Doosan Articulated Dump Truck DA40-5 Shop Manual MX533346 2014
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Doosan Articulated Dump Truck DA40-5 Shop Manual MX533346 2014
Size: 60.37 MB
Format: PDF
Language: English
Brand: Doosan
Type of Machine: Articulated Dump Truck
Type of Manual: Shop Manual
Model: Doosan DA40-5 Articulated Dump Truck
Part Number: MX533346
Publication Date: 2014
Number of Pages: 1070 Pages
Contents:
Front Cover Da40-5 A3 Image
Chapter 00 - General
Foreword
Doosan Adt Payload Policy
Torque Limit Table
Types Of Sealing-/Locking Compounds And Lubricants
Safety In Workshop
Working On Machine
Personal Protective Equipment (Ppe)
Vibration
Injurious Noise
Organic Solvent
Fueling
Fire And Explosion Prevention
Fire And Explosion Risks
In Case Of Fire
Coolant
Refrigerant
Air Pollution
Operation In Extreme Conditions
Liquid Or Gas Under High Pressure
Asbestos
Lead
Battery Hazard Prevention
Disposal Of Hazardous Materials
Jacked Up Vehicle Or Bodywork
Crushing And Cutting Danger
Heavy Units
More Than One Person Working With The Same Object
Involuntary Start Of Electric Motors Etc.
Rotating Parts
Splinters, Flying Object When Using Certain Tools
Springs Under Load
Precautions For Disassembly And Assembly
Chapter 01 - Engine Pde
Engine Identification
Removal Of Engine Assembly
Lifting The Engine
Starting The Engine
Important Information About The Fuel
Fuel System Tier2 (Pde)
Schematic Diagram Of The Fuel System Tier2
Overflow Valve
General
Fuel
Temperature Dependency Of The Fuel
Fuel Filter
Changing The Fuel Filter
Water Separating Prefilter Pde
Changing The Water Separating Fuel Filter
Bleeding The Fuel System
Feed Pump
Renewing The Control Unit
Removing The Ecu Wiring Tier2
Cylinder Head - Pde System Tier2
Cylinder Head, Parts View. Pde Tier2
Special Tools
Valve Mechanism
Dismantling
Renewing The Valve Stem Seal
Replacement Of Valve Seats
Machining The Valve Seats Insert
Renewing The Valve Guides
Renewing Pde Unit Injector Sleeves
Assembly
Fitting
Unit Injector And Flywheel
Valve And Unit Injector Adjustment With Pde
Order Of Adjustment For Valve Clearance And Pde Unit Injectors
Flywheel Readings (Da40)
Flywheel Readings (Da30)
Adjusting The Valve Clearance And Unit Injectors
Turbocharger
Measuring Radial Clearance And Axial Clearance
Renewing The Turbocharger
General
Changing Oil Filter
Oil Analysis
Checking Oil Level
Changing The Oil
Special Tools
Pistons And Cylinder Liners
Special Tools
Connecting Rods
Removing And Dismantling Connecting Rods And Pistons
Renewal Of Bearing Bushing In Connecting Rod
Pistons
Assembling Piston And Connecting Rod
Cylinderblock
Cylinder Liner
Removing The Cylinder Liners
Measuring The Cylinder Liner Height
Measuring The Cylinder Wear Ridge And Cylinder Bore
Fitting The Cylinder Liners
Fitting The Piston And Connecting Rod
Flywheel And Flywheel Housing
Special Tools
Removing The Flywheel
Renewing The Rear Crankshaft Seal
Removing The Flywheel Housing
Fitting Flywheel Housing
Fitting The Flywheel
Timing Gear - 13 And 9 Liter
Gear Drive
Belt Drive Collant Pump, Generator And Ac Compressor
Checking The Drive Belt
Check For Leaks
Renewing The Seal In The Front Cover
Crankshaft Damper
Timing Gear, View Exploded
Special Tools
Intermediate Gear
Camshaft Gear
Crankshaft Gear
Camshaft
Replacement Of Camshaft Bearing
Crankshaft
Removal
Fitting
Adjust - Machining The Crankshaft
Lubrication System
Oil Pump
Lubrication Oilways
Oil Pressure
Oil Cooler, Engine
Oil Cooler View Se 010009
Renewing Seals And Leakage Testing
Oil Filter
Centrifugal Oil Cleaner
Dismantling And Assembly
Oil Mist Separator
General
High Levels Of Oil Carryover
Crankcase Pressure Measurement
Oil Mist Separator Exploded View
Oil Mist Separator Disassemble
Check - Rotational Speed On Oil Mist Separator
Alternator 100 A
Check
Output Test
Renewal - Bearing And Carbon Brushes
Oil Pump, Brake Cooling Circulate (Da40)
Exploded View
Disassemble And Overhaul The Oil Pump
Checking And Renewing Parts
Oil Circulate Pump Assemble.
Renewing The Gasket
Cooling Fan
View Of The Radiator System Da40
Cooling System
Principal View Of The Cooling System
Circulation
Coolant
Checking Coolant Level
Checking The Antifreeze Level
Changing Coolant
Filling Coolant
Cleaning The Cooling System
Removing Oil Cooler
Disassemble The Cooling Unit
Thermostat And Thermostat Housing
Thermostat
Coolant Pump
External Cleaning
Internal Cleaning
Technical Data Dc13 With Pde
General Data
Technical Data Dc9 With Pde
General Data
Troubleshooting Ecom / Canbus
To Do:
Troubleshooting, -Basic Info.
