Daewoo Novus M2SEF Manual
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Daewoo Novus M2SEF Manual

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We would like to take this opportunity to thank you for choosing a TATA 
DAEWOO  product  and  assure  you  for  our  continuing  interest  in  your 
motoring pleasure and satisfaction. 
This  manual  has  been  prepared  to  acquaint  you  with  the  operation  and 
Maintenance  of  your  new  TATA  DAEWOO  TRUCK  and  to  provide 
important safety information. We urge you to read it carefully and follow 
the  recommendation  to  help  assure  the  most  enjoyable,  safe  and 
trouble‐free operation of your vehicle. 
When  it  comes  to  service,  remember  that  your  TATA  DAEWOO  dealer 
knows your vehicle best and is interested in your full satisfaction. 
This  manual  should  be  considered  as  a  permanent  part  of  your  vehicle, 
and must remain with the vehicle at the time of resale. 
All information, illustrations  and  specifications contained in this  manual 
are  based  on  the  latest  product  information  available  at  the  time  of 
publication. 
The right is reserved to make changes at any time without notice. 
 
https://www.truck-manuals.net/
FOREWORD 
FOREWORD 
TATA DAEWOO COMMERCIAL VEHICLE 
 
 
 
 
 

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  • Page 1 FOREWORD      FOREWORD  We would like to take this opportunity to thank you for choosing a TATA  DAEWOO  product  and  assure  you  for  our  continuing  interest  in  your    motoring pleasure and satisfaction.  This  manual  has  been  prepared  to  acquaint  you  with  the  operation  and  maintenance  of  your  new  TATA  DAEWOO  TRUCK  and  to  provide ...
  • Page 2 https://www.truck-manuals.net/ TABLE OF CONTENTS 1. HOW TO HANDLE THE VEHICLE 2. DRIVING 3. INSPECTION AND MAINTENANCE 4. TROUBLE SHOOTING AND CORRECTIONS 5. MISCELLANEOUS CONTROLS AND OPTIONS 6. SPECIFICATIONS AND SERVICE...
  • Page 3 https://www.truck-manuals.net/ HOW TO HANDLE THE VEHICLE 1. OPERATION OF NEW VEHICLE 2. OPERATION OF CAB TILT 3. OPENING OR CLOSING OF FRONT LID 4. INSTRUMENTS AND CONTROLS 1) Attachments of steering column 2) Peripheral devices of steering column 3) Instruments and indicator lamps 4) Controls of center console 5) Miscellaneous controls...
  • Page 4 https://www.truck-manuals.net/ 1-1 HOW TO HANDLE THE VEHICLE 1. OPERATION OF NEW VEHICLE It is important to follow the instructions as outlined here, because careful breaking-in of your vehicle will greatly increase its life and performance. MTA0011 1) Follow oil change interval. Service intervals for changing Engine type engine oil and filter...
  • Page 5 https://www.truck-manuals.net/ 1-2 HOW TO HANDLE THE VEHICLE (4) During the first 4,000 km, limit engine speed to 70 percent of the maximum allowance, and frequently watch tachometer to prevent engine over-running while driving your vehicle. Maximum allowable engine speed (rpm) Engine First 4,000 km After 4,000 km...
  • Page 6 https://www.truck-manuals.net/ 1-3 HOW TO HANDLE THE VEHICLE 6) How to Handle the vehicle(for DDC engine) (1) IDLE SHUT DOWN function 1) Engine automatically stops after 5 minutes passed when engine is idling for reducing fuel consumption and air pollution 2) Restart engine for driving after engine has stopped automatically Caution MTA0041...
  • Page 7 https://www.truck-manuals.net/ 1-4 HOW TO HANDLE THE VEHICLE 6) Seat belts Always fasten your seat belts when driving over long distance or in downtown. Passengers not wearing their seat belts may endanger your safe driving. MTA1120 The seat belt warning lamp comes on when the ignition switch is placed in the "ON"...
  • Page 8 https://www.truck-manuals.net/ 1-5 HOW TO HANDLE THE VEHICLE 2. OPERATION OF CAB TILT 1) Preparation for cab tilting (1) Place the vehicle on level ground and ensure that there is a sufficient space in front of and above the cab. And then, position starter switch "ON".
  • Page 9 https://www.truck-manuals.net/ 1-6 HOW TO HANDLE THE VEHICLE 3) How to lower the cab (1) Position the direction change lever in "D" posi- tion. descending position MTA1231 (2) If you insert cap tilt lever into pump socket and move it up and down, cab will descend. (3) Make sure that lock lever is locked into hook.
  • Page 10 1. While driving you should set the direction change lever in "D" position. 2. Be sure to check that the lock lever is locked in hook. In the event of troubles with cab tilting sys- tem, call for check and necessary services of your nearest Daewoo dealer.
  • Page 11 https://www.truck-manuals.net/ 1-8 HOW TO HANDLE THE VEHICLE 3. OPENING OR CLOSING OF FRONT LID 1) Opening procedure (1) Pull forward the front lid lever located at lower left-hand side of the instrument panel. MTA1150 (2) Put your hand between the front lid and radia- hook tor grille to pull forward the hook located in the middle of the front part, and then the front lid...
  • Page 12 1-9HOW TO HANDLE THEVEHICLE https://www.truck-manuals.net/ 4. INSTRUMENTS AND CONTROLS 14 15 18 19 17 20 28 29 2630 31 32 33 MTS0121 1. Speaker 15. Cigarette lighter 26. Trailer hand brake 2. Overhead stowage 16. Side mirror adjusting switch (tractor, pull cargo) 3.
  • Page 13 https://www.truck-manuals.net/ 1-10 HOW TO HANDLE THE VEHICLE 1) Attachments of steering column • Steering wheel and horn button The steering wheel should not be turned while the vehicle is stationary as it adversely affects the tires and steering system. Horn button is equipped on the middle of steering wheel.
  • Page 14 1-11 HOW TO HANDLE THE VEHICLE Caution 1. Daewoo heavy trucks are equipped with the preheat- ing and postheating systems designed to improve engine starting and to reduce the generation of white smoke. 2. With the starting key positioned "On", it is automati- cally preheated according to the temperature of cool- ant.
  • Page 15 https://www.truck-manuals.net/ 1-12 HOW TO HANDLE THE VEHICLE • Windshield wiper switch The windshield wiper switch has 3 positions to control the windshield wiper. 1. OFF = Off 2. INT = Intermittent wipe 3. LO = Continuous wipe, slow speed 4. HI = Continuous wipe, fast speed Caution Do not operate the wipers when the windshield remains dry.
  • Page 16 https://www.truck-manuals.net/ 1-13 HOW TO HANDLE THE VEHICLE 2) Peripheral devices of steering column (1) Differential lock switch(FRT/RR) (2) Differential lock switch(L/R) (3) Air conditioning switch (4) Fog lamp switch (5) Air parking brake valve (6) Idle control Knob(for DE/DV Engine) (7) Front lid opening lever (8) Side mirror adjusting switch(option) MTS0253...
  • Page 17 https://www.truck-manuals.net/ 1-14 HOW TO HANDLE THE VEHICLE (3) Air donditioning switch Pressing this switch turns on the air conditioer and indicator lamp simultaneously. MTA0681 (4) Fog lamp switch Fog lamps provide auxiliary illumination and improve your vision in fog or snow. MTA0691 (5) Air parking brake valve When the valve knob is pulled, the parking brake...
  • Page 18 https://www.truck-manuals.net/ 1-15 HOW TO HANDLE THE VEHICLE (7) Front lid opening lever When this lever is pulled up, front lid is re- leased from locking to be ready to open. The levels of engine oil, clutch fluid, and washer fluid can be checked from inside the front lid. MTA0320 Side mirror adjusting switch(option) Side mirror...
  • Page 19 https://www.truck-manuals.net/ 1-16 HOW TO HANDLE THE VEHICLE 3) Instruments and indicator lamps BULB CHECK MTD0590 1. Blank 5. Air pressure gauge 9. Illumination control switch 2. Temperature gauge 6. Engine tachometer 10. Turn signal/hazard warning indicator 3. Fuel gauge 7. Tachograph 11.
  • Page 20 https://www.truck-manuals.net/ 1-17 HOW TO HANDLE THE VEHICLE (2) Fuel gauge This gauge indicates fuel level of the fuel tank all the time regardless of the starter switch po- sition. MTA0360 (3) Oil pressure gauge This gauge indicates oil pressure in the engine lubricating system.
