Doosan Articutaled Dump Truck DA30 Shop Manual MX534794 2019
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Doosan Articutaled Dump Truck DA30 Shop Manual MX534794 2019
Size: 135.31 MB
Format: PDF
Language: English
Brand: Doosan
Type of Machine: Dump Truck
Type of Manual: Shop Manual, Electrical Diagram, Hydraulic Diagram
Model: Doosan DA30 Dump Truck
Serial Number:
Pre-series: 7x1501 - 7x1510
Series: 721511→, 741511→
Part Number: MX534794
Publication Date: 2019
Number of Pages: 1133 Pages
Contents:
Foreword
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
Da30 Final S1 - 1 Engine Pde (Verkst-Bok - 1081902 - 1 - B) - 1
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
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 Fitting And Flywheel Access
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
Flexible Coupling
Safety Instructions
Functional Description
Disassembly And Dismantling The Coupling
Assembling The Coupling →7x1126;→8x1128.
Installation Instructions
Friction Disk, Friction Ring
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, Exploded View
Special Tools
Intermediate Gear
Renewal Of Bearing In Intermediate Gear For The Camshaft
Camshaft Gear
Crankshaft Gear
Camshaft
Replacement Of Camshaft Bearing
Crankshaft
Removal
Fitting
Adjust - Machining The Crankshaft
Lubrication System
General
Oil Pump
Lubrication Oilways
Oil Pressure
Oil Cooler, Engine
Oil Cooler View See 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
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 Pde
General Data
Technical Data Dc9 With Pde
General Data
Troubleshooting Sdp3 / Canbus
To Do:
Troubleshooting - Basic Info
Diagnostic Procedure
Use Of Diagnostic Kit
Connection Point Canpc + Obdii Conector
Can Bus Overview
Sdp3 Scania Dagnostic
Troubleshooting Manual
White Smoke
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
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
Da30 Final S1 - 1 Engine Xpi (Verkst-Bok - 1064892 - 1 - B) - 1
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 Filter
Changing The Fuel Filter
Water Separating Prefilter
Changing The Water Separating Fuel Filter
Overflow Valve
Fuel System Components
Schematic Diagram Of The Fuel System:
Important Information About The Fuel
Exhaust System Xpi
Introduction System Overview
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
Egr Valve And Actuator Removal
Checking The Control Cylinder
Leak Testing The Egr Cooler
Renewing The Control Unit
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
Vgt (Variable Geometry Turbo)
Vgt Removal
Vgt Fitting
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 →7x1126;→8x1128.
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, Exploded View
Special Tools
Intermediate Gear
Camshaft Gear
Crankshaft Gear
Camshaft
Replacement Of Camshaft Bearing
Crankshaft
Removal
Fitting
Adjust - Machining The Crankshaft
Lubrication System
General
Oil Pump
Lubrication Oil-Ways
Oil Pressure
Oil Cooler, Engine
Oil Cooler View
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
Removing And Fitting Thermostat
Coolant Pump
External Cleaning
Internal Cleaning
Technical Data Dc13 With Xpi
General Data
Technical Data Dc9 With Xpi
General Data
Troubleshooting Sdp3 / Canbus
To Do:
Troubleshooting - Basic Info.
