Dump trucks complying with the directives display the CE mark. The dump truck must not be modified in such a way that it no longer complies with the EC – directive. • Improper operation and maintenance of this dump truck can be hazardous and could result in serious injury or death.
- Operators and maintenance personnel should read this manual thoroughly before operation or maintenance. • Some actions involved in operation and maintenance of the dump truck can cause serious accidents, if they are not carried out in a manner described in this manual.
- The procedures and precautions given in this manual apply only to intended uses of the dump truck. If you use your dump truck for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others.
- In no event should you or others engage in the prohibited uses or actions which are described in this manual. • Doosan Infracore Norway AS delivers dump trucks that comply with all applicable regulations and standards of the country to which it has been shipped.
- If this dump truck has been purchased in another country or purchase from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local Doosan Dealer before operating the dump truck.
- Safety descriptions are given in SAFETY INFORMATION on page 12 and in SAFETY INSTRUCTION, chapter 2.
Introduction
Intended use
This Doosan articulated dump truck is designed to be used mainly for earth moving at sites, both on and off road conditions. The basic machine is intended to be used under normal conditions, that is, outdoors, above ground, off road, for earthmoving, and in an ambient temperature between -25°C and +45°C with maintained performance. Condition that deviate from this are also described in this manual. For use on public roads the machine must be adapted according to governing national legislation (only DA30). If it is used for other purposes or in potentially dangerous environments for example explosive atmosphere, areas with dust contain asbestos etc. special safety regulations must be followed and the machine must be equipped for such use and handling. Contact the Doosan dealer for more information. The machine is designed for a maximum machine weight (includes equipment and attachments) of 51,400 kg for DA30 and 70,300 kg for DA40. If the maximum weight is exceeded, no warranties on the part of the manufacturer will apply. However, always pay attention to national regulations for traveling on public roads
General description
Doosan DA30, DA40 is an articulated, 6-wheel drive dump truck. The free-swinging rear tandem housing, and the special articulation system, provide excellent performance in soft and difficult terrain. The special body design ensures that a low centre of gravity is maintained and an even load distribution to front and rear wheels, for stability on uneven ground and for fast easy tipping. The Doosan dump truck is designed and manufactured to work under difficult conditions. In addition, the wide range of optional equipment allows the dump truck to be used for several different applications
Environmental requirements
Be aware of the environment when operating and during service and maintenance of the machine. Always follow local and national environmental legislation applicable to all handling of the machine
Engine
DA30 and DA40 has a Scania DC9 (9,3 liter) and DC13 (12,7 liter) engines . DA30 T4i/Stage3B and DA40 T4i/Stage 3B – These engines have a optimised cylinder block containing wet cylinder liners that can easiliy be exchanged.Individual cylinder heads with 4 valves per cylinder promotes repairability and fuel economy. The engine is equipped with a Scania developed Engine Management System, EMS, in order to ensure the control of all aspects related to engine performance. The injection system is Scania’s XPI (Extra High Pressure Injection), a common rail system that in combination with SCR (Selective Catalytic Reduction) gives low exhaust emissions with good fuel economy and a high torque
DA30 T2 and DA40 T2 – These engines have a optimised cylinder block containing wet cylinder liners that can easiliy be exchanged. Individual cylinder heads with 4 valves per cylinder promotes repairability and fuel economy. The engine is equipped with a Scania developed Engine Management System, EMS, in order to ensure the control of all aspects related to engine performance. The injection system is based on electronically controlled unit injectors that gives low exhaust emissions with good fuel economy and a high torque.
Electrical System
The machine has three control units. The Gauge Panel for the instrumentation is integrated with the display unit and also warning lights and instruments and provides the operator with information via there. The VCU( vehicle control unit) for the machine, receives signals from sensors on the machine and these are passed to the main screen . The E-ECU controls the engine.