  • Page 21 https://www.truck-manuals.net/ 1-18 HOW TO HANDLE THE VEHICLE (6) Tachograph The tachograph is consisted of speedometer, odometer and clock. The vehicle speed and running distances are registered in a single chart. The speedmeter indicates the vehicle speed in kilometer per hour(km/h). The odometer indicates individual trip distances.
  • Page 22 In the case of serious trouble, call for check and proper services of your nearest Daewoo dealer. * DE/DV Engine...
  • Page 23 https://www.truck-manuals.net/ 1-20 HOW TO HANDLE THE VEHICLE • Low air pressure warning signal for park- ing brake circuit When air pressure in parking tank falls to the "cut-in" pressure (around 5.3bar), the low air pressure warning signal comes on. After that, if it continues to fall to 4.2bar, the low air pressure warning lamp blinks.
  • Page 24 Such problems are to Therefore, you must contact immediately the nearest Daewoo Service Center for proper be displayed by the codes. service. (2) 1 pin connector in white can be a sub- stitute for engine diagnosis switch on ECU connector.
  • Page 25 https://www.truck-manuals.net/ 1-22 HOW TO HANDLE THE VEHICLE • Air cleaner dust indicator lamp The air cleaner indicator lamp comes on when the air cleaner element has been re- stricted. At this time, clean or replace the element, as required. MTS0601 •...
  • Page 26 https://www.truck-manuals.net/ 1-23 HOW TO HANDLE THE VEHICLE • Door open warning lamp This lamp comes on when a door is either opened or closed insecurely. Before moving your vehicle, check that the warning lamp is off. MTA0641 • Pre-heater warning lamp This lamp is designed to indicate pre-heat- ing of the engine.
  • Page 27 https://www.truck-manuals.net/ 1-24 HOW TO HANDLE THE VEHICLE • Trailer hand brake indicator lamp (trac- tor and pull cargo truck) The trailer hand brake indicator lamp comes on when the trailer hand brake lever is op- erated. MTA0501 • Working lamp indicator lamp(for tractor, special purpose vehicles) When positioning the working lamp switch "ON", the working lamp indicator lamp...
  • Page 28 https://www.truck-manuals.net/ 1-25 HOW TO HANDLE THE VEHICLE • Differential lock indicator lamp(FRT/RR) When differential lock switch is set to"ON" position, the corresponding indicator lamp comes on and the warning buzzer goes off, which indicates that the two rear axles are not in differential operation.
  • Page 29 https://www.truck-manuals.net/ 1-26 HOW TO HANDLE THE VEHICLE • Shifting lever range HIGH indicator(for DDC and Cummins engine) Indicator turns on when gear position is high range between 5th to 8th gear, except for 24ton dump of which turns on in low range. MTS1491 •...
  • Page 30 https://www.truck-manuals.net/ 1-27 HOW TO HANDLE THE VEHICLE • Cab tilt warning lamp This lamp comes on when the cap is lifted or locking device for cab tilting is defective. Be sure to check the warning lamp before driving, and check the locking device if the lamp is on.
  • Page 31 https://www.truck-manuals.net/ 1-28 HOW TO HANDLE THE VEHICLE 4) Controls of center console DDC engine CRUISE A SR RES/INC SET/DEC MTD0673 1. Self steer switch RES/INC switch(for DDC engine) (for 20.5ton/21ton/22.5ton/24ton/25ton cargo SET/DEC switch(for DDC engine) truck) CRUISE PTO switch(for DDC engine) 2.
  • Page 32 https://www.truck-manuals.net/ 1-29 HOW TO HANDLE THE VEHICLE (1) Self-steer switch (for 20.5ton/21ton/22.5ton/25ton cargo truck) Before attempting to travel, lower the selfsteer(with the self-steer switch turned to"OFF") when loading materials onto your ve- hicle so that the weight of the payload can be distributed evenly.
  • Page 33 Therefore, you must contact immediately the by extending the engine driving using the engine di- nearest Daewoo Service Center for proper agnostic switch continuously, severe engine damage service. may result. Therefore, you must stop your vehicle...
  • Page 34 https://www.truck-manuals.net/ 1-31 HOW TO HANDLE THE VEHICLE * DDC Engine 1. How to read engine diagnostic codes Code 13(SEL Active codes) Code 21(CEL Inactive codes) ⇔ ⇔ ⇔ 1 Flash 3 Flashes 2 Flashes 1 Flash The active code will be flashed on the SEL(code "25" if there is no malfunction code). Then the inactive code will be flashed on the CEL(code "25"...
  • Page 35 https://www.truck-manuals.net/ 1-32 HOW TO HANDLE THE VEHICLE 2) DE12TIS Engine 1. Check Engine Indicator comes on while ignition key positioned ON when engine problem occurs. Such problems are to be displayed by the codes. 2. 1 pin connector in white can be a substitute for engine diagnosis switch on ECU connector.
  • Page 36 https://www.truck-manuals.net/ 1-33 HOW TO HANDLE THE VEHICLE (7) Power take-off switch(for dump, special purpose truck) This switch is used to operate the power take- off device. When the switch is pressed to "ON", the P.T.O. device starts working, P.T.O. indica- tor lamp on the instrument panel is turned on, and warning buzzer sounds all the while P.T.O.
  • Page 37 https://www.truck-manuals.net/ 1-34 HOW TO HANDLE THE VEHICLE (11) Jake Brake switch(for DDC engine) This switch is used in conjunction with the right lever of the combination switch. Pressing this switch will actuate the Jake Brake and light up indicator lamps on the instrument panel light up.
  • Page 38 https://www.truck-manuals.net/ 1-35 HOW TO HANDLE THE VEHICLE (12) Heating and air conditioning control(option) D. Recirculation switch B. Air direction control switch A. Fan control switch C. Temperature control switch Air conditioning switch MTA0750 A. Fan control switch The fan control switch can control the speed of air flow in 4 steps.
  • Page 39 https://www.truck-manuals.net/ 1-36 HOW TO HANDLE THE VEHICLE C. Temperature control switch This switch is used to adjust the flow of the engine coolant to control indoor temperature. blue MTA0780 D. Recirculation switch Press this switch when driving in dusty con- ditions or traffic fumes, and also when quick cooling or heating is required, and the inside air will be recirculated in the vehicle.
  • Page 40 https://www.truck-manuals.net/ 1-37 HOW TO HANDLE THE VEHICLE • Normal heating Air conditioning switch: "OFF" Recirculation switch: "OFF" Temperature switch: As required (in red colored zone) Fan control : As required Use this procedure to adjust inside temperature in cold weather. MTA0820 •...
  • Page 41 1-38 HOW TO HANDLE THE VEHICLE (13) Radio and cassette tape player(SCE-4084: option) LUO ST PROG DAEWOO HIGH POWER AUTO - REVERSE TDNE A.ME MTA0860 a. Liquid crystal display(LCD) h. Frequency/current time(F/C) selection button i. Tuning button b. EJECT button c.
  • Page 42 https://www.truck-manuals.net/ 1-39 HOW TO HANDLE THE VEHICLE FUNCTIONS Liquid crystal display(LCD) h. Frequency/current time(F/C) selection This panel displays the radio or tape playback button function, and time. Pressing this button indicates the frequency of the radio which you are listening to or the b.
  • Page 43 https://www.truck-manuals.net/ 1-40 HOW TO HANDLE THE VEHICLE SELECTING THE DESIRED STATION Tuning button Either press this button once to adjust frequency by each step or press and hold for quick adjustment. 2. SEEK button Press this button to automatically seek for the next available station. 3.
  • Page 44 https://www.truck-manuals.net/ 1-41 HOW TO HANDLE THE VEHICLE 3) To adjust HOUR, press " " of TUNING button while pressing F/C button. 4) To adjust MINUTE, press " " of TUNING button while pressing F/C button. 5) For faster adjustment, keep pressing F/C button and " "(or " ") of TUNING button. LISTENING ON THE RADIO Turn the knob to the right to turn on the power.
  • Page 45 https://www.truck-manuals.net/ 1-42 HOW TO HANDLE THE VEHICLE 5) Miscellaneous controls • Gearshift lever When shifting the gear, fully depress the clutch pedal. When preparing to back up, you must stop the vehicle completely and then shift to reverse position. MTA0900 K-10S6 T/M MEA0292 •...
  • Page 46 https://www.truck-manuals.net/ 1-43 HOW TO HANDLE THE VEHICLE In the case of ZF16S-221 transmission, when ZF16S-221 T/M preparing to shift from 4th to 5th position, press the upper edge of the range change switch and then depress the clutch pedal and push the gearshift lever into the 1st position.
