Doosan DA40 Shop Manual

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Page 2 Ch 0 page GENERAL INSTRUCTIONS SHOP MANUAL Manufacturer: Dealer: Doosan Infracore Norway AS N - 6440 Elnesvågen - NORWAY Printed in Norway SHOP MANUAL...
Page 3 GENERAL INSTRUCTIONS Ch 0 page Contents 0 General 1 Engine 2 Transmission 3 Driveline 4 Lubrication 5 Hydraulic 6 Electrical system 7 Front frame 8 Rear frame 9 Option 10 Error codes list SHOP MANUAL...
Page 4: Table Of Contents
Ch 0 page GENERAL INSTRUCTIONS Chapter 0 General instructions Index Foreword ....................4 Torque limit table ................. 5 Types of sealing-/locking compounds and lubricants ..... 6 Safety in workshop ................7 Working on machine ................8 Personal Protective Equipment (PPE) ..........11 Vibration .....................
Page 5: Foreword
Subscribed Shop Manuals will automatically be updated at revisions. This manual is originally produced by Doosan Infracore Norway AS, 6440 Elnesvågen, Norway, and must not be reproduced, translated or made available to a third party, fully or partly, without our written permission.
Page 6: Torque Limit Table
Ch 0 page GENERAL INSTRUCTIONS Torque limit table This tables indicates standard torque limits in Nm for the various screw and bolt qualities and dimensions. The torques are valid for screws on the outside of the components. i l a : s s i l a : s s...
Page 7: Types Of Sealing-/Locking Compounds And Lubricants
GENERAL INSTRUCTIONS Ch 0 page Types of sealing-/locking compounds and lubricants Loctite 242/243: Middle strength (for locking of screws, bolts and nuts). Loctite 270/2701: High strength (for locking of screws, bolts and nuts). Loctite 603: High strength (for locking of bearings bushings, etc.). Loctite 638: Extra high strength (for locking of bearings, bushings, etc.).
Page 8: Safety In Workshop
The workshop manual provides instructions about work methods and equipment that reduces the risk of acci- dents. Mechanical skill This is a very important factor. The Doosan-mechanic is skilled and well trained for his job. Without these qualities, risks are much greater and more difficult to anticipate. Common sense This characteristic should form the basis of activities in the workshop.
Page 9: Working On Machine
• Never service DOOSAN equipment without instructions. • Always lower lift arm and attachment to ground before doing any maintenance.
Page 10 Ch 0 page GENERAL INSTRUCTIONS • Use correct procedure to lift and support machine. • Cleaning and maintenance are required daily. • Welding or grinding painted parts must be done in well ventilated areas. • Wear a dust mask when grinding painted parts. Toxic dust and gas can be produced.
Page 11 GENERAL INSTRUCTIONS Ch 0 page • Lower work equipment and stop engine before perform- ing maintenance. • Park machine on firm, level ground. • Turn starter switch to "ON' position and set pilot cutoff switch to "I" (ON) position. Cycle work levers (joysticks) back and forth, left and right at full stroke 2 to 3 times to eliminate remaining internal pressure in hydraulic circuit.
Page 12: Personal Protective Equipment (Ppe)
Proper Work Tools and Attachments Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attach- ment, and general information related to attachments in this manual.
Page 13: Vibration
GENERAL INSTRUCTIONS Ch 0 page Vibration When using vibrating tools e.g. chisel hammer, impact drill, impact nut runner, grinder injuries may be sustained by transition of tool vibrations to the hands. Risks Vibrations may cause vascular spasms (prickling and pain) in the surface veins.
Page 14: Injurious Noise
Ch 0 page GENERAL INSTRUCTIONS Injurious noise Rule of thumb: Noise that is louder than 85 db (A) and that prevails for more than 8 hours is classed as injurious. (Some countries have other limits.) High frequency noise (high-pitched) is more injurious than low frequency noise (low-pitched) of the same amplitude.
Page 15: Organic Solvent
GENERAL INSTRUCTIONS Ch 0 page Organic solvent Organic solvents are mixtures of organic liquids (different from e.g. water) that dissolve grease, paint, varnish, wax, oil, glue, rubber etc. Examples: Petroleum spirits -Toluen Trichlore ethylene -Thinner Petrol -Alcohols Xylen -Plastics and appertaining glues Risks Solvents release fumes.