Troubleshooting Fuel System
Troubleshooting Guide
Diagnostic Prosedure
Use Of Diagnostic Kit, Tier 2
Connection Point Can Pc Vcu + Testman
Can Bus Overview
Connection Point Sdp3 Scania Dagnostic
Troubleshooting Manual
White Smoke
White Smoke, Water Vapour
White Smoke, Water Vapour
Black Smoke On Starting
Blue Smoke
Fuel In The Oil
Oil In Coolant
Coolant/Water In Oil
Low Oil Pressure
High Oil Pressure (Engine Warmed Up)
Abnormal Wear (Liner, Piston Rings, Etc.)
Vibration, No Driven Components Engaged
Vibration When The Clutch Or Reverse Gear Is Engaged
Vibration When Alternator Is In Operation
Engine Speed Hunting - Single-Speed Engines With Rq Governor
Engine Speed Hunting - Single-Speed Engines With Rsv Governor
Delivery Pipe Fractures
External Corrosion On Cylinder Liner
Engine Difficult To Start
Fluid Stroke
Knocking/Noise
High Oil Consumption
High Fuel Consumption
Low Compression
Low Engine Output
Hot Engine
Cold Engine
Coolant Loss
Polluted Coolant
Polluted Coolant
High Oil Temperature
High Exhaust Temperature
Low Charge Air Pressure
Low Fuel Pressure
Low System Voltage
High System Voltage
External Oil Leakage
External Fuel Leakage
External Coolant Leakage
Oil Pressed Out Via Crankcase Ventilation
Turbocharger Breakdown
Compressed Air System
Chapter 01 - Engine Xpi
Engine Identification
Removal Of Engine Assembly
Lifting The Engine
Starting The Engine
Xpi Fuel System Da30/40
Route Of The Fuel On 9 And 13 Liter Engines
Fuel Filter And Water Separation
Changing The Fuel Filter
Overflow Valve
Fuel System Components
Schematic Diagram Of The Fuel System:
Important Information About The Fuel
Exhaust System Xpi
Introduction System Overview
Control System For Exhaust Gas Aftertreatment
Control Unit Eec3
System Overview For Mechanics
System Overview For Electronics
Ad Blue Filter Change
Reductant Doser
Start-Up Instruction For New Scr Pump
Reductant Pump, Function
Renewing The Control Unit
Removing The Ecu Wiring Tier2
Common Rail Injectors Tier4/Xpi
Cylinder Head - Xpi System Tier4
Cylinder Head, Parts View. Xpi System Tier4
Injector Scania Xpi
Order Of Adjustment For 13 Liter Engines
Valve Adjustment Dc13 With Xpi
Cylinder Configuration, 6 Cylinder Engines
Valve Adjustment Dc9 With Xpi
Cylinder Configuration, 5 Cylinder Engines
Turbocharger
Measuring Radial Clearance And Axial Clearance
Renewing The Turbocharger
General
Changing Oil Filter
Oil Analysis
Checking Oil Level
Changing The Oil
Special Tools
Pistons And Cylinder Liners
Special Tools
Connecting Rods
Removing And Dismantling Connecting Rods And Pistons
Renewal Of Bearing Bushing In Connecting Rod
Pistons
Assembling Piston And Connecting Rod
Cylinderblock
Cylinder Liner
Removing The Cylinder Liners
Measuring The Cylinder Liner Height
Measuring The Cylinder Wear Ridge And Cylinder Bore
Fitting The Cylinder Liners
Fitting The Piston And Connecting Rod
Flywheel And Flywheel Housing
Special Tools
Removing The Flywheel
Renewing The Rear Crankshaft Seal
Removing The Flywheel Housing
Fitting Flywheel Housing
Fitting The Flywheel
Flexible Coupling
Safety Instructions
Functional Description
Disassembly And Dismantling The Coupling
Assembling The Coupling
Installation Instructions
Friction Disk, Friction Ring
Timing Gear - 13 And 9 Liter With Xpi
Gear Drive
Belt Drive Collant Pump, Generator And Ac Compressor
Checking The Drive Belt
Check For Leaks
Renewing The Seal In The Front Cover
Crankshaft Damper
Timing Gear, View Exploded
Special Tools
Intermediate Gear
Camshaft Gear
Crankshaft Gear
Camshaft
Replacement Of Camshaft Bearing
Crankshaft
Removal
Fitting
Adjust - Machining The Crankshaft
Lubrication System
Oil Pump
Lubrication Oil-Ways
Oil Pressure
Oil Cooler, Engine
Oil Cooler View Se 010009
Renewing Seals And Leakage Testing
Oil Filter
Centrifugal Oil Cleaner
Dismantling And Assembly
Oil Mist Separator
General
High Levels Of Oil Carryover
Crankcase Pressure Measurement
Oil Mist Separator Exploded View
Oil Mist Separator Disassemble
Check - Rotational Speed On Oil Mist Separator
Alternator 100 A
Check
Output Test
Renewal - Bearing And Carbon Brushes
Oil Pump, Brake Cooling Circulate (Da40)
Exploded View
Disassemble And Overhaul The Oil Pump
Checking And Renewing Parts
Oil Circulate Pump Assemble.