  • Page 47 https://www.truck-manuals.net/ 1-44 HOW TO HANDLE THE VEHICLE • Clutch pedal Fully depress the clutch pedal when changing gears. Do not rest your foot on the pedal when the clutch is not in use. Premature wear of the clutch will result. MTA0960 •...
  • Page 48 https://www.truck-manuals.net/ 1-45 HOW TO HANDLE THE VEHICLE • Vents Outdoor air can be directed into the cab through these vents. Airflow and air direction can be adjusted as desired. MTA0980 • Cigarette lighter Push in this lighter and wait about 15 seconds until it is heated, then it will pop out.
  • Page 49 https://www.truck-manuals.net/ 1-46 HOW TO HANDLE THE VEHICLE • Fluorescent room lamp Press fluorescent room lamp switch to illuminate the vehicle cab. Press again this switch to put out the fluorescent lamp. MTA1020 • Spot lamps (1) Left lamp "ON", "OFF" (2) Right lamp "ON", "OFF"...
  • Page 50 https://www.truck-manuals.net/ 1-47 HOW TO HANDLE THE VEHICLE • Door (1) Using the starter key, open and close the door on the driver's seat side or the fellow driver's seat side. (2) Pressing the door lock button up and down, open and close each door. Caution Ensure that all the doors are closed firmly before travel.
  • Page 51 https://www.truck-manuals.net/ 1-48 HOW TO HANDLE THE VEHICLE • Front lamp (1) Fog lamp (2) Head lamp (3) Turn signal lamp (4) Parking lamp (5) Clearance lamp and cornering lamp (6) Sub turn signal lamp MTA1070 • Front lamp(dump truck) (1) Fog lamp (2) Head lamp (3) Trun signal lamp (4) Parking lmap...
  • Page 52 https://www.truck-manuals.net/ 1-49 HOW TO HANDLE THE VEHICLE • Rear lamp(dump truck) (1) Turn signal lamp (2) Parking lamp, clearance lamp, and stop lamp (3) Back up lamp (4) License plate lamp MTA1082 • Speed indicator lamp(option) yellow- yellow- green red green Vehicle No.
  • Page 53 https://www.truck-manuals.net/ 1-50 HOW TO HANDLE THE VEHICLE • Auxiliary parking brake (20.5/21/22.5ton Cargo with self steer axle) Use this lever for additional parking brake force. Auxiliary parking Caution 1. This brake alone shall not be used for the purpose Driving of parking.
  • Page 54 https://www.truck-manuals.net/ DRIVING 1. BEFORE STARTING THE ENGINE 2. STARTING AND STOPPING THE ENGINE 3. BEFORE DRIVING OFF 4. WHEN DRIVING OFF 5. DRIVING FOR ECONOMY 6. WHILE TRAVELING 7. TRAVEL ON HIGHWAY 8. OPERATION AND CARE IN HOT WEATHER 9. OPERATION AND CARE IN COLD WEATHER...
  • Page 55 https://www.truck-manuals.net/ 2-51 DRIVING 1. BEFORE STARTING THE ENGINE 1) Check items for the inside of front lid (1) Engine oil level (2) Clutch fluid level (3) Windshield washer fluid level MTB0010 (1) Engine oil level 1. Pull out the oil level gauge(oil dipstick) to check if the oil tank has been filled up to the specified level.
  • Page 56 https://www.truck-manuals.net/ 2-52 DRIVING 2) Check items the outside of vehicle (1) Tire (2) Chassis spring (3) Draining of air tank (4) Battery (5) Power steering fluid level (6) Coolant level (7) Fan belt tension (8) Brake fluid level MTA0011 (1) Tire 1.
  • Page 57 MTB0110 (5) Power steering fluid level 1. Check the fluid level and replenish as necessary. 2. Check the pipe joints for fluid leakage. Caution We strongly urge you to use Daewoo-recommended power steering fluid for replenishment. MTB0120...
  • Page 58 https://www.truck-manuals.net/ 2-54 DRIVING (6) Coolant level The level of coolant in the surge tank should be maintained between "MIN" and "MAX" marks. When the coolant level is found to be lower than "MIN" mark, check the cooling system for leaks, and then top it up to the "MAX"...
  • Page 59 https://www.truck-manuals.net/ 2-55 DRIVING 2. STARTING AND STOPPING THE ENGINE 1) starting the engine(DE, DV engine) (1) Apply the parking brake so that the vehicle is not moved and move the gearshift lever to NEUTRAL position. (2) Turn the starter key to "ON". Caution To start the engine, the gearshift lever should be positioned to NEUTRAL.
  • Page 60 1. Start the engine after the warning lamp goes out. 2. Warning lamp keeps coming on when engine system has trouble. At this time, consult your nearest Daewoo dealer for necessary services. MTB0192 4. Turn the starter key to START position.
  • Page 61 https://www.truck-manuals.net/ 2-57 DRIVING 3) Starting the engine in cold weather (1) With the switch in the "ON" position the indica- START tor lamp will light up showing the engine is pre- LOCK heated automatically. After pre-heating is com- pleted, the indicator lamp will go out. (2) After pre-heating is completed, press the clutch pedal and accelerator pedal to start the engine.
  • Page 62 https://www.truck-manuals.net/ 2-58 DRIVING 3. BEFORE DRIVING OFF 1) Steering wheel free play Check the amount of the steering wheel free play by gently turning the wheel in both directions. The free play should be within the range of 30~50mm at the periphery of the wheel when checked with the front wheels positioned straight ahead.
  • Page 63 https://www.truck-manuals.net/ 2-59 DRIVING 5) Clutch pedal free play Pedal free play should be within the range of 40~50mm.(ZF T/M : 25~35mm) Transmission model Vehicle Free play Deluxe 40~50mm Super deluxe LOCAL 25~35mm Ultra 40~50mm 25~35mm (25~35mm) MEB0040 6) Brake pedal free play Pedal free play should be 15mm.
  • Page 64 https://www.truck-manuals.net/ 2-60 DRIVING 4. WHEN DRIVING OFF 1) Check if the needle of air pressure gauge indicates 5.3kg/cm or above. If the gauge indicates below this range of air pressure, keep the engine running at fast idle until the gauge needle points to the rated pressure.
  • Page 65 If the cause of trouble was not located, check at your nearest Daewoo dealer. MTB0350 4) If the air pressure falls below 5.3kg/cm , stop the engine and check to locate the cause of trouble.
  • Page 66 https://www.truck-manuals.net/ 2-62 DRIVING 6) Avoid engine racing, unnecssary sudden accelera- tion, or sudden stops. MTA0031 7) Do not drive with your foot resting on the clutch pedal as it produces a partially disengaged condi- tion, causing premature wear of clutch facing. TMB0390 8) Stop your vehicle completely when attempting to shift into reverse.
  • Page 67 https://www.truck-manuals.net/ 2-63 DRIVING 10) When descending a slope, shift to lower gear to gain retardation effect of the engine. It is avisable to use the exhaust brake and engine brake in com- Exhaust Brake bination when descending a slope. Frequent use brake pedal of foot brakes while descending a long slope will...
  • Page 68 https://www.truck-manuals.net/ 2-64 DRIVING (2) Braking distance Braking efficiency is the most important thing when driving on highway. When recognizing the hazard ahead and preparing to apply the brake, your reaction time will take about one second. This means that your vehicle, if assumed to have run at speed of 80km/h, will travel additional 20 to 30m the moment you applied the brake.
  • Page 69 1. Re-check the troubles found during the previous operation and take necessary corrective actions. For such troubles difficult to correct, contact your nearest Daewoo dealer. 2. Inspect and clean each part, and check for leakage and oil levels.
  • Page 70 To prevent freezing and corrosion of the engine when operating the vehicle in extremely cold places, be sure to add a specified amount of antifreeze to coolant. It is strongly recommended to use Daewoo- approved antifreeze. Fill up the coolant circulation system with a 50/ 50 mixture of specified antifreeze and water in all seasons.
  • Page 71 https://www.truck-manuals.net/ 2-67 DRIVING 6) Use of light oil in winter (1) Paraffin composition included fuel may cause troubles to fuel lines. Due to solidification at the below zero temperature. (2) In cold climates, use winter-fuels supplied by the oil companies. 7) Use of light oil in hard winter A hard winter (below -15 C) may cause troubles due to the solidification of paraffin even though...
  • Page 72 https://www.truck-manuals.net/ INSPECTION AND MAINTENANCE 1. DAILY CHECK BEFORE DRIVING 2. PERIODIC INSPECTION AND MAINTE- NANCE 3. PERIODIC INSPECTION CHART 4. IN CASE OF EMERGENCY 5. VEHICLE REPAIR...