Troubleshooting Fuel System
Troubleshooting Guide
Diagnostic Procedure
Use Of Diagnostic Kit
Connection Point Canpc + Testman
Can Bus Overview
Sdp3 Scania Diagnostic
Troubleshooting Manual
White Smoke
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
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
Da30 Final S1 - 2 Transmission (Verkst-Bok - 1064894 - 1 - B) - 1
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
Gear Schematics
Measuring Points And Connections
Table
Measuring Points For Pressure Oil And Temperature
Installation Sheet
Special Tools For Disassembly And Reassembly
Commercial Tools For Disassembly And Reassembly
Removal Of Transmission, Disassembly
Disassemble The Structure Bar
Disassemble The Hydraulic Hoses
Positioning For Disassembly And Reassembly
Removal And Refitting Various Components
Transmission
Lkv Axle Insert
Separate Axle Insert Lkv From Transmission
Removal Of Speed Sensor N4-Output
Disassembly Of Shifting Block I And Speed Sensors
Engine Connection
Oil Supply
Removal Of Shifting Block Ii, Valve Block Primary
Pump And Retarder
Retarder
Valve Block
Shifting Block Ii
Primary Pump
Output To Front And Rear Axle
Output To Front Axle With Axle Insert Lkv
Output To Front Axle Without Axle Insert Lkv
Output To Rear Axle
Power Take-Off
Version With 1st Pto
Emergency Steering Pump
Planetary Drive “F”
Separate Planetary Drive From Housing Ii
Removal Input Shaft And Clutches
Separate Housing I And Housing Ii
Housing I
Differential “G”
Clutches “V”; “R”; “A”; “B”; “C”; “D”; “E”
Housing Ii
Clutches „V“; „R“; „A“; „B“; „C“; „D“; „E“ And Differential
Clutch “E”
Clutch “R”
Idler
Gear
Clutch
Clutch “B“
Idler/Gear
Gear
Clutch
Clutch “V“
Clutch “C“
Idler
Gear
Clutch
Clutch “D“
Idler
Gear
Clutch
Clutch “A“
Idler
Gear
Clutch
Differential ”G“-”Da40 F“
Differential Without Axle Insert Lkv ”G“
Differential ”G“-”Da30 F“
Differential With Axle Insert Lkv ”G“
Reassembly
Clutches „V“; „R“; „A“; „B“; „C“; „D“; „E“ And Differential
Clutch ”E“
Clutch “R“
Clutch “B“
Clutch “V“
Clutch “C“
Clutch “D“
Clutch “A“
Differential ”G“-”Da40 F“
Differential Without Axle Insert Lkv ”G“
Differential ”G“-”Da30 F“
Differential With Axle Insert Lkv ”G“
Installation Input Shaft And Clutches
Housing Ii
Clutches “V”;“R”;“A”;“B”;“C”;“D”;“E”
Housing I
Assemble Housing I And Housing Ii
Oil Supply
Shifting Block Ii
Valve Block
Retarder
Primary Pump
Installation Retarder, Primary Pump, Valve Block And Shifting Block Ii
Engine Connection
Planetary Drive “F”
Planetary Drive
Mount Planetary Drive To Housing Ii
Output To Front And Rear Axle
Output To Front Axle With Axle Insert Lkv ”Da30 F“
Output To Rear Axle
Power Take-Off
Version With 1st Power Take-Off (Pto)
Pto-Gear – 1st Power Take-Off
Pto-Input Shaft
Emergency Steering Pump
Version With Emergency Steering Pump
Reassembly Of Shifting Block I And Speed Sensors:
Shifting Block I
Refitting Of Speed Sensor N4-Output
Refitting Breather, Oil Sight Level Glass, Cover Plate And Screw Plug
Version With Connection 1st Pto
Refitting Of Lkv Axle Insert
Disassembly Of Lkv Axle Insert ”Da30 F“
Disassembly
Reassembly Of Lkv Axle Insert ”Da30 F“
Resassembly
Determination Of Shim For Contact Pattern
Reassembly Of Pinion
Reassembly Of Differential
Setting Of Backlash/Crown Wheel Set And Bearing Rolling Torque/Differential
Contact Pattern Check (Figure 843 And Figure 844)
Preassembly And Reinstallation Of Flange Shaft
Contact Pattern Examples Of Gleason Tooth System
Field Of Application:
Ideal Contact Pattern:
Contact Pattern Setting:
Flank Glossary:
Example 1: Dedendum Tooth Position
Example 2: Addendum Tooth Position
Example 3: “Line” Contact Pattern
Transmission Assembly
Clutch Calibration
Transmission Oil Check
Da30 - Da45 Final S2 - 3 Drive Line (22
Introduction
General
Structure Of The Repair Manual
Denomination Of Standard Dimensions
Conversion Table
Kessler Special Tools For Da30
Driveline Components
Hub Assembly Wheel Gear Front With Brake
Hub Assembly Wheel Gear
Assembly Of The Hub Assembly
Overwiew Of Parts
Assembly Of The Thrust Ring
Assembly Of The Spacer Ring
Assembly Hub Assembly
Prepare And Mount Wheel Hub
Prepare Wheel Hub
Assembly Wheel Hub
Adjustment Of Wheel Bearings
Tightening Torque Of Wheel Safety Nut
Assembly Wheel Bearing Adjustment Nut
Locking Wheel Bearing Adjustment Nut
Disassembly Of Planetary Gear
Disassembly Of Sun Gear
Loosening The Wheel Bearing Adjustment Nut
Checking The Wheel Bearing Adjustment Nut
Assembly Of The Face Seal
Assembly Of The Ring Gear And Ring Gear Carrier
Prepare The Ring Gear And The Ring Gear Carrier
Assembly Of The Ring Gear Carrier
Assembly Wheel Bearing Adjustment Nut.