Renewing The Gasket
Cooling Fan
View Of The Radiator System Da40
Cooling System
Principal View Of The Cooling System
Circulation
Coolant
Checking Coolant Level
Pressure Testing The Cooling System Xpi
Delivery Valve
External Leakage
Internal Leakage
Checking The Antifreeze Level
Changing Coolant
Filling Coolant
Cleaning The Cooling System
Removing Oil Cooler
Disassemble The Cooling Unit
Thermostat And Thermostat Housing
Thermostat
Coolant Pump
External Cleaning
Internal Cleaning
Technical Data Dc13 With Xpi
General Data
Technical Data Dc9 With Xpi
General Data
Troubleshooting Ecom / Canbus
To Do:
Troubleshooting, -Basic Info.
Troubleshooting Fuel System
Troubleshooting Guide
Diagnostic Prosedure
Use Of Diagnostic Kit, Tier 2
Connection Point Can Pc Vcu + Testman
Can Bus Overview
Connection Point Sdp3 Scania Dagnostic
Troubleshooting Manual
White Smoke
White Smoke, Water Vapour
White Smoke, Water Vapour
Black Smoke On Starting
Blue Smoke
Fuel In The Oil
Oil In Coolant
Coolant/Water In Oil
Low Oil Pressure
High Oil Pressure (Engine Warmed Up)
Abnormal Wear (Liner, Piston Rings, Etc.)
Vibration, No Driven Components Engaged
Vibration When The Clutch Or Reverse Gear Is Engaged
Vibration When Alternator Is In Operation
Engine Speed Hunting - Single-Speed Engines With Rq Governor
Engine Speed Hunting - Single-Speed Engines With Rsv Governor
Delivery Pipe Fractures
External Corrosion On Cylinder Liner
Engine Difficult To Start
Fluid Stroke
Knocking/Noise
High Oil Consumption
High Fuel Consumption
Low Compression
Low Engine Output
Hot Engine
Cold Engine
Coolant Loss
Polluted Coolant
Polluted Coolant
High Oil Temperature
High Exhaust Temperature
Low Charge Air Pressure
Low Fuel Pressure
Low System Voltage
High System Voltage
External Oil Leakage
External Fuel Leakage
External Coolant Leakage
Oil Pressed Out Via Crankcase Ventilation
Turbocharger Breakdown
Compressed Air System
Chapter 02 - Transmission
General
Structure Of The Repair Manual
Denomination Of Standard Dimensions
Conversion Table
Torque Limits For Screws.
Table
Labeling Of Type Plate
Information On Spare Parts Ordering
Configuration Of Transmission
Transmission Schematics And Gear Schematics
Measuring Points And Connections
Table
Clutch Calibration
Installation Sheet
Specjal Tools For Disassembly And Reassembly
Commercial Tools For Disassembly And Reassembly
Removal Of Transmission, Disass’y
Disassemble The Structure Bar
Disassemble The Hydraulic Hoses
Positioning For Disassembly And Reassembly
Removal And Refitting Various Components
Transmission
Lkv Axle Insert
Removal And Refitting Of Speed Sensor N4-Output
Removal:
Retting:
Removal And Refitting Of Solenoid Valves Of Shifting Block Ii And Temperature Sensors
Removal:
Refitting:
Disassembly And Reassembly Of Shifting Block I And Speed Sensors
Disassembly:
Reassembly:
Removal And Refitting Of Lkv Axle Insert
Separation Of Lkv Axle Insert From Transmission:
Attachment Of Lkv Axle Insert To Transmission
Sealing Of Outputs Towards Rear Axle And Lkv Axle Insert
Exchange Of Shaft Seal Ring Towards Lkv Axle Insert
Removal Of Shaft Seal Ring
Fitting Of Shaft Seal Ring:
Exchange Of Shaft Seal Ring Towards Rear Axle
Removal Of Shaft Seal Ring
Fitting Of Shaft Seal Ring
Transmission Assembly
Chapter 03 - Drive Line
Introduction
General
Structure Of The Repair Manual
Denomination Of Standard Dimensions
Conversion Table
Torque Limits For Screws.
Table
Main Drive Line Components
Front Hub
Outer View And Section Drawing
Tools For Wdb
Check The Brake Chamber/Wheel Head For Leak Tightness
Leakage Test Of Brake Hydraulics
Wdb Cirquit Front Brake
Drive Shafts
Front Frame
Rear Frame
Mounting The Bearings On The Intermediate Shaft (B)
Front Differential And Transmission
Brakes
Service Brakes
Service Brake Description
Testing Of Parking Brake
Remove The Linings
Disassembly The Park Brake Unit
Assembly The Park Brake Unit.
Adjust The Initial Caliper Clearance
Park Brake Maintenance
Disc
Troubleshooting Park Brake
Rear Differential
General Function
Illustrated Tables - Special Tools
Illustrated Tables - Special Tools
Disassemble The Tk-Differential
Safety Precautions.
Disassemble The Differentilal From The Axle Housing
Disassembling The Axle Housing From The Tandemhousing
Disassembly New Differential (Mod No. 8x0660)
Contact Pattern Examples Of Gleason Tooth System
Example 1: Dedendum Tooth Position
Example 2: Dedendum Tooth Position
Example 3: „Line“Contact Pattern
Assemble The Tandem Housing Unit To The Rear
Rear Wheel Hub,
Outer View And Section Drawing
Disassembly The Rear Wheel Hub
Assemble The Wdb Rear Hub
Cooling Cirquit Rear Brake
Axle And Tandem Housing Bearing
Cross Section
Checking Clearance In The Tandem Bearing.