  • Page 73 https://www.truck-manuals.net/ 3-68 INSPECTION AND MAINTENANCE 1. DAILY CHECK BEFORE DRIVING In order to maintain safety and dependable operation, following checks should be performed daily before driving: System Check item Check point • 1) Steering Steering wheel and 1. Vibrations or shimmy of steering wheel system 2.
  • Page 74 Caution Clean the element with diesel fuel and visually It is strongly advisable to use genuine check gaskets installed on the upper and lower Daewoo oil filter element. sides of element for damage and hardening, and replace as necessary.
  • Page 75 https://www.truck-manuals.net/ 3-70 INSPECTION AND MAINTENANCE • DDC Engine oil filter (1) Remove the spin-on filter cartridges using strap wrench, drive socket wrench, and extension, and then drain the used oil completely. (2) Clean the filter adaptor with a clean, lint-free colth.
  • Page 76 https://www.truck-manuals.net/ 3-71 INSPECTION AND MAINTENANCE 4) Transmission oil (1) Oil level check Filler/level plug At end of first 1,000km and thereafter at every 4,000km driving, check oil level and replenish if oil remains below the level plug. (2) Oil or oil filter change Specifications: API GL-4, SAE 80W90 Tropical region specifications: API GL4, SAE85W140(thermostat-open 71...
  • Page 77 https://www.truck-manuals.net/ 3-72 INSPECTION AND MAINTENANCE 6) Power steering oil and oil filter (1) Oil level check At end of first 1,000km and thereafter every 4,000km operation, keep the front wheels straight ahead and check oil level with level mark on oil tank. (2) Type of oil Specifications: ATF(DEXRON II-D) MTB0120...
  • Page 78 Prior to changing steering oil or filter element, oil strainer installed in the filler of oil tank shall be cleaned. Remove dust or other foreign mat- ters from the oil strainer before reinstalling it. MTC0120 Caution It is strongly advisable to use genuine Daewoo oil filter element.
  • Page 79 https://www.truck-manuals.net/ 3-74 INSPECTION AND MAINTENANCE 7) Air cleaner(dry type) (1) Replacement or cleaning of element A partially blocked air cleaner will restrict the flow of air to the engine. Restricted air flow will decrease the performance of the engine and increase the fuel consumption and discharging of black smoke.
  • Page 80 4. Attach the element horizontally, tighten the element retaining wing nuts, refit the outer cover, and then tighten the wing nuts to retain the air cleaner securely. Caution It is strongly advisable to use genuine Daewoo MTC0160 air cleaner element. Caution rear cover...
  • Page 81 1. Clean the area around fuel filter head. It is strongly advisable to use genuine 2. Remove the fuel filter. Daewoo fuel filter element. 3. Remove the fuel filterthread adapter seal ring. Use a clean lint free cloth to clean the gasket surface of the filter head.
  • Page 82 https://www.truck-manuals.net/ 3-77 INSPECTION AND MAINTENANCE (4) Fuel filter (for DDC engine) 1) Every 6 month or every 15,000km change to- gether first and secondary filter. Primary secondary fuel fuel filter MTC0181 filter 2) How to replace the fuel filters 1. With the engine shut down, place a suitable container under the filter.
  • Page 83 https://www.truck-manuals.net/ 3-78 INSPECTION AND MAINTENANCE 9) Air bleeding of fuel system DE engine DV engine Bleeding to fuel system must be performed when fuel filter has been removed to clean or when the Air bleeding screw Air bleeding engine has been stopped due to lack of fuel. screw Air bleeding procedure (1) Turn the feed pump cap anti-clockwise.
  • Page 84 https://www.truck-manuals.net/ 3-79 INSPECTION AND MAINTENANCE Fuel system diagram(DE engine) 1. Fuel filter 2. Air bleeder screw 3. Injection nozzle 4. Fuel return pipe 5. Fuel feed pipe (filterpump) 6. Overflow valve 7. Injection pipe 8. Fuel feed pipe (pumpfilter) 9. Fuel tank 11 12 10.
  • Page 85 https://www.truck-manuals.net/ 3-80 INSPECTION AND MAINTENANCE 10) Valve clearance adjustment (1) Adjustment intervals Engine model Adjustment intervals At end of first 1,000km, Every 10,000km Every 192,000km (2) Rated valve clearance(cold) Engine model Valve clearance Intake: 0.3mm Exhaust: 0.3mm Intake: 0.25mm Exhaust: 0.35mm Intake: 0.203mm Exhaust: 0.660mm (3) Adjustment of valve clearance...
  • Page 86 https://www.truck-manuals.net/ 3-81 INSPECTION AND MAINTENANCE - DV Engine DV Engine Cyl. No. 1 Valve in ex in ex in ex in ex in ex in ex in ex in ex No. 6 No. 1 In the above charts, with the intake and exhaust valves of No.
  • Page 87 DV15TI 204 kg/cm to make such inspection, contact your nearest DV15TIS 250 kg/cm Daewoo dealer for nozzle test. 352 kg/cm 12) Fuel tank Remove drain plug from fuel tank, and take out the strainer to clean it at every 8,000km.
  • Page 88 https://www.truck-manuals.net/ 3-83 INSPECTION AND MAINTENANCE 14) Coolant Filter(for DDC engine) The engine cooling system filter is a compact by- pass type unit with a replaceable spin-on type el- ement. Any impurities such as sand and rust particles suspended in the cooling system will be removed by the straining action of the element.
  • Page 89 https://www.truck-manuals.net/ 3-84 INSPECTION AND MAINTENANCE 15) Inspection and adjustment of clutch pedal The clutch pedal free play decreases as wear develops in the clutch driven plate. The clutch pedal free play should be adjusted at every 4,000km, or when the amount of play becomes less than the standards, since the use of the ve- m m) hicle without making an adjustment will result in...
  • Page 90 2. If the section of the brake linings becomes semicircular, it indicates excessive wear beyond the limit. Frequently check and re- place them, and contact your nearest Daewoo dealer, if necessary. MTC0320 (2) Adjustment of brake lining clearance • Full air type Insert a 0.3mm feeler gauge into the lining...
  • Page 91 https://www.truck-manuals.net/ 3-86 INSPECTION AND MAINTENANCE 17) Air Bleeding of clutch hydraulic circuits 1) Fill the clutch fluid reservoir to the specified level with clutch fluid and keep it filled during bleed- ing operation. MTC0343 Air bleeding 2) Remove bleeder rubber cap and connect a vi- screw nyl pipe to the bleeder and hold free end of the pipe in a transparent container filled with clutch...
  • Page 92 https://www.truck-manuals.net/ 3-87 INSPECTION AND MAINTENANCE 18) Tires (1) Tire pressure inspection Check tire pressure with a tire air gauge and add compressed air if required. Improper in- flation will adversely affect the life of tire, es- pecially underinflation is a major contributor to overheating of tire, resulting in explosion.
  • Page 93 https://www.truck-manuals.net/ 3-88 INSPECTION AND MAINTENANCE 2. Clean the wheel pins and nuts and apply oil to the threads. MTC0400 3. Place an oil jack as shown. MEC0060 • 6x4 series 1. Front wheel 2. Rear front wheel 3. Rear rear wheel 4.
  • Page 94 https://www.truck-manuals.net/ 3-89 INSPECTION AND MAINTENANCE • 20.5ton/21ton/22.5ton cargo, 24ton dump vehicles 1. Front front wheel(1st shaft) 2. Front rear wheel(2nd shaft) 3. Rear front wheel(3rd shaft) 4. Rear rear wheel(4th shaft) 5. Spare tire MTD0430 • 10x4 series 1. Front front wheel(1st shaft) 2. Front rear wheel(2nd shaft) 3.
  • Page 95 https://www.truck-manuals.net/ 3-90 INSPECTION AND MAINTENANCE 19) Greasing points (1) 4x2 series chassis greasing point diagram 13 16 14 18 Engine Transmission 5 14 12 15 14 MEC0080 1. Bracket support cap sus. 6. Drag link, front 12. Tie rod, left upper, left 7.
  • Page 96 https://www.truck-manuals.net/ 3-91 INSPECTION AND MAINTENANCE (2) 6x4 series chassis greasing point diagram 3 14 9 11 13 16 14 19 Trans- Engine mission 5 14 8 10 7 12 15 14 MDC0130 1. Bracket support cap sus. upper, left 11. King pin, right, lower 12.