Page 16: Fueling
Ch 0 page GENERAL INSTRUCTIONS Fueling Use caution when you are refueling a machine. Fuel is flammable and can catch fire if it is brought close to a flame. Stop engine and let it cool before adding fuel. Do not smoke while you are refueling a machine. Do not refuel a machine near flames or sparks.
Page 17 GENERAL INSTRUCTIONS Ch 0 page Maintenance The machine and some attachments have components that reach high temperatures under normal operating conditions. The primary source of high temperatures are the engine and exhaust system. If damaged or incorrectly maintained, the electrical system can be a source of arcs or sparks.
Page 18: Fire And Explosion Risks
Ch 0 page GENERAL INSTRUCTIONS Fire and explosion risks Examples of flammable and explosive substances are: • • Petrol • Diesel fuel • Organic solvents (varnish, plastic, detergents) • Anti-corrosive • Acetylene and other gas for welding and heating Examples of reason for setting on fire: •...
Page 19: In Case Of Fire
GENERAL INSTRUCTIONS Ch 0 page In case of Fire If a fire occurs: • Do not attempt to move machine or continue operations. • Turn starter switch to "O" (OFF) position to stop engine. • Use handrails and steps to get off machine. •...
Page 20: Coolant
Ch 0 page GENERAL INSTRUCTIONS Coolant Risks Attempting to remove caps, drain oil or coolant, or replacing filters may lead to serious burns, if done when hot. Relieve all pressure in cooling system, before any lines, fittings or related items are disconnected.
Page 21: Refrigerant
GENERAL INSTRUCTIONS Ch 0 page Refrigerant Refrigerants are used in various thermal equipment e.g. air conditioning in vehicles. Risks Refrigeration equipment operates under pressure. A refriger- ant that is leaking may cause frost-bite. A refrigerant that is leaking and exposed to heat e.g. by a welding flame or cigarette becomes very dangerous to breath.
Page 22: Air Pollution
Ch 0 page GENERAL INSTRUCTIONS Air pollution Examples: • Carbon monoxide present in exhaust fumes • Nitric oxide - present in exhaust fumes • Welding fumes, especially fumes from galvanized or painted metals. • Oil mist (e.g. in anti-corrosion treatment) •...
Page 23: Operation In Extreme Conditions
GENERAL INSTRUCTIONS Ch 0 page Operation in extreme conditions Operation In Extreme Cold In extremely cold weather, avoid sudden travel movements and stay away from even slight slopes. The machine could slide down the slope. Snow accumulation could hide potential hazards and slippery surfaces. Warming up the engine for a short period may be necessary to avoid operating with sluggish or reduced working capacity.
Page 24 Ch 0 page GENERAL INSTRUCTIONS Operation in Extreme Heat Continuous operation of machine in high temperatures can cause machine to overheat. Monitor engine and hydraulic system tempera- tures and stop machine to let it cool, when necessary. 1. Frequently inspect and maintain fan and radiator. Check coolant level in radiator.
Page 25 GENERAL INSTRUCTIONS Ch 0 page Operation In Dusty and Sandy Areas Operation of machine can cause dust in almost any area. However, when in predominantly dusty or sandy areas, additional precautions must be taken. 1. Keep cooling system fins and cooling areas clean. Blow out with compressed air, if possible, as often as necessary.
Page 26 Ch 0 page GENERAL INSTRUCTIONS Operation at High Altitudes Operation instructions at high altitudes are the same as those provided for extreme cold. Before operating at high altitudes, engine fuel and air mixture may have to be adjusted according to appropriate engine manual. 1.
Page 27: Liquid Or Gas Under High Pressure
GENERAL INSTRUCTIONS Ch 0 page Liquid or gas under high pressure Pipes etc may become damaged when working and liquid or gas may burst out. Liquid or gas may also burst out when loosening a connection. High pressure may remain in the system even if a pump has stopped.
Page 28: Asbestos
Ch 0 page GENERAL INSTRUCTIONS Asbestos The dust that is emitted by brake and clutch linings partly consists of asbestos fibres. WARNING Avoid exposure to dust containing asbestos as it can cause death or serious injury to the lungs and other organs (mesothe- lioma, lung and other cancers, and asbestosis).