View Of The Tandem Bearing
Calculation Of The Tandem Bearing
Disassemble Tandem Housing Unit
Safety Precautions.
Disassemble The Tandem Unit From The Rear Frame
Disassembly The Axle Housing From The Tandemhousing
Disassemble The Tandem Bearings
Assemble The Tandem Housing To The Axle
Housing.
Disassemble The Tandem Housing’s Inside Parts
Assembly Piniong In The Tandem House
Tyres
Chapter 04 - Lubrication
Lubrication System Parts
Greasing Cycles
Lubrication Points On Da Series
Grease Pressure Switch
The 5/2 Way Valve
The Relief Valve
The Minimum Level Switch
System Test
Introduction
The Single-Test Cycle
The Continuous-Test Cycle
Warning Signal
Maintenance
Regularly Checks Of The Greasing System
Bleeding The Pump
Bleeding The System
Technical Data
Dimensions Of The Twin Pump
Central Lubrication Main Unit, (Overview)
Chapter 05 - Hydraulic System
Components, Capacities And Oil Types
Startup Test Procedure
Main Pump
Steering System
Tilting System
Fan System
Brakes
Accumulators
Chapter 06 - Electrical System
How To Use The Electrical Documentation
Troubleshooting, What To Do
Description Of The Vcu2 Functionality
Doosan Moxy Vcu 2
Find Wiring Contact On Vcu2
Lcd Instrumentation Unit
Warning Lights Display
Lcd Screen Main Menu
Lcd Use Description
Pos Reference List
Description Of The Main Electrical System.
General Description
Welding On The Dump Truck
Battery Hazard Prevention
Component Position
Electrical Parts View
El.System, Outside Front And Rear
Electrical Equipment Inside Cab
El.System, Cab Inside
Switch Panel
Heater Unit Exploded
Heater Unit Parts List
Ignition Key Switch
Air Conditioning System Componenets
Product Final Inspection
Refrigerant Charging
Regulation Controll
Preassure Reading And Troubleshooting
Use Of The A.T.C
Rear Frame
Da Series Functions And Parameters
Brake/Brake Charge System (Accumulators) (7)
Wdb Cooling (Only On Da40) (7)
Emergency Steering System (9)
Park Brake (6)
Low Engine Oil Pressure (2)
Low Coolant Level (3)
Clogged Air Filter (4)
Central Lubrication Pump (11)
Charge Lamp (12)
Body Tip System (13)
Load Weighing (32)
Differential Lock (28)
Cooling Fan Control
Quick Warmup Function
Cooldown Function
Alternative Engine Speed
Interior Light
Retarder And Engine Brake (24 - 25)
Emergency Stop
Fuel Heater
A/C Compressor Control
To Be Implented
Engine Electrical Components.
Engine Ems S6 / S8
Electrical Cable Routing
Ems Connection Chart
Ems Pin List
Engine Management System S8
Engine Speed And Camsghaft Sensors
Wastergate Solenoid Valve
Control Unit Ems S8
Fuel Pressure Sensor
Fuel Inlet Metering Valve
Solenoid Valve For Xpi Injector
Transmission Spesification Of Electrical Components
Transmission Speed Sensors
Transmission Temperature Sensors
Transmission Solenoid Valves
Transmission Pressure Switch
Transmission Electric Switch
Sensors Hydraulic System
Steering Valve, El. Connection
Main Valve El. Connection
Parking Brake Sensor
Body Float Sensor
Electrical Chart And Circuit
Cab Roof Cable Set
Cab Floor Cable Set
Cab Inside Rear Wall Cable Set
Wiring (Cable Set) S1 - S6
Cirquit Chart Cabine (No1)
Junction Box Battery Compartment
Cirquit Chart Front And Rear Frame (No2)
Exhaust Emmission Control
Wiring Diagram For The Exhaust Emission Control
System Overview For Electrics
Chapter 07 - Front Wagon
7.1 Introduction
7.2.1 Hydraulic Gas Cylinder Disassembly
7.2.2 Repairing The Hydraulic Gas Cylinder
7.2.3 Hydraulic Gas Cylinder Reassembly
7.2.4 Panhard Bar
7.2.5 Suspension Bearing
7.2.6 Cross Tube Bushings
7.3.1 Articulation Bearing
7.3.3 Calculation Of The Tandem Bearing
7.3.4 Articulation Hinge
7.4.1 Fender Rh
7.4.2 Fender Lh
7.4.3 Mudguard
7.4.4 Bonnet Lock
7.4.5 Bonnet
7.4.6 Bonnet Adjustment And Control
7.5.1 Cab Removal
7.5.2 Cab Ventilation Control Panel
7.5.3 Cab Ventilation Unit
7.5.4 Cab Door
7.5.5 Door Damper Cylinder
7.5.6 Steering Column
Chapter 08 - Rear Frame
8.1 Introduction
8.2.1 Dumper Body
8.2.2 Tilt Bearing
Chapter 09 - Option
9 Optional Equipment
9.1 Automatic Tail Gate
9.2 Body Heating System
9.2.1 View Of The Exhaust Body Heating System
9.2.2 Assembly Of The Exhaust Body Heating System
9.4 View Of The Engine Heater
9.4.1 Engine Heater Assembly
9.6 Webasto
9.7 Telematic System Installation
Chapter 10 - Error Codes List
English
Sm Back Cover Da40-5
Size: 60.37 MB
Format: PDF
Language: English
Brand: Doosan
Type of Machine: Articulated Dump Truck
Type of Manual: Shop Manual
Model: Doosan DA40-5 Articulated Dump Truck
Part Number: MX533346
Publication Date: 2014
Number of Pages: 1070 Pages
Contents:
Front Cover Da40-5 A3 Image
Chapter 00 - General
Foreword
Doosan Adt Payload Policy
Torque Limit Table
Types Of Sealing-/Locking Compounds And Lubricants
Safety In Workshop
Working On Machine
Personal Protective Equipment (Ppe)
Vibration
Injurious Noise
Organic Solvent
Fueling
Fire And Explosion Prevention
Fire And Explosion Risks
In Case Of Fire
Coolant
Refrigerant
Air Pollution
Operation In Extreme Conditions
Liquid Or Gas Under High Pressure
Asbestos
Lead
Battery Hazard Prevention
Disposal Of Hazardous Materials
Jacked Up Vehicle Or Bodywork
Crushing And Cutting Danger
Heavy Units
More Than One Person Working With The Same Object
Involuntary Start Of Electric Motors Etc.