  • Page 97 https://www.truck-manuals.net/ 3-92 INSPECTION AND MAINTENANCE (3) 8x4 series chassis greasing point diagram 2 4 3 31 21 38 39 15 9 23 27 40 41 19 11 29 25 46 47 48 49 Trans- Engine mission 42 43 32 44 45 30 5 6 20 34 35 12 8 22 26 7 36 37 16 10 28 24 MTC0610 1.
  • Page 98 https://www.truck-manuals.net/ 3-93 INSPECTION AND MAINTENANCE (4) 10x4 series(self steer axle), chassis greasing point diagram MTC0601 1. Brake cam shaft, right 6. King pin, right, lower 2. Brake cam shaft, left 7. King pin, right, upper 3. Slack adjuster, right 8. King pin, right, lower 4.
  • Page 99 https://www.truck-manuals.net/ 3-94 INSPECTION AND MAINTENANCE (5) Greasing points(nipples) Use a greasing pump to inject every 15,000km of grease to each nipple. • King pin MTC0440 • Drag link MTC0450 • Inside spline shaft of steering column MTC0460...
  • Page 100 https://www.truck-manuals.net/ 3-95 INSPECTION AND MAINTENANCE • Gearshift control rod (to gearshift lever) MTC0480 • Gearshift control rod (to cab lower) MTC0490 • Gearshift control rod(to frame) MTC0500 • Spring pins and shackle pins MTC0510...
  • Page 101 https://www.truck-manuals.net/ 3-96 INSPECTION AND MAINTENANCE • Spring pads MTC0520 • Trunnion shaft MTC0530 • Front wheel brake chamber and slack adjuster MTC0540 • Rear wheel brake chamber and slack adjuster MTC0550...
  • Page 102 https://www.truck-manuals.net/ 3-97 INSPECTION AND MAINTENANCE • Propeller shaft universal joints and slid- ing sleeve MTC560 • Tie rod ends MTC570 • Front and rear hubs MTC0580 • P.T.O Drive shaft MTC0581...
  • Page 103 https://www.truck-manuals.net/ 3-98 INSPECTION AND MAINTENANCE 18) Air dryer (1) Function of air dryer Since moisture contained in the atmosphere is compressed and warmed by the air compressor, the amount of moisture is in proportion to that of compressed air. This hot and humid air is cooled down in fluid tanks or pipings to form condensa- tion.
  • Page 104 https://www.truck-manuals.net/ 3-99 INSPECTION AND MAINTENANCE (4) Inspection of air dryer 1. At end of every 15,000km or 2 months operation Check for the drain amount and outflow of oil when draining condensation and dirts from air tank. (When oil is detected, check compressor.) 2.
  • Page 105 https://www.truck-manuals.net/ 3-100 INSPECTION AND MAINTENANCE (6) Troubleshooting for air dryer Daily inspection and periodic inspections will prevent the greater portion of air dryer troubles. In the event of troubles or complaints as listed, follow the correction precedures to correct the difficulty.
  • Page 106 https://www.truck-manuals.net/ 3-101 INSPECTION AND MAINTENANCE 19) Electrical (1) Headlamp aiming 1. Be sure to have the headlamps be aimed correctly after changing or refitting sealed beam. 2. Use a head lamp tester or aimer to aim the headlamps. 3. Use the 3 aiming screws to make low or high beam adjustment.
  • Page 107 https://www.truck-manuals.net/ 3-102 INSPECTION AND MAINTENANCE (3) Fuse and relay box (Inside the cab) 1) Fuse, relay and unit positions ( ):DDC engine (15A) (15A) (10A) (15A) (10A) Fuse and relay position diagram Fuse: The starter relay are located on the to"F", Relay and unit: "R"...
  • Page 108 https://www.truck-manuals.net/ 3-103 INSPECTION AND MAINTENANCE 3) Designations of fuse, relay and unit 1. Designations of fuses ( ) : DDC engine No. Capa. No. Capa. No. Capa. Ignition switch/Meter F12 10A Mirror heat/Auto-mirror F23 (15A) User's(ENG. ECM) Axle lift Room lamp F13 10A F24 (15A) User's(ENG.
  • Page 109 https://www.truck-manuals.net/ 3-104 INSPECTION AND MAINTENANCE 4) Auxiliary fuse and relay box 1. Fuse, relay and unit positions MTS0112 2. Fuses corresponding to each position of the starter key MTS0111 Fuse No. Position of starter key "OFF" F2, F3, F4, F5, F8 (Constant power source) "ACC"...
  • Page 110 https://www.truck-manuals.net/ 3-105 INSPECTION AND MAINTENANCE 22) Battery care Caution (1) Battery checks(PT Battery) 1. Be sure to set the ignition switch to "OFF" position before attempting to disconnect 1. Your vehicle is equipped with maintenance battery terminals. free(PT) batteries, which do not require pe- 2.
  • Page 111 https://www.truck-manuals.net/ 3-106 INSPECTION AND MAINTENANCE (2) Cautions when handling batteries 1. Wipe the battery terminals thoroughly and carefully with a soft brush and baking soda to remove corrosion around them. Then, wipe them again with hot water-soaked rag and apply vaseline or grease to them. 2.
  • Page 112 https://www.truck-manuals.net/ 3-107 INSPECTION AND MAINTENANCE Caution 23) Ether start system(DDC engine) 1. Ether is highly flammable and explosive. Ether start system is an engine starting system 2. Do not smoke when servicing ether sys- designed to spray ether into the air intake system tem.
  • Page 113 https://www.truck-manuals.net/ 3-108 INSPECTION AND MAINTENANCE 4. Remove the old gasket from the valve and dis- card. Check that only one gasket is used. 5. Coat the new cylinder's threads with clean en- gine oil. 6. Install the starting fluid cylinder by turning the cylinder in the direction of the arrow (clockwise), until the cylinder dirt and moisture seal O-ring contacts the valve.
  • Page 114 https://www.truck-manuals.net/ 3-109 INSPECTION AND MAINTENANCE 3. PERIODIC INSPECTION CHART To ensure driving safety and maximum operating economy, periodic inspection and maintenance should be performed in accordance with the maintenance schedules as shown in the following chart. More frequent maintenance is required under severe conditions such as repeated short trip, driving on rough or dusty roads, driving in extremely cold weather, or driving on salted roads.
  • Page 115 https://www.truck-manuals.net/ 3-110 INSPECTION AND MAINTENANCE Service intervals(mileage x 1,000km) First 1,000km 4 12 16 20 24 28 32 36 40 44 48 Check item • SUSPENSION U-bolt nuts-Tighten Spring damage Looseness or damage of mountings Oil leakage from and damage of shock absorber •...
  • Page 116 https://www.truck-manuals.net/ 3-111 INSPECTION AND MAINTENANCE DDC engine inspection Months ITEM Mileage x 1,000km Lubricating oil-Replace Every 15,000km Fuel tank Cooling system Tachometer drive Drive Belts Air compressor Lubricating oil filter-Replace Every 15,000km Fuel filter-Replace Every 15,000km(1st, 2nd fuel filter) Coolant filter/inhibitor level-Replace Air system Exhaust system Engine (steam clean)
  • Page 117 https://www.truck-manuals.net/ 3-112 INSPECTION AND MAINTENANCE 4. IN CASE OF EMERGENCY 1) Emergency stopping (1) In case of vehicle trouble or emergency stop- ping, pull up the vehicle to the roadside as early as possible. MTC0741 (2) Set the parking brake and turn on the emer- gency warning lamp to prevent possible safety hazard.
  • Page 118 https://www.truck-manuals.net/ 3-113 INSPECTION AND MAINTENANCE 3) Cautions when being towed (1) Put the gearshift lever in the NEUTRAL posi- tion. MDB0021 (2) When the transmission is found to have been bound into gear, disconnect completely propel- ler shaft from rear axle flange to tightly fix the propeller shaft to the frame.
  • Page 119 https://www.truck-manuals.net/ 3-114 INSPECTION AND MAINTENANCE 5. VEHICLE REPAIR For the maintaining the proper performance and operations for the long hours, refer to the fol- lows. Vehicle cleaning 1) Remove dust while sprinkling water on the cabin, tires, fenders, etc. 2) Remove any cleaner on the surface with water, then wipe off with the piece of sponge.
  • Page 120 https://www.truck-manuals.net/ TROUBLESHOOTING AND CORRECTIONS 1. ENGINE AND RELATED PARTS 2. CHASSIS AND RELATED PARTS 3. ELECTRICAL 4. DUMP...
  • Page 121 https://www.truck-manuals.net/ 4-115 TROUBLESHOOTING AND CORRECTIONS 1. ENGINE AND RELATED PARTS • • Starter motor won't turn over or turns over Engine overheating slowly. Cause Correction Cause Correction Radiator covered with Remove curtain. curtain Irregular action of contact Place battery main switch point of battery relay in "ON"...