Locking Wheel Bearing Adjustment Nut.
Preparation And Assembly Axle Shaft.
Assembly Of The Thrust Ring
Assembly Of The Sun Gear
Planetary Gear Drive
Assembly Of Planetary Gear
Prepare Planetary Gear
Assembly Of The Planetary Housing
Disassembly Of Planetary Gear
Assembly / Disassembly Of Cageless Needle Bearing
Assembly
Disassembly
Hub Assembly Wheel Gear Rear With Brake
Hub Assembly Wheel Gear
Overview Of Parts
Hub Assembly Wheel Gear Rear Without Brake
Hub Assembly Wheel Gear
Overview Of Parts
Wet Multiple Disc Brake
Connections Wet Multiple Disc Brake
Disassembly Wet Multiple Disc Brake
Assembly Wet Multiple Disc Brake
Air Gap Setting With Piston Adjustment
Assembly Wet Multiple Disc Brake On The Axle
Test Of The Cooling Oil Chamber
Bleeding The Wet Multiple Disc Brake
Final Assembly
Check The Air Gap (Pressurized)
Alignment Of The Discs
Drive Shafts
Front Frame
Rear Frame
Mounting The Bearings On The Intermediate Shaft (B)
Front Differential And Transmission
Brakes
Service Brake
Service Brake Description
Parking Brake
Brake Disc Runout
Testing Of Parking Brake
Removal Of The Linings
Removal Of The Park Brake Unit From Dump Truck
Disassembly Of The Park Brake Unit.
Assembly Of The Park Brake Unit
Assembly Of The Park Brake
Adjustment Of The Initial Caliper Clearance
Disc
Measure Disc Thickness
Lining Wear Measurement Of Wet Multiple Disk Brake
Troubleshooting The Park Brake
Rear Differential
Overview Of Parts
Exchange Of The Complete Rear Differential
Safety Precautions.
Disassembly
Complete Removal Of The Differential
Disassembly Of Differential And Carrier Assembly
Assembly Of Differential And Carrier Assembly
Adjustment Of Drive Pinion Distance
Sample Calculations ( Dimensions In Mm)
Assembly Of The Drive Pinion Bearing
Assembly Radial Seal Ring On The Drive Flange
Assembly Drive Flange
Assembly Lock Nut
Securing Of The Lock Nut
Limited-Slip Differential
Operating Sequence
Assembly Ring Gear
Tightening Torque For Standard Metric Threads.
Assembly Tapered Roller Bearing Onto Differential Housing
Installation Of The Pre-Assembled Differential
Fastening Bearing Caps
Dimension Of Backlash
Adjustment Of Backlash
Adjustment Differential
Checking The Contact Pattern Of The Gear Teeth
Locking The Bearing Adjustment Rings
Assembly Differential And Axle House
Assembly Wear Ring Axle House
Assembly Bearingpacks Axle House
Tandem
Bogie Housing Overview
Tandem Section View
Assembly Gearwheels
Installation Of Gearwheels “B” In Tandem
Installation Of Gearwheels “A” In Tandem
Installation Of Hub In Tandem
Installation Of Gearwheels “C” In Tandem
Checking Clearance In The Tandem Bearing.
View Of The Tandem Bearing
Assembly Bogie - Tandem To Diff.