Rotating Parts
Splinters, Flying Object When Using Certain Tools
Springs Under Load
Precautions For Disassembly And Assembly
Chapter 01 - Engine Pde
Engine Identification
Removal Of Engine Assembly
Lifting The Engine
Starting The Engine
Important Information About The Fuel
Fuel System Tier2 (Pde)
Schematic Diagram Of The Fuel System Tier2
Overflow Valve
General
Fuel
Temperature Dependency Of The Fuel
Fuel Filter
Changing The Fuel Filter
Water Separating Prefilter Pde
Changing The Water Separating Fuel Filter
Bleeding The Fuel System
Feed Pump
Renewing The Control Unit
Removing The Ecu Wiring Tier2
Cylinder Head - Pde System Tier2
Cylinder Head, Parts View. Pde Tier2
Special Tools
Valve Mechanism
Dismantling
Renewing The Valve Stem Seal
Replacement Of Valve Seats
Machining The Valve Seats Insert
Renewing The Valve Guides
Renewing Pde Unit Injector Sleeves
Assembly
Fitting
Unit Injector And Flywheel
Valve And Unit Injector Adjustment With Pde
Order Of Adjustment For Valve Clearance And Pde Unit Injectors
Flywheel Readings (Da40)
Flywheel Readings (Da30)
Adjusting The Valve Clearance And Unit Injectors
Turbocharger
Measuring Radial Clearance And Axial Clearance
Renewing The Turbocharger
General
Changing Oil Filter
Oil Analysis
Checking Oil Level
Changing The Oil
Special Tools
Pistons And Cylinder Liners
Special Tools
Connecting Rods
Removing And Dismantling Connecting Rods And Pistons
Renewal Of Bearing Bushing In Connecting Rod
Pistons
Assembling Piston And Connecting Rod
Cylinderblock
Cylinder Liner
Removing The Cylinder Liners
Measuring The Cylinder Liner Height
Measuring The Cylinder Wear Ridge And Cylinder Bore
Fitting The Cylinder Liners
Fitting The Piston And Connecting Rod
Flywheel And Flywheel Housing
Special Tools
Removing The Flywheel
Renewing The Rear Crankshaft Seal
Removing The Flywheel Housing
Fitting Flywheel Housing
Fitting The Flywheel
Timing Gear - 13 And 9 Liter
Gear Drive
Belt Drive Collant Pump, Generator And Ac Compressor
Checking The Drive Belt
Check For Leaks
Renewing The Seal In The Front Cover
Crankshaft Damper
Timing Gear, View Exploded
Special Tools
Intermediate Gear
Camshaft Gear
Crankshaft Gear
Camshaft
Replacement Of Camshaft Bearing
Crankshaft
Removal
Fitting
Adjust - Machining The Crankshaft
Lubrication System
Oil Pump
Lubrication Oilways
Oil Pressure
Oil Cooler, Engine
Oil Cooler View Se 010009
Renewing Seals And Leakage Testing
Oil Filter
Centrifugal Oil Cleaner
Dismantling And Assembly
Oil Mist Separator
General
High Levels Of Oil Carryover
Crankcase Pressure Measurement
Oil Mist Separator Exploded View
Oil Mist Separator Disassemble
Check - Rotational Speed On Oil Mist Separator
Alternator 100 A
Check
Output Test
Renewal - Bearing And Carbon Brushes
Oil Pump, Brake Cooling Circulate (Da40)
Exploded View
Disassemble And Overhaul The Oil Pump
Checking And Renewing Parts
Oil Circulate Pump Assemble.
Renewing The Gasket
Cooling Fan
View Of The Radiator System Da40
Cooling System
Principal View Of The Cooling System
Circulation
Coolant
Checking Coolant Level
Checking The Antifreeze Level
Changing Coolant
Filling Coolant
Cleaning The Cooling System
Removing Oil Cooler
Disassemble The Cooling Unit
Thermostat And Thermostat Housing
Thermostat
Coolant Pump
External Cleaning
Internal Cleaning
Technical Data Dc13 With Pde
General Data
Technical Data Dc9 With Pde
General Data
Troubleshooting Ecom / Canbus
To Do:
Troubleshooting, -Basic Info.