  • Page 122 https://www.truck-manuals.net/ 4-116 TROUBLESHOOTING AND CORRECTIONS 2. CHASSIS AND RELATED PARTS 3. ELECTRICAL • • Abnormal noise in transmission or differential Battery discharge Cause Correction Cause Correction Lack of gear oil Replenish Battery terminals After trimming the disconnected, loosened, corrosion with a file, •...
  • Page 123 https://www.truck-manuals.net/ MISCELLANEOUS CONTROLS AND OPTIONS 1. TACHOGRAPH 2. AIR SUSPENSION SEAT 3. AUTO GREASER 4. TURBO CHARGER 5. ZF TRANSMISSION 6. OPERATION OF DUMP SYSTEM 7. OPERATION OF TRACTOR-TRAILER 8. BULK CEMENT TRACTOR 9. SELF STEER 10. HYDRAULIC DEVICE FOR CAR CARRIER 11.
  • Page 124 https://www.truck-manuals.net/ 5-117 MISCELLANEOUS CONTROLS AND OPTIONS 1. TACHOGRAPH(option) 1) Construction FIG 1 FIG 2 FIG 3 MTF0011 1. Key hole 8. Minute hand 9. Speed recording needle 2. Speed indicator lamp 3. Hour hand 10. Vibration recording meedle 4. Speedometer needle 11.
  • Page 125 https://www.truck-manuals.net/ 5-118 MISCELLANEOUS CONTROLS AND OPTIONS 2) How to read tachograph records FIG 1,2 FIG 3 14 10 15 15 MTF0020 Speeds at which the vehicle is driven and duration of each trip Time and duration of each stop Distance travelled for each trip Example: The following is a recording example to contain vehicle running information.
  • Page 126 https://www.truck-manuals.net/ 5-119 MISCELLANEOUS CONTROLS AND OPTIONS 3) How to handle tachograph (1) Open the cover Turn the lock anti-clockwise with the key, then open the cover carefully. Do not jerk the cover or impose a heavy load on it, or a trouble will result. MTF0030 (2) Key Used for locking or unlocking the cover.
  • Page 127 https://www.truck-manuals.net/ 5-120 MISCELLANEOUS CONTROLS AND OPTIONS (5) Setting of clock Set the time by turning the time setting knob as necessary. MTF0120 (6) Setting of recording chart paper set • Position the recording chart paper set under the knife, then align the time on the paper with the red color mark near the knife.
  • Page 128 https://www.truck-manuals.net/ 5-121 MISCELLANEOUS CONTROLS AND OPTIONS 2. AIR SUSPENSION SEAT(option) Seat lock lever Slide adjustment lever Lumbar support adjustment buttons(or lever) Lumbar support adjustment buttons(or lever) Height and tilt adjustment lever(forward) Height and tilt adjustment lever(backward) Back angle adjustment lever Lumbar support air pack(lower) Lumbar support air pack(upper) MTF0150...
  • Page 129 https://www.truck-manuals.net/ 5-122 MISCELLANEOUS CONTROLS AND OPTIONS 3. AUTO GREASER(option) 1. Control unit 4. Gear pump unit 2. Fuse box 5. Starter switch 6.Indicator lamp 3.Distributor MTF0180 • Basic rules of operation Control unit This is an electronic device designed to de- •...
  • Page 130 https://www.truck-manuals.net/ 5-123 MISCELLANEOUS CONTROLS AND OPTIONS 4. TURBO CHARGER 1) Basic rules of operation DV engine When the turbine blades installed at exhaust gas outlet are rotated at high speed by the high pres- sure and heat energy of exhaust gas discharged after combustion in the engine, the compressor Compressor Engine...
  • Page 131 https://www.truck-manuals.net/ 5-124 MISCELLANEOUS CONTROLS AND OPTIONS The low speed idling for first 1 minute forms hydraulic pressure in the engine lubrication system. Then, if increasing the idle speed for 3~4 minutes, engine oil can be distributed from the oil pump sufficiently up to the individual lubricating points of the turbo charger installed considerably high above the other engine com- ponents.
  • Page 132 https://www.truck-manuals.net/ 5-125 MISCELLANEOUS CONTROLS AND OPTIONS In addition, thermal stress resulting from quick cooling of the turbo charger will lower the After idling for durability of engine components and accelerate 2~3 minutes consumption of coolant. Accordingly, idle the engine for 2~3 minutes after finishing the Lock operation of the vehicle, so that the turbo charger may be cooled down slowly and...
  • Page 133 https://www.truck-manuals.net/ 5-126 MISCELLANEOUS CONTROLS AND OPTIONS 5) Diagnosis chart Lack of Discharge Complaints Excessive Discharge Unusual Repeated generation Oil leakage Oil leakage engine of black consumption of blue sound from of high and low from from output smoke of engine oil smoke turbo unusual sound from compressor turbine...
  • Page 134 https://www.truck-manuals.net/ 5-127 MISCELLANEOUS CONTROLS AND OPTIONS 5. ZF TRANSMISSION 1) Construction and power flow diagram Clutch housing Main shaft Selector fork Planetary gears for range change group Input shaft Output shaft Lay shaft P.T.O. Splitter 4-speed section with Range group reverse gear change group 1st gear...
  • Page 135 https://www.truck-manuals.net/ 5-128 MISCELLANEOUS CONTROLS AND OPTIONS 2) Connection diagram for pneumatic control(ZF 16S-151) 9 10 11 12 13 14 MTF0299 1. Clutch fluid reservoir 8. Splitter group preselector valve 2. Hi-Low switch 9. Indicator switch for neutral position 3. Clutch pedal 10.
  • Page 136 https://www.truck-manuals.net/ 5-129 MISCELLANEOUS CONTROLS AND OPTIONS 3) Connection diagram for pneumatic control(ZF 16S-221) : Air line Main air : Harness Range Splitter Air tank MTF0291 9. Speed meter cable 1. Knob 10. ECU 2. Splitter group relay valve 3. 4/2 way valve 11.
  • Page 137 https://www.truck-manuals.net/ 5-130 MISCELLANEOUS CONTROLS AND OPTIONS 4) Operation As ZF transmission is of synchro mesh change gear type, gear shifting can be performed with no need to use double clutch, and so it is very easy to manipulate it. Double "H" gearshift pattern MTF0300 (1) How to range change group(ZF16S-151 T/M) Double "H"...
  • Page 138 https://www.truck-manuals.net/ 5-131 MISCELLANEOUS CONTROLS AND OPTIONS (3) How to change ranges(ZF 16S-151 T/M) a. As ZF transmission is of synchro mesh change gear type, avoid changing gears forcibly. b. When changing ranges in the neutral sec- tion, lightly tap to right or left with the palm for gear changing operation.
  • Page 139 https://www.truck-manuals.net/ 5-132 MISCELLANEOUS CONTROLS AND OPTIONS (5) Operation of the splitter As high and low ranges are provided at each High gearshift position, the splitter offers diverse gear ratios to ensure economical operation of the vehicle and to increase in traction efficiency. a.
  • Page 140 https://www.truck-manuals.net/ 5-133 MISCELLANEOUS CONTROLS AND OPTIONS (7) How to operate a. When operating the vehicle, be plainly dressed, and make sure of the route in ad- vance keeping busy or smooth traffic sec- tions and obstacles in mind. b. On slopes, gear down appropriately in ad- vance.
  • Page 141 https://www.truck-manuals.net/ 5-134 MISCELLANEOUS CONTROLS AND OPTIONS (10) Adjustment of HI-LO switch at the rear of clutch pedal For the trouble-free shifting of the splitter group, it is alsolutely necessary that the HI/LO electrical switch at the rear of the clutch pedal is correctly adjusted.
  • Page 142 https://www.truck-manuals.net/ 5-135 MISCELLANEOUS CONTROLS AND OPTIONS 5) Care 1. Regular oil level check (1) Using the recommended lubricants 2. Regular oil change Specifications: Engine oil API CD/CE/CF/SF/SG, 3. Using the recommended lubricants SAE 30 Refer to "RECOMMENDED LUBRICANTS". Capacity: 11L(ZF 16S-151) 13L(ZF 16S-221) (2) Oil level check and oil change Filler/level plug...
  • Page 143 https://www.truck-manuals.net/ 5-136 MISCELLANEOUS CONTROLS AND OPTIONS 6) Inspection and adjustment of the clutch pedal Items How to adjust a. Check the oil tank for the clutch master cylinder for a. The clutch would not be dis-en- clutch oil level. gaged even though it has been fully depressed.