Install Rear Axle To Frame Bearing
General Information
Recommendation For Repairs
Oil Change For Tandem Housing And Planetary Drive(Hubs)
General Information
Differential + Axle Housing
Bogie Housing
Oil Change Front And Rear Hubs With Brakes
Oil Change Rear Hubs Without Brakes
Note:
Da30 Final S1 - 4 Lubrication (Verkst-Bok - 1064895 - 1 - B) - 1
Lubrication System Parts
Greasing Cycles
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
Blank Page
Da30 - Da45 Final S2 - 5 Hydraulic System (22.08
Components, Capacities And Oil Types
Startup Test Procedure
Main Pump
Steering System
Tilting System
Fan System
Brakes
Accumulators
Da30 Final S1 - 6 Electrical System (Verkst-Bok - 1064897 - 1 - B) - 1
Safety Instructions
Diagnostic
Components
Electrical Circuits
Blank Page
Da30 Final S1 - 7 Front Frame (19.08.2019)
7.1 Introduction
Hydraulic Cylinder Disassembly
Hydraulic Cylinder Reassembly
Suspension Cylinder Repair Instructions
Panhard Bar
Suspension Bearing
Cross Tube Bushings
Articulation Bearing
Calculation Of The Tandem Bearing
Articulation Hinge
Fender Rh
Fender Lh
Mudguard
Bonnet Lock
Bonnet
Bonnet Adjustment And Control
Disassembly Of The Cooling System
Disassembly Of The Cooling Radiator
Disassembly Of The Cooling Systems Hydraulic Motor
Cab Removal
Cab Ventilation Control Panel
Cab Ventilation Unit
Cab Door
Door Damper Cylinder
Steering Column
Da30 Final S1 - 8 Rear Frame (19.08.2019)
8.1 Introduction
Dumper Body
Tilt Bearing
Overview Of The Dumper Body
Da30 Final S1 - 9 Option (19.08.2019)
9 Optional Equipment
Automatic Tail Gate
View Of The Exhaust Body Heating System
Assembly Of The Exhaust Body Heating System
View Of The Engine Heater
Engine Heater Assembly
Webasto
Assembly Preparation
Telematic System Installation
Overview
Installation Procedure
Checking Functionality
Da30 Final S1 - 10 Error Codes List (Verkst-Bok - 1064893 - 1 - A) - 1
English
Blank Page
Size: 135.31 MB
Format: PDF
Language: English
Brand: Doosan
Type of Machine: Dump Truck
Type of Manual: Shop Manual, Electrical Diagram, Hydraulic Diagram
Model: Doosan DA30 Dump Truck
Serial Number:
Pre-series: 7x1501 - 7x1510
Series: 721511→, 741511→
Part Number: MX534794
Publication Date: 2019
Number of Pages: 1133 Pages
Contents:
Foreword
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
Da30 Final S1 - 1 Engine Pde (Verkst-Bok - 1081902 - 1 - B) - 1
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
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 Fitting And Flywheel Access
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
Flexible Coupling
Safety Instructions
Functional Description
Disassembly And Dismantling The Coupling
Assembling The Coupling →7x1126;→8x1128.
Installation Instructions
Friction Disk, Friction Ring
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, Exploded View
Special Tools
Intermediate Gear
Renewal Of Bearing In Intermediate Gear For The Camshaft
Camshaft Gear
Crankshaft Gear
Camshaft
Replacement Of Camshaft Bearing
Crankshaft
Removal
Fitting
Adjust - Machining The Crankshaft
Lubrication System
General
Oil Pump
Lubrication Oilways
Oil Pressure
Oil Cooler, Engine
Oil Cooler View See 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
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 Pde
General Data
Technical Data Dc9 With Pde
General Data
Troubleshooting Sdp3 / Canbus
To Do:
Troubleshooting - Basic Info
Diagnostic Procedure
Use Of Diagnostic Kit
Connection Point Canpc + Obdii Conector
Can Bus Overview
Sdp3 Scania Dagnostic
Troubleshooting Manual
White Smoke
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
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
Da30 Final S1 - 1 Engine Xpi (Verkst-Bok - 1064892 - 1 - B) - 1
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 Filter
Changing The Fuel Filter
Water Separating Prefilter
Changing The Water Separating Fuel Filter
Overflow Valve
Fuel System Components
Schematic Diagram Of The Fuel System:
Important Information About The Fuel
Exhaust System Xpi
Introduction System Overview
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
Egr Valve And Actuator Removal
Checking The Control Cylinder
Leak Testing The Egr Cooler
Renewing The Control Unit
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
Vgt (Variable Geometry Turbo)
Vgt Removal
Vgt Fitting
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 →7x1126;→8x1128.