Troubleshooting Fuel System
Troubleshooting Guide
Diagnostic Prosedure
Use Of Diagnostic Kit, Tier 2
Connection Point Can Pc Vcu + Testman
Can Bus Overview
Connection Point Sdp3 Scania Dagnostic
Troubleshooting Manual
White Smoke
White Smoke, Water Vapour
White Smoke, Water Vapour
Black Smoke On Starting
Blue Smoke
Fuel In The Oil
Oil In Coolant
Coolant/Water In Oil
Low Oil Pressure
High Oil Pressure (Engine Warmed Up)
Abnormal Wear (Liner, Piston Rings, Etc.)
Vibration, No Driven Components Engaged
Vibration When The Clutch Or Reverse Gear Is Engaged
Vibration When Alternator Is In Operation
Engine Speed Hunting - Single-Speed Engines With Rq Governor
Engine Speed Hunting - Single-Speed Engines With Rsv Governor
Delivery Pipe Fractures
External Corrosion On Cylinder Liner
Engine Difficult To Start
Fluid Stroke
Knocking/Noise
High Oil Consumption
High Fuel Consumption
Low Compression
Low Engine Output
Hot Engine
Cold Engine
Coolant Loss
Polluted Coolant
Polluted Coolant
High Oil Temperature
High Exhaust Temperature
Low Charge Air Pressure
Low Fuel Pressure
Low System Voltage
High System Voltage
External Oil Leakage
External Fuel Leakage
External Coolant Leakage
Oil Pressed Out Via Crankcase Ventilation
Turbocharger Breakdown
Compressed Air System
Chapter 01 - Engine Xpi
Engine Identification
Removal Of Engine Assembly
Lifting The Engine
Starting The Engine
Xpi Fuel System Da30/40
Route Of The Fuel On 9 And 13 Liter Engines
Fuel Filter And Water Separation
Changing The Fuel Filter
Overflow Valve
Fuel System Components
Schematic Diagram Of The Fuel System:
Important Information About The Fuel
Exhaust System Xpi
Introduction System Overview
Control System For Exhaust Gas Aftertreatment
Control Unit Eec3
System Overview For Mechanics
System Overview For Electronics
Ad Blue Filter Change
Reductant Doser
Start-Up Instruction For New Scr Pump
Reductant Pump, Function
Renewing The Control Unit
Removing The Ecu Wiring Tier2
Common Rail Injectors Tier4/Xpi
Cylinder Head - Xpi System Tier4
Cylinder Head, Parts View. Xpi System Tier4
Injector Scania Xpi
Order Of Adjustment For 13 Liter Engines
Valve Adjustment Dc13 With Xpi
Cylinder Configuration, 6 Cylinder Engines
Valve Adjustment Dc9 With Xpi
Cylinder Configuration, 5 Cylinder Engines
Turbocharger
Measuring Radial Clearance And Axial Clearance
Renewing The Turbocharger
General
Changing Oil Filter
Oil Analysis
Checking Oil Level
Changing The Oil
Special Tools
Pistons And Cylinder Liners
Special Tools
Connecting Rods
Removing And Dismantling Connecting Rods And Pistons
Renewal Of Bearing Bushing In Connecting Rod
Pistons
Assembling Piston And Connecting Rod
Cylinderblock
Cylinder Liner
Removing The Cylinder Liners
Measuring The Cylinder Liner Height
Measuring The Cylinder Wear Ridge And Cylinder Bore
Fitting The Cylinder Liners
Fitting The Piston And Connecting Rod
Flywheel And Flywheel Housing
Special Tools
Removing The Flywheel
Renewing The Rear Crankshaft Seal
Removing The Flywheel Housing
Fitting Flywheel Housing
Fitting The Flywheel
Flexible Coupling
Safety Instructions
Functional Description
Disassembly And Dismantling The Coupling
Assembling The Coupling
Installation Instructions
Friction Disk, Friction Ring
Timing Gear - 13 And 9 Liter With Xpi
Gear Drive
Belt Drive Collant Pump, Generator And Ac Compressor
Checking The Drive Belt
Check For Leaks
Renewing The Seal In The Front Cover
Crankshaft Damper
Timing Gear, View Exploded
Special Tools
Intermediate Gear
Camshaft Gear
Crankshaft Gear
Camshaft
Replacement Of Camshaft Bearing
Crankshaft
Removal
Fitting
Adjust - Machining The Crankshaft
Lubrication System
Oil Pump
Lubrication Oil-Ways
Oil Pressure
Oil Cooler, Engine
Oil Cooler View Se 010009
Renewing Seals And Leakage Testing
Oil Filter
Centrifugal Oil Cleaner
Dismantling And Assembly
Oil Mist Separator
General
High Levels Of Oil Carryover
Crankcase Pressure Measurement
Oil Mist Separator Exploded View
Oil Mist Separator Disassemble
Check - Rotational Speed On Oil Mist Separator
Alternator 100 A
Check
Output Test
Renewal - Bearing And Carbon Brushes
Oil Pump, Brake Cooling Circulate (Da40)
Exploded View
Disassemble And Overhaul The Oil Pump
Checking And Renewing Parts
Oil Circulate Pump Assemble.