  • Page 144 https://www.truck-manuals.net/ 5-137 MISCELLANEOUS CONTROLS AND OPTIONS 6. OPERATION OF DUMP SYSTEM The dump system is operated hydraulically and controlled by manipulating the P.T.O. lever and con- trol lever which are installed at the left-hand side of the driver's seat. Telescopic cylinder Oil tank Stabilizer MTF0580...
  • Page 145 https://www.truck-manuals.net/ 5-138 MISCELLANEOUS CONTROLS AND OPTIONS 1) Inspection prior to operation Check the hydraulic oil level in the oil tank. The hy- draulic oil level should be normally brought to the high level on the oil tank gauge with the deck low- ered fully.
  • Page 146 https://www.truck-manuals.net/ 5-139 MISCELLANEOUS CONTROLS AND OPTIONS (4) Place the control lever in the "NEUTRAL" posi- NEUTRAL tion immediately after raising the deck to unload the materials. MTF0630 3) When attempting to stop the deck halfway NEUTRAL (1) When attempting to stop the deck for a short interval in the middle of ascending or descend- ing, place the control lever in the "NEUTRAL"...
  • Page 147 https://www.truck-manuals.net/ 5-140 MISCELLANEOUS CONTROLS AND OPTIONS (2) Place the dump control lever in the "NEUTRAL" position immediately after the deck comes down NEUTRAL completely. MTF0660 5) Cautions (1) With the PTO lever being in operation, driving of the vehicle over a prolonged time may cause damage to PTO and gear pump.
  • Page 148 https://www.truck-manuals.net/ 5-141 MISCELLANEOUS CONTROLS AND OPTIONS (4) When changing oil or replenishing grease with the deck raised, be sure to support it with safety posts and chock the wheels for your safety. MTF0700 (5) Avoid raising the deck on a downward slope. MTF0710 (6) Avoid raising the deck on a unpaved road or in the swamp.
  • Page 149 https://www.truck-manuals.net/ 5-142 MISCELLANEOUS CONTROLS AND OPTIONS 6) Checking and changing of hydraulic oil Suggested hydraulic oil (1) Specification of hydraulic oil Manufacturer Suggested oil - ISO VG 32(hydraulic oil) Esoo Chemical AZOLA ZS 32 Mobil Korea HYDRAULIC 28 Yukong HARMONY AW 32 Korea Shell TELLAS 32 Honam Refinery...
  • Page 150 https://www.truck-manuals.net/ 5-143 MISCELLANEOUS CONTROLS AND OPTIONS (4) Changing of air filter and oil filter(with en- gine stopped) Replace the air filter and oil filter concurrently with hydraulic oil change. Air filter The air filter is a paper type filter installed within Oil filter the oil filler, while the oil filter is a paper type filter installed on the line through which the hy-...
  • Page 151 https://www.truck-manuals.net/ 5-144 MISCELLANEOUS CONTROLS AND OPTIONS (2) Restarts the engine and turn the gear pump at NEUTRAL the minimum speed to place the tipping valve in the "UP" position. Slightly loosen and then retighten the high pressure hose on the gear pump side until the air is not seen in the hy- draulic oil which is flowing out.
  • Page 152 https://www.truck-manuals.net/ 5-145 MISCELLANEOUS CONTROLS AND OPTIONS 8) Greasing points Greasing should be performed once a week. The greasing points are illustrated as follows: MTF0770 Greasing points The number Lifting bracket, right and left Chassis bracket, right and left Rear gate locking device, right and left Deck hinge, right and left Rear gate locking device rod Rear gate pivot, right and left...
  • Page 153 https://www.truck-manuals.net/ 5-146 MISCELLANEOUS CONTROLS AND OPTIONS 7. OPERATION OF TRACTOR-TRAILER 1) Driving of tractor-trailer Much more care should be taken when driving trac- tor-trailer than when driving tractor only. Observe the following inspection and operation methods. MTF0380 (1) Turning of tractor-trailer 1.
  • Page 154 https://www.truck-manuals.net/ 5-147 MISCELLANEOUS CONTROLS AND OPTIONS 2) Connection of trailer with tractor • The trailer should be connected with the tractor on a level ground. • The tires of the trailer should be choked. MTF0410 (1) Cautions when connecting 1. Ensure that the trailer king pin is fitted 30~50 mm lower than the upper face of coupler.
  • Page 155 https://www.truck-manuals.net/ 5-148 MISCELLANEOUS CONTROLS AND OPTIONS 3. Pull the parking brake valve of the tractor before connecting the air hoses. Pull the parking brake valve of the trac- tor, and the trailer will be subjected to braking force when connecting the air hoses.
  • Page 156 https://www.truck-manuals.net/ 5-149 MISCELLANEOUS CONTROLS AND OPTIONS (2) Checks after coupling up 1. Checking the connection state a. Pull the brake lever of the trailer to apply the brake only to the trailer. Then, start up the tractor with gears being put in 1st or 2nd position.
  • Page 157 https://www.truck-manuals.net/ 5-150 MISCELLANEOUS CONTROLS AND OPTIONS 4) Caution when disconnecting Park the vehicle on a level ground when dis-con- necting the trailer from the tractor. MTF0510 (1) Turn the lag gear crank handle anti-clockwise to lower the support leg on ground surface(in the case that the trailer is not of a mechanical type).
  • Page 158 https://www.truck-manuals.net/ 5-151 MISCELLANEOUS CONTROLS AND OPTIONS (4) After disconnecting the air hoses and jumper cable, fit the anti-dust cap(dust cover) in the cou- pler of the trailer, and store the air hoses and jumper cable in the place designated at the rear side of the cap.
  • Page 159 https://www.truck-manuals.net/ 5-152 MISCELLANEOUS CONTROLS AND OPTIONS 6) Caution for operation (DU20BS Coupler) (1) Coupler greasing Greasing point Upper face of base Graphite grease Graphite grease or Sliding surface of jaw and yoke (left, right) chassis grease Bushing of beam shaft Graphite grease or chassis grease (left, right)
  • Page 160 https://www.truck-manuals.net/ 5-153 MISCELLANEOUS CONTROLS AND OPTIONS 7) Jost coupler angle adjustment(JSK 37G Coupler) Rolling angle adjust lever (1) Range of rolling angle adjustment - For travel at high speed: 0 - For travel on rough road: 3, 7 Coupler Caution Excepting unusual things, don't adjust rolling angle to 7...
  • Page 161 https://www.truck-manuals.net/ 5-154 MISCELLANEOUS CONTROLS AND OPTIONS BULK CEMENT TRACTOR External view of BCT MTF0780...
  • Page 162 https://www.truck-manuals.net/ 5-155 MISCELLANEOUS CONTROLS AND OPTIONS External view of compressor 1. Oil box 5. Delivery cover 2. Cylinder 6. Wheel 3. Check valve 7. Delivery pipe 4. Intake cover 8. Air cleaner MTF0780 Specifications of compressor Descriptions Specifications Items Model VS - 715 Type Air cooling, oil-free...
  • Page 163 https://www.truck-manuals.net/ 5-156 MISCELLANEOUS CONTROLS AND OPTIONS Drive system diagram Driving force applied using the transmission PTO of tractor is transmitted through belt pulley to the compressor, as shown in the following diagram. The rotor which draws in and discharges air recip- rocates at 90 degrees.
  • Page 164 https://www.truck-manuals.net/ 5-157 MISCELLANEOUS CONTROLS AND OPTIONS Caution during operation 1) The engine clutch must be operated in sequence. If the clutch pedal is released instantaneously, power is transmitted instantaneously to affect PTO, crank components, and rotating parts, result- ing in damage to the related parts. 2) Do not increase or decrease compressor RPM using the accelerator pedal in the cab.
  • Page 165 https://www.truck-manuals.net/ 5-158 MISCELLANEOUS CONTROLS AND OPTIONS Troubleshooting (1) Much vibration Cause: Loose compression mounting bolts (2) Abnormal noise(Noise is generated mainly from the circumference of the cylinder or case.) 1) Cause: Loose connection between rotor and driving arm In this case, the driving arm is loosened and causes the valve base to be in contact with the rotor, generating a great noise.
  • Page 166 https://www.truck-manuals.net/ 5-159 MISCELLANEOUS CONTROLS AND OPTIONS (3) Oil pressure does not increase. 1) Cause: Restricted oil strainer Correction: Open the top cover of the crankcase to check and clean. 2) Cause: Malfunction of oil pump Correction: Disconnect the pump to check for defects and replace, if necessary. 3) Cause: Viscosity of oil is so high that oil cannot be absorbed.