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, Exploded View
Special Tools
Intermediate Gear
Camshaft Gear
Crankshaft Gear
Camshaft
Replacement Of Camshaft Bearing
Crankshaft
Removal
Fitting
Adjust - Machining The Crankshaft
Lubrication System
General
Oil Pump
Lubrication Oil-Ways
Oil Pressure
Oil Cooler, Engine
Oil Cooler View
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
Removing And Fitting Thermostat
Coolant Pump
External Cleaning
Internal Cleaning
Technical Data Dc13 With Xpi
General Data
Technical Data Dc9 With Xpi
General Data
Troubleshooting Sdp3 / Canbus
To Do:
Troubleshooting - Basic Info.
Troubleshooting Fuel System
Troubleshooting Guide
Diagnostic Procedure
Use Of Diagnostic Kit
Connection Point Canpc + Testman
Can Bus Overview
Sdp3 Scania Diagnostic
Troubleshooting Manual
White Smoke
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
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
Da30 Final S1 - 2 Transmission (Verkst-Bok - 1064894 - 1 - B) - 1
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
Gear Schematics
Measuring Points And Connections
Table
Measuring Points For Pressure Oil And Temperature
Installation Sheet
Special Tools For Disassembly And Reassembly
Commercial Tools For Disassembly And Reassembly
Removal Of Transmission, Disassembly
Disassemble The Structure Bar
Disassemble The Hydraulic Hoses
Positioning For Disassembly And Reassembly
Removal And Refitting Various Components
Transmission
Lkv Axle Insert
Separate Axle Insert Lkv From Transmission
Removal Of Speed Sensor N4-Output
Disassembly Of Shifting Block I And Speed Sensors
Engine Connection
Oil Supply
Removal Of Shifting Block Ii, Valve Block Primary
Pump And Retarder
Retarder
Valve Block
Shifting Block Ii
Primary Pump
Output To Front And Rear Axle
Output To Front Axle With Axle Insert Lkv
Output To Front Axle Without Axle Insert Lkv
Output To Rear Axle
Power Take-Off
Version With 1st Pto
Emergency Steering Pump
Planetary Drive “F”
Separate Planetary Drive From Housing Ii
Removal Input Shaft And Clutches
Separate Housing I And Housing Ii
Housing I
Differential “G”
Clutches “V”; “R”; “A”; “B”; “C”; “D”; “E”
Housing Ii
Clutches „V“; „R“; „A“; „B“; „C“; „D“; „E“ And Differential
Clutch “E”
Clutch “R”
Idler
Gear
Clutch
Clutch “B“
Idler/Gear
Gear
Clutch
Clutch “V“
Clutch “C“
Idler
Gear
Clutch
Clutch “D“
Idler
Gear
Clutch
Clutch “A“
Idler
Gear
Clutch
Differential ”G“-”Da40 F“
Differential Without Axle Insert Lkv ”G“
Differential ”G“-”Da30 F“
Differential With Axle Insert Lkv ”G“
Reassembly
Clutches „V“; „R“; „A“; „B“; „C“; „D“; „E“ And Differential
Clutch ”E“
Clutch “R“
Clutch “B“
Clutch “V“
Clutch “C“
Clutch “D“
Clutch “A“
Differential ”G“-”Da40 F“
Differential Without Axle Insert Lkv ”G“
Differential ”G“-”Da30 F“
Differential With Axle Insert Lkv ”G“
Installation Input Shaft And Clutches
Housing Ii
Clutches “V”;“R”;“A”;“B”;“C”;“D”;“E”
Housing I
Assemble Housing I And Housing Ii
Oil Supply
Shifting Block Ii
Valve Block
Retarder
Primary Pump
Installation Retarder, Primary Pump, Valve Block And Shifting Block Ii
Engine Connection
Planetary Drive “F”
Planetary Drive
Mount Planetary Drive To Housing Ii
Output To Front And Rear Axle
Output To Front Axle With Axle Insert Lkv ”Da30 F“