Renewing The Gasket
Cooling Fan
View Of The Radiator System Da40
Cooling System
Principal View Of The Cooling System
Circulation
Coolant
Checking Coolant Level
Pressure Testing The Cooling System Xpi
Delivery Valve
External Leakage
Internal Leakage
Checking The Antifreeze Level
Changing Coolant
Filling Coolant
Cleaning The Cooling System
Removing Oil Cooler
Disassemble The Cooling Unit
Thermostat And Thermostat Housing
Thermostat
Coolant Pump
External Cleaning
Internal Cleaning
Technical Data Dc13 With Xpi
General Data
Technical Data Dc9 With Xpi
General Data
Troubleshooting Ecom / Canbus
To Do:
Troubleshooting, -Basic Info.
Troubleshooting Fuel System
Troubleshooting Guide
Diagnostic Prosedure
Use Of Diagnostic Kit, Tier 2
Connection Point Can Pc Vcu + Testman
Can Bus Overview
Connection Point Sdp3 Scania Dagnostic
Troubleshooting Manual
White Smoke
White Smoke, Water Vapour
White Smoke, Water Vapour
Black Smoke On Starting
Blue Smoke
Fuel In The Oil
Oil In Coolant
Coolant/Water In Oil
Low Oil Pressure
High Oil Pressure (Engine Warmed Up)
Abnormal Wear (Liner, Piston Rings, Etc.)
Vibration, No Driven Components Engaged
Vibration When The Clutch Or Reverse Gear Is Engaged
Vibration When Alternator Is In Operation
Engine Speed Hunting - Single-Speed Engines With Rq Governor
Engine Speed Hunting - Single-Speed Engines With Rsv Governor
Delivery Pipe Fractures
External Corrosion On Cylinder Liner
Engine Difficult To Start
Fluid Stroke
Knocking/Noise
High Oil Consumption
High Fuel Consumption
Low Compression
Low Engine Output
Hot Engine
Cold Engine
Coolant Loss
Polluted Coolant
Polluted Coolant
High Oil Temperature
High Exhaust Temperature
Low Charge Air Pressure
Low Fuel Pressure
Low System Voltage
High System Voltage
External Oil Leakage
External Fuel Leakage
External Coolant Leakage
Oil Pressed Out Via Crankcase Ventilation
Turbocharger Breakdown
Compressed Air System
Chapter 02 - Transmission
General
Structure Of The Repair Manual
Denomination Of Standard Dimensions
Conversion Table
Torque Limits For Screws.
Table
Labeling Of Type Plate
Information On Spare Parts Ordering
Configuration Of Transmission
Transmission Schematics And Gear Schematics
Measuring Points And Connections
Table
Clutch Calibration
Installation Sheet
Specjal Tools For Disassembly And Reassembly
Commercial Tools For Disassembly And Reassembly
Removal Of Transmission, Disass’y
Disassemble The Structure Bar
Disassemble The Hydraulic Hoses
Positioning For Disassembly And Reassembly
Removal And Refitting Various Components
Transmission
Lkv Axle Insert
Removal And Refitting Of Speed Sensor N4-Output
Removal:
Retting:
Removal And Refitting Of Solenoid Valves Of Shifting Block Ii And Temperature Sensors
Removal:
Refitting:
Disassembly And Reassembly Of Shifting Block I And Speed Sensors
Disassembly:
Reassembly:
Removal And Refitting Of Lkv Axle Insert
Separation Of Lkv Axle Insert From Transmission:
Attachment Of Lkv Axle Insert To Transmission
Sealing Of Outputs Towards Rear Axle And Lkv Axle Insert
Exchange Of Shaft Seal Ring Towards Lkv Axle Insert
Removal Of Shaft Seal Ring
Fitting Of Shaft Seal Ring:
Exchange Of Shaft Seal Ring Towards Rear Axle
Removal Of Shaft Seal Ring
Fitting Of Shaft Seal Ring
Transmission Assembly
Chapter 03 - Drive Line
Introduction
General
Structure Of The Repair Manual
Denomination Of Standard Dimensions
Conversion Table
Torque Limits For Screws.
Table
Main Drive Line Components
Front Hub
Outer View And Section Drawing
Tools For Wdb
Check The Brake Chamber/Wheel Head For Leak Tightness
Leakage Test Of Brake Hydraulics
Wdb Cirquit Front Brake
Drive Shafts
Front Frame
Rear Frame
Mounting The Bearings On The Intermediate Shaft (B)
Front Differential And Transmission
Brakes
Service Brakes
Service Brake Description
Testing Of Parking Brake
Remove The Linings
Disassembly The Park Brake Unit
Assembly The Park Brake Unit.
Adjust The Initial Caliper Clearance
Park Brake Maintenance
Disc
Troubleshooting Park Brake
Rear Differential
General Function
Illustrated Tables - Special Tools
Illustrated Tables - Special Tools
Disassemble The Tk-Differential
Safety Precautions.
Disassemble The Differentilal From The Axle Housing
Disassembling The Axle Housing From The Tandemhousing
Disassembly New Differential (Mod No. 8x0660)
Contact Pattern Examples Of Gleason Tooth System
Example 1: Dedendum Tooth Position
Example 2: Dedendum Tooth Position
Example 3: „Line“Contact Pattern
Assemble The Tandem Housing Unit To The Rear
Rear Wheel Hub,
Outer View And Section Drawing
Disassembly The Rear Wheel Hub
Assemble The Wdb Rear Hub
Cooling Cirquit Rear Brake
Axle And Tandem Housing Bearing
Cross Section
Checking Clearance In The Tandem Bearing.