  • Page 167 https://www.truck-manuals.net/ 5-160 MISCELLANEOUS CONTROLS AND OPTIONS Periodical Inspection Chart Service intervals Daily Check items inspection month months months months year years years Unusual sound Abnormal vibration Compressor Operation of safety valve Oil level in Compressor oil case Suction filter element Oil change Strainer cleaning Loose mounting...
  • Page 168 https://www.truck-manuals.net/ 5-161 MISCELLANEOUS CONTROLS AND OPTIONS 9. SELF STEER 1) Maintenance Items Inspection Check for excessive wear & movement every 30 days. Busings Check for air leaks daily before using. Air leaks Check unit for bolt torque per instruction given in section 10. Bolt torque Check for proper operation daily before moving and using the unit in any manner.
  • Page 169 https://www.truck-manuals.net/ 5-162 MISCELLANEOUS CONTROLS AND OPTIONS 3) Adjusting air pressure (1) Adjustment of pressure Do not run under the normal pressure when usualy running • New vehicle's air pressure SELF STEER MARKER WASTON SAMWOO VEHICLE (OLD) (NEW) 21TON CARGO 90psi(6.2 TON) 0.37Mpa(6TON) 75psi(5.2 TON) 0.53Mpa(8TON)
  • Page 170 https://www.truck-manuals.net/ 5-163 MISCELLANEOUS CONTROLS AND OPTIONS 10. HYDRAULIC DEVICE OF CAR CARRIER Circuit diagram Oil tank Suction strainer Gear pump Solenoid relief valve Return valve Stopping valve Pressure gauge Oil hose - Socket Oil hose - Plug MTF1000 Operation Hydraulic pressure is generated by gear pump driven by PTO. Oil with high pressure is then trans- ferred to the unit of the car carrier and its pressure is maintained below(4) solenoid relief valve preset pressure (100kg/cm ).
  • Page 171 https://www.truck-manuals.net/ 5-164 MISCELLANEOUS CONTROLS AND OPTIONS Solenoid relief valve This controls pressure of a circuit and oil flow to car- carrier unit (1) Pressure control bolt : Clockwise - ascending, Counter Clockwise - descending Initial Preset pressure : 100kg/cm (2) Stopping valve : Always let it be closed except for checking of oil pressure (3) Pressure gauge Caution...
  • Page 172 https://www.truck-manuals.net/ 5-165 MISCELLANEOUS CONTROLS AND OPTIONS 11. TOOL LIST Tool Name Q'ty Vehicle model Handle - S/Tire All vehicles other than dump trucks Carrier 100x200x610 MTF0820 Oil jack asm All vehicles w/lever MTF0830 Plier All vehicles MTF0840 Wrench monkey All vehicles MTF0850 Spanner 7x8 All vehicles...
  • Page 173 https://www.truck-manuals.net/ 5-166 MISCELLANEOUS CONTROLS AND OPTIONS Tool Name Q'ty Vehicle model All vehicles MTF0920 Wrench – Wheel nut All vehicles φ41xφ24 MTF0940 Handle-wrench All vehicles wheel nut MTF0950 19ton/19.5ton/20.5ton/21ton/22.5ton/ 25ton cargo, 19ton/24ton dump Cab tilt lever All vehicles except above vehicles MTF0960 :Use the oil lever Tool bag...
  • Page 174 https://www.truck-manuals.net/ 5-167 MISCELLANEOUS CONTROLS AND OPTIONS 8. SERVICE ELECTRIC EQUIPMENTS FOR USER 1) Consent for cellular phone charger (12V: Super deluxe) If do you want to use of cellular phone charger, you can connect it to the consent installed below the cassette tape holder.
  • Page 175 Special harness is located at the inside glove box. MTF1110 Caution In the case that customer will use electric equipments mounted to other position beside harness for custom- ers. Ask service center autorized by Daewoo because it is caused of trouble of fire to various electric equipments.
  • Page 176 https://www.truck-manuals.net/ SPECIFICATIONS AND SERVICE DATA 1. LOCATION OF CHASSIS NUMBER AND ENGINE NUMBER 2. MAIN DATA 3. RECOMMENDED LUBRICANTS...
  • Page 177 The vehicle identification number plate is affixed to the center of the inside of the front lid. Always refer to this information when ordering parts or servicing. DAEWOO MDA0031 Chassis number The chassis number is stamped on the front face of the right-hand chassis frame.
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  • Page 222 6-214 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ GENERAL K4DEF  DIAGRAM  DIMENSIONS (mm) Overall Length 7,745 Width 2,495 Height 3,060 Tread Front 2,050 Rear 1,855 4,605 Wheelbase Rear axle to frame 1,080 Ground to roof 2,930 Frame-ground above bogie 1,100 Usable cab to axle 3,170 Deck offset...
  • Page 223 6-215 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ POWER TRAIN K4DEF  ENGINE Manufacturer DOOSAN INFRACORE Model DE12TIS EURO Ⅱ Emission certificate Type Turbo intercooler, diesel engine Maximum power 340ps (250kw)/ 2,100rpm Maximum torque 145kg.m (1421N.m)/ 1,260rpm No. of cylinder In line 6- cylinder Bore×Stroke 123×155(mm) Displacement...
  • Page 224 6-216 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ CHASSIS K4DEF  FRAME Type Ladder type, double channel Size (H×W×T) 320×90×(8+7) (mm) Frame width behind cab: 850mm Towing hook Equipped front & rear  STEERING Handle position Left-hand drive Type Recirculating ball with integral power assisted by oil Steering column Tilt &...
  • Page 225 6-217 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ K4DEF  CAB Type All –welded cab of tilt type Hydraulic Tilt. Tilt angle 50˚ Number of crew Cab suspension Coil spring & shock absorber  INSTRUMENTATION Gauges & meters Speedometer Water temperature gauge Air pressure gauge, fuel gauge Engine tachometer gauge ...
  • Page 226 6-218 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ GENERAL K4DVF  DIAGRAM  DIMENSIONS (mm) Overall Length 7,745 Width 2,495 Height 3,080 Tread Front 2,050 Rear 1,855 Wheelbase 4,605 Rear axle to frame 1,080 Ground to roof 2,930 Frame-ground above bogie 1,070 Usable cab to axle 3,205 Deck offset...
  • Page 227 6-219 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ POWER TRAIN K4DVF  ENGINE Manufacturer DOOSAN INFRACORE Model DV15TIS EURO Ⅱ Emission certificate Type Turbo intercooler, diesel engine Maximum power 390ps (287kw)/ 2,100rpm Maximum torque 160kg.m (1569N.m)/ 1,200rpm No. of cylinder Vee 8 cylinder Bore×Stroke 128×142(mm) Displacement...
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  • Page 238 6-230 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ GENERAL M2SEF  DIAGRAM  DIMENSIONS (mm) Overall Length 6,190 Width 2,495 Height 2,915 Tread Front 2,050 Rear 1,855 Wheelbase 3,700 Rear axle to frame Ground to roof 2,915 Frame-ground above bogie 1,065 Usable cab to axle 2,710 Coupler offset Coupler height...
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  • Page 242 6-234 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ GENERAL V3TEF  DIAGRAM  DIMENSIONS (mm) Overall Length 6,925 Width 2,495 Height 2,915 Tread Front 2,050 Rear 1,850 Wheelbase 4,540 Rear axle to frame Ground to roof 2,915 Frame-ground above bogie 1,075 Usable cab to axle 3,100 Coupler offset Coupler height...
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  • Page 246 6-238 SPECIFICATIONS AND SERVICE DATA https://www.truck-manuals.net/ GENERAL V3TVF  DIAGRAM  DIMENSIONS (mm) Overall Length 6,925 Width 2,495 Height 2,915 Tread Front 2,050 Rear 1,850 Wheelbase 4,540 Rear axle to frame Ground to roof 2,915 Frame-ground above bogie 1,075 Usable cab to axle 3,100 Coupler offset Coupler height...
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  • Page 250   6-242 SPECIFICAT TIONS AND S SERVICE DAT https://www.truck-manuals.net/     Engin ne specifica ations Model DE12TI DE12TIS DV15T DV15TIS DV15TI In-line, 4-strok V-type 90°, 4-str roke, In-line, 4-st troke, ← ← ← Type vertical type diesel engine vertical ty Cylinder r bore x stroke ←...
  • Page 251 2. It is oil capacity of dry condition so it is variable at the time of change. 3. Use only genuine Daewoo part oil filters and in order to use no recommended oil, must be confirmed above specification before use.

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