Transmission
The transmissions ZF ErgoPower L II 8 EP 320(DA30) and 8 EP 420(DA40) consist of a multi-speed powershift transmission with integrated transfer case and front-mounted hydrodynamic torque converter. The torque converter is a wear-free starting device which is continuously variable adapting itself to the given situations (necessary input torque). Input by direct mounting via diaphragm to the engine, or by using a joint-shaft with mechanic
TABLE OF CONTENTS:
Daewoo Doosan ADT DA30 DA40 Operation & Maintenance Manual MX532099-1 – PDF DOWNLOAD
1. Foreword…………………………………………………… 1-5
Introduction…………………………………………………. 1-6
Safety information………………………………………… 1-12
Federal emission control systems………………….. 1-14
California emission control warranty statement… 1-20
2. Safety Instructions…………………………………….. 2-1
1. Dump truck knowledge…………………………….. 2-3
2. General precautions. ………………………………. 2-3
3. Precautions before starting the engine………. 2-8
4. When starting the engine…………………………. 2-10
5. Do not go close to high-voltage cables………. 2-10
6. Battery hazard prevention…………………………. 2-11
7. Air conditioning system hazard prevention….. 2-12
8. Rules to follow when filling fuel or oil………….. 2-13
9. Expansion tank coolant level…………………….. 2-13
10. Machine turning…………………………………….. 2-13
11. Emergency steering………………………………… 2-14
12. Travelling on slopes………………………………… 2-14
13. Operation of brakes………………………………… 2-14
14. Engine over speed (Emergency retarder)…… 2-15
15. Wading…………………………………………………. 2-15
16. Dangerous loads……………………………………. 2-16
17. Welding on the dump truck………………………. 2-17
18. Top tailgate……………………………………………. 2-18
19. Engine bonnet……………………………………….. 2-19
20. Tiltable cab……………………………………………. 2-19
21. Body support…………………………………………. 2-21
22. Service position……………………………………… 2-22
23. Wheel chocks………………………………………… 2-22
24. Articulation lock……………………………………… 2-23
25. Lifting / hoisting……………………………………… 2-23
26. Dump truck transportation……………………….. 2-24
27. High pressure………………………………………… 2-24
28. Safety labels………………………………………….. 2-25
3. Operating Controls…………………………………….. 3-1
Overview of the instrument panels and controls. 3-3
Instruments…………………………………………………. 3-5
Monitor warning / indicator symbols and lights…. 3-9
Groeneveld pump test………………………………….. 3-16
Keypad, buttons and switches……………………….. 3-18
Cab ventilation…………………………………………….. 3-21
Controls……………………………………………………… 3-24
Other cab equipment……………………………………. 3-30
4. Running-in period……………………………………… 4-1
1. Running-in operation……………………………….. 4-3
2. Running-in services…………………………………. 4-4
5. Operating Instructions……………………………….. 5-1
Precautions on work sites…………………………….. 5-3
Some simple rules to be observed prior to
operation…………………………………………………….. 5-6
1. Starting the engine…………………………………… 5-7
2. Operating the dump truck…………………………. 5-9
3. Parking the dump truck……………………………. 5-22
4. Stopping the engine………………………………… 5-22
5. Checks after stopping the engine………………. 5-23
6. Loading and tipping…………………………………. 5-23
7. Tyre handling………………………………………….. 5-25
8. Cold weather………………………………………….. 5-27
9. Long term storage…………………………………… 5-28
10. Battery power assistance…………………………. 5-29
11. Towing the dump truck……………………………… 5-30
12. Manual release of parking brake……………….. 5-30
13. Manual release of the ball valve on
tilting circuit…………………………………………………. 5-31
14. Troubleshooting………………………………………. 5-32
6. Lubricants…………………………………………………. 6-1
Lubrication schedule DA30 T2/T4/Stage 3B…….. 6-3
Overview of oil and lubrication points (DA30
T2/T4/Stage 3B…………………………………………… 6-4
Oil specification sheet (DA30 T2/T4/Stage 3B…. 6-5
Filling capacities (DA30 T2/T4/Stage 3B…………. 6-6
Lubrication schedule (DA40 T2/T4/Stage 3B…… 6-7
Overview of oil and lubrication points (DA40
T2/T4/Stage 3B…………………………………………… 6-8
Oil specification sheet (DA40 T2/T4/Stage 3B…. 6-9
Filling capacities (DA40 T2/T4/Stage 3B…………. 6-10
Transmission oil list………………………………………. 6-11
Axles oil list…………………………………………………. 6-14
Operating & Maintenance Manual 1-3
Table of contents 1. Foreword
Maintenance…………………………………………………… 7-1
Maintenance precautions……………………………… 7-3
Maintenance table……………………………………….. 7-5
Initial 100 Hours Service ……………………………… 7-8
Initial 500 Hours Service………………………………. 7-12
8 Hours / Daily Service…………………………………. 7-17
40 Hours / Weekly Service……………………………. 7-25
500 Hours Service……………………………………….. 7-28
1000 Hours Service……………………………………… 7-43
2000 Hours Service……………………………………… 7-57
4000 Hours Service……………………………………… 7-65
Yearly recommended maintenance………………… 7-69
8. Technical Data…………………………………………… 8-1
Measurements…………………………………………….. 8-3
Engine……………………………………………………….. 8-4
Transmission………………………………………………. 8-4
Hydraulic system…………………………………………. 8-5
Tyre pressures…………………………………………….. 8-5
Electrical system…………………………………………. 8-6
Bulbs ……………………………………………………….. 8-7
Metering conversion table…………………………….. 8-7
Tool kit content (standard)…………………………….. 8-7
Tool kit content (optional)……………………………… 8-7
Rimpull Performance …………………………………… 8-8
Graph of altitude power reduction
DA30 T2/T4/Stage 3B…………………………………… 8-10
Graph of altitude power reduction .
DA40 T2/T4/Stage 3B…………………………………… 8-11
Engine and retarder brake capacity chart……….. 8-12
Torque limits for bolts……………………………………. 8-13
Reference information………………………………….. 8-13
Consumeable parts……………………………………… 8-13
Product signs………………………………………………. 8-14
Periodic service…………………………………………… 8-16
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M