Output To Rear Axle
Power Take-Off
Version With 1st Power Take-Off (Pto)
Pto-Gear – 1st Power Take-Off
Pto-Input Shaft
Emergency Steering Pump
Version With Emergency Steering Pump
Reassembly Of Shifting Block I And Speed Sensors:
Shifting Block I
Refitting Of Speed Sensor N4-Output
Refitting Breather, Oil Sight Level Glass, Cover Plate And Screw Plug
Version With Connection 1st Pto
Refitting Of Lkv Axle Insert
Disassembly Of Lkv Axle Insert ”Da30 F“
Disassembly
Reassembly Of Lkv Axle Insert ”Da30 F“
Resassembly
Determination Of Shim For Contact Pattern
Reassembly Of Pinion
Reassembly Of Differential
Setting Of Backlash/Crown Wheel Set And Bearing Rolling Torque/Differential
Contact Pattern Check (Figure 843 And Figure 844)
Preassembly And Reinstallation Of Flange Shaft
Contact Pattern Examples Of Gleason Tooth System
Field Of Application:
Ideal Contact Pattern:
Contact Pattern Setting:
Flank Glossary:
Example 1: Dedendum Tooth Position
Example 2: Addendum Tooth Position
Example 3: “Line” Contact Pattern
Transmission Assembly
Clutch Calibration
Transmission Oil Check
Da30 - Da45 Final S2 - 3 Drive Line (22
Introduction
General
Structure Of The Repair Manual
Denomination Of Standard Dimensions
Conversion Table
Kessler Special Tools For Da30
Driveline Components
Hub Assembly Wheel Gear Front With Brake
Hub Assembly Wheel Gear
Assembly Of The Hub Assembly
Overwiew Of Parts
Assembly Of The Thrust Ring
Assembly Of The Spacer Ring
Assembly Hub Assembly
Prepare And Mount Wheel Hub
Prepare Wheel Hub
Assembly Wheel Hub
Adjustment Of Wheel Bearings
Tightening Torque Of Wheel Safety Nut
Assembly Wheel Bearing Adjustment Nut
Locking Wheel Bearing Adjustment Nut
Disassembly Of Planetary Gear
Disassembly Of Sun Gear
Loosening The Wheel Bearing Adjustment Nut
Checking The Wheel Bearing Adjustment Nut
Assembly Of The Face Seal
Assembly Of The Ring Gear And Ring Gear Carrier
Prepare The Ring Gear And The Ring Gear Carrier
Assembly Of The Ring Gear Carrier
Assembly Wheel Bearing Adjustment Nut.
Locking Wheel Bearing Adjustment Nut.
Preparation And Assembly Axle Shaft.
Assembly Of The Thrust Ring
Assembly Of The Sun Gear
Planetary Gear Drive
Assembly Of Planetary Gear
Prepare Planetary Gear
Assembly Of The Planetary Housing
Disassembly Of Planetary Gear
Assembly / Disassembly Of Cageless Needle Bearing
Assembly
Disassembly
Hub Assembly Wheel Gear Rear With Brake
Hub Assembly Wheel Gear
Overview Of Parts
Hub Assembly Wheel Gear Rear Without Brake
Hub Assembly Wheel Gear
Overview Of Parts
Wet Multiple Disc Brake
Connections Wet Multiple Disc Brake
Disassembly Wet Multiple Disc Brake
Assembly Wet Multiple Disc Brake
Air Gap Setting With Piston Adjustment
Assembly Wet Multiple Disc Brake On The Axle
Test Of The Cooling Oil Chamber
Bleeding The Wet Multiple Disc Brake
Final Assembly
Check The Air Gap (Pressurized)
Alignment Of The Discs
Drive Shafts
Front Frame
Rear Frame
Mounting The Bearings On The Intermediate Shaft (B)
Front Differential And Transmission
Brakes
Service Brake
Service Brake Description
Parking Brake
Brake Disc Runout
Testing Of Parking Brake
Removal Of The Linings
Removal Of The Park Brake Unit From Dump Truck
Disassembly Of The Park Brake Unit.