View Of The Tandem Bearing
Calculation Of The Tandem Bearing
Disassemble Tandem Housing Unit
Safety Precautions.
Disassemble The Tandem Unit From The Rear Frame
Disassembly The Axle Housing From The Tandemhousing
Disassemble The Tandem Bearings
Assemble The Tandem Housing To The Axle
Housing.
Disassemble The Tandem Housing’s Inside Parts
Assembly Piniong In The Tandem House
Tyres
Chapter 04 - Lubrication
Lubrication System Parts
Greasing Cycles
Lubrication Points On Da Series
Grease Pressure Switch
The 5/2 Way Valve
The Relief Valve
The Minimum Level Switch
System Test
Introduction
The Single-Test Cycle
The Continuous-Test Cycle
Warning Signal
Maintenance
Regularly Checks Of The Greasing System
Bleeding The Pump
Bleeding The System
Technical Data
Dimensions Of The Twin Pump
Central Lubrication Main Unit, (Overview)
Chapter 05 - Hydraulic System
Components, Capacities And Oil Types
Startup Test Procedure
Main Pump
Steering System
Tilting System
Fan System
Brakes
Accumulators
Chapter 06 - Electrical System
How To Use The Electrical Documentation
Troubleshooting, What To Do
Description Of The Vcu2 Functionality
Doosan Moxy Vcu 2
Find Wiring Contact On Vcu2
Lcd Instrumentation Unit
Warning Lights Display
Lcd Screen Main Menu
Lcd Use Description
Pos Reference List
Description Of The Main Electrical System.
General Description
Welding On The Dump Truck
Battery Hazard Prevention
Component Position
Electrical Parts View
El.System, Outside Front And Rear
Electrical Equipment Inside Cab
El.System, Cab Inside
Switch Panel
Heater Unit Exploded
Heater Unit Parts List
Ignition Key Switch
Air Conditioning System Componenets
Product Final Inspection
Refrigerant Charging
Regulation Controll
Preassure Reading And Troubleshooting
Use Of The A.T.C
Rear Frame
Da Series Functions And Parameters
Brake/Brake Charge System (Accumulators) (7)
Wdb Cooling (Only On Da40) (7)
Emergency Steering System (9)
Park Brake (6)
Low Engine Oil Pressure (2)
Low Coolant Level (3)
Clogged Air Filter (4)
Central Lubrication Pump (11)
Charge Lamp (12)
Body Tip System (13)
Load Weighing (32)
Differential Lock (28)
Cooling Fan Control
Quick Warmup Function
Cooldown Function
Alternative Engine Speed
Interior Light
Retarder And Engine Brake (24 - 25)
Emergency Stop
Fuel Heater
A/C Compressor Control
To Be Implented
Engine Electrical Components.
Engine Ems S6 / S8
Electrical Cable Routing
Ems Connection Chart
Ems Pin List
Engine Management System S8
Engine Speed And Camsghaft Sensors
Wastergate Solenoid Valve
Control Unit Ems S8
Fuel Pressure Sensor
Fuel Inlet Metering Valve
Solenoid Valve For Xpi Injector
Transmission Spesification Of Electrical Components
Transmission Speed Sensors
Transmission Temperature Sensors
Transmission Solenoid Valves
Transmission Pressure Switch
Transmission Electric Switch
Sensors Hydraulic System
Steering Valve, El. Connection
Main Valve El. Connection
Parking Brake Sensor
Body Float Sensor
Electrical Chart And Circuit
Cab Roof Cable Set
Cab Floor Cable Set
Cab Inside Rear Wall Cable Set
Wiring (Cable Set) S1 - S6
Cirquit Chart Cabine (No1)
Junction Box Battery Compartment
Cirquit Chart Front And Rear Frame (No2)
Exhaust Emmission Control
Wiring Diagram For The Exhaust Emission Control
System Overview For Electrics
Chapter 07 - Front Wagon
7.1 Introduction
7.2.1 Hydraulic Gas Cylinder Disassembly
7.2.2 Repairing The Hydraulic Gas Cylinder
7.2.3 Hydraulic Gas Cylinder Reassembly
7.2.4 Panhard Bar
7.2.5 Suspension Bearing
7.2.6 Cross Tube Bushings
7.3.1 Articulation Bearing
7.3.3 Calculation Of The Tandem Bearing
7.3.4 Articulation Hinge
7.4.1 Fender Rh
7.4.2 Fender Lh
7.4.3 Mudguard
7.4.4 Bonnet Lock
7.4.5 Bonnet
7.4.6 Bonnet Adjustment And Control
7.5.1 Cab Removal
7.5.2 Cab Ventilation Control Panel
7.5.3 Cab Ventilation Unit
7.5.4 Cab Door
7.5.5 Door Damper Cylinder
7.5.6 Steering Column
Chapter 08 - Rear Frame
8.1 Introduction
8.2.1 Dumper Body
8.2.2 Tilt Bearing
Chapter 09 - Option
9 Optional Equipment
9.1 Automatic Tail Gate
9.2 Body Heating System
9.2.1 View Of The Exhaust Body Heating System
9.2.2 Assembly Of The Exhaust Body Heating System
9.4 View Of The Engine Heater
9.4.1 Engine Heater Assembly
9.6 Webasto
9.7 Telematic System Installation
Chapter 10 - Error Codes List
English
Sm Back Cover Da40-5
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