Assembly Of The Park Brake Unit
Assembly Of The Park Brake
Adjustment Of The Initial Caliper Clearance
Disc
Measure Disc Thickness
Lining Wear Measurement Of Wet Multiple Disk Brake
Troubleshooting The Park Brake
Rear Differential
Overview Of Parts
Exchange Of The Complete Rear Differential
Safety Precautions.
Disassembly
Complete Removal Of The Differential
Disassembly Of Differential And Carrier Assembly
Assembly Of Differential And Carrier Assembly
Adjustment Of Drive Pinion Distance
Sample Calculations ( Dimensions In Mm)
Assembly Of The Drive Pinion Bearing
Assembly Radial Seal Ring On The Drive Flange
Assembly Drive Flange
Assembly Lock Nut
Securing Of The Lock Nut
Limited-Slip Differential
Operating Sequence
Assembly Ring Gear
Tightening Torque For Standard Metric Threads.
Assembly Tapered Roller Bearing Onto Differential Housing
Installation Of The Pre-Assembled Differential
Fastening Bearing Caps
Dimension Of Backlash
Adjustment Of Backlash
Adjustment Differential
Checking The Contact Pattern Of The Gear Teeth
Locking The Bearing Adjustment Rings
Assembly Differential And Axle House
Assembly Wear Ring Axle House
Assembly Bearingpacks Axle House
Tandem
Bogie Housing Overview
Tandem Section View
Assembly Gearwheels
Installation Of Gearwheels “B” In Tandem
Installation Of Gearwheels “A” In Tandem
Installation Of Hub In Tandem
Installation Of Gearwheels “C” In Tandem
Checking Clearance In The Tandem Bearing.
View Of The Tandem Bearing
Assembly Bogie - Tandem To Diff.
Install Rear Axle To Frame Bearing
General Information
Recommendation For Repairs
Oil Change For Tandem Housing And Planetary Drive(Hubs)
General Information
Differential + Axle Housing
Bogie Housing
Oil Change Front And Rear Hubs With Brakes
Oil Change Rear Hubs Without Brakes
Note:
Da30 Final S1 - 4 Lubrication (Verkst-Bok - 1064895 - 1 - B) - 1
Lubrication System Parts
Greasing Cycles
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
Blank Page
Da30 - Da45 Final S2 - 5 Hydraulic System (22.08
Components, Capacities And Oil Types
Startup Test Procedure
Main Pump
Steering System
Tilting System
Fan System
Brakes
Accumulators
Da30 Final S1 - 6 Electrical System (Verkst-Bok - 1064897 - 1 - B) - 1
Safety Instructions
Diagnostic
Components
Electrical Circuits
Blank Page
Da30 Final S1 - 7 Front Frame (19.08.2019)
7.1 Introduction
Hydraulic Cylinder Disassembly
Hydraulic Cylinder Reassembly
Suspension Cylinder Repair Instructions
Panhard Bar
Suspension Bearing
Cross Tube Bushings
Articulation Bearing
Calculation Of The Tandem Bearing
Articulation Hinge
Fender Rh
Fender Lh
Mudguard
Bonnet Lock
Bonnet
Bonnet Adjustment And Control
Disassembly Of The Cooling System
Disassembly Of The Cooling Radiator
Disassembly Of The Cooling Systems Hydraulic Motor
Cab Removal
Cab Ventilation Control Panel
Cab Ventilation Unit
Cab Door
Door Damper Cylinder
Steering Column
Da30 Final S1 - 8 Rear Frame (19.08.2019)
8.1 Introduction
Dumper Body
Tilt Bearing
Overview Of The Dumper Body
Da30 Final S1 - 9 Option (19.08.2019)
9 Optional Equipment
Automatic Tail Gate
View Of The Exhaust Body Heating System
Assembly Of The Exhaust Body Heating System
View Of The Engine Heater
Engine Heater Assembly
Webasto
Assembly Preparation
Telematic System Installation
Overview
Installation Procedure
Checking Functionality
Da30 Final S1 - 10 Error Codes List (Verkst-Bok - 1064893 - 1 - A) - 1
English
Blank Page
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