Page 29: Battery Hazard Prevention
GENERAL INSTRUCTIONS Ch 0 page Battery hazard prevention Battery electrolyte contains diluted sulfuric acid and gener- ates hydrogen gas. Hydrogen gas is highly explosive, and improper handling can cause death or serious injury, or fire. Do not allow electrolyte to contact skin or eyes. Always wear safety goggles and protective clothing when servicing batteries.
Page 30 Ch 0 page GENERAL INSTRUCTIONS • When disconnecting battery terminals, wait for approxi- mately one minute after turning engine starter switch key to "O" (OFF) position, and be sure to disconnect ground- ing terminal; negative (-) terminal first. Conversely, when connecting them, begin with posi- tive (+) terminal and then grounding (-) terminal, Make sure that all terminals are connected securely.
Page 31: Disposal Of Hazardous Materials
GENERAL INSTRUCTIONS Ch 0 page Disposal of hazardous materials Physical contact with used motor oil or gear oil could create a health risk. Wipe oil from your hands promptly and wash off any remaining residue. Used motor oil or gear oil is an environmental contaminant and should only be disposed of at approved collec- tion facilities.
Page 32: Jacked Up Vehicle Or Bodywork
Ch 0 page GENERAL INSTRUCTIONS Jacked up vehicle or bodywork Risks Mechanical or hydraulic lifting equipment may topple and could also be lowered because of incorrect handling or interference. Falling objects may also cause crushing. Protective measures Do not crawl underneath a vehicle that is jacked up without stands.
Page 33: Heavy Units
GENERAL INSTRUCTIONS Ch 0 page Heavy units Risks Lifting heavy objects may cause back injuries. Dropping a unit or letting it fall from a lifting device may cause both injury and damage. Example: When lifting a unit (gearbox, central gear) away from a vehicle it may drop from the jack.
Page 34: More Than One Person Working With The Same Object
Ch 0 page GENERAL INSTRUCTIONS More than one person working with the same object If more than one person is working on the same vehicle, involuntary movements could injure another person. Example: By turning a wheel on a drive axle, parts of another drive wheel may be caused to turn and injure somebody who is working with e.g.
Page 35: Rotating Parts
GENERAL INSTRUCTIONS Ch 0 page Rotating parts Examples: Cooling fan Belts Injection pump coupling Propeller shaft Drilling machines, lathes and other machines with rotating parts. Risks Rotating parts may cause injury when touched by e.g. inserting the fingers in the cooling fan. Rotating parts may also cause a serious accident by catching clothes, gloves or long hair.
Page 36: Splinters, Flying Object When Using Certain Tools
Ch 0 page GENERAL INSTRUCTIONS Splinters, flying object When using certain tools RISKS PROTECTIVE MEASURES Burr loosens from Check tools drift or chisel. Grind where necessary Hammer head Check loosens from Repair or change handle. Saw jabs or Keep the supporting wobbles.
Page 37: Springs Under Load
GENERAL INSTRUCTIONS Ch 0 page Springs under load Examples: Balancing springs for bonnets and front panels Parking brake chambers Return springs for brake shoes Retaining rings Valve springs Risks By loosing the grip a spring and flying parts may cause injury. Even small springs and retaining rings are dangerous as they could injure the eyes.
Page 38: Precautions For Disassembly And Assembly
Ch 0 page GENERAL INSTRUCTIONS Precautions for disassembly and assembly Disassembly • Before attempting to disassemble, determine the cause of the trouble by systematically checking and analysing the symptoms. Needless disassembly will not only hinder troubleshooting, but will also result in losses through unnecessary replacement of parts and man-hour costs.
Page 39 GENERAL INSTRUCTIONS Ch 0 page Assembly • Thoroughly clean all parts before assembly. Wash clean those parts relating to the drive line. Also, check for scratches and nicks on the surfaces of the parts and repair, if any. Wash new parts to remove rust preventives, if coated, before assembly.
Page 40 Ch 0 page GENERAL INSTRUCTIONS • Be sure to tighten each bolt to the specified torque with a suitable torque wrench. Apply an even tightening force to the bolts by screwing them alternately or in a criss-cross fashion. • Apply thread locking (see table for sealing/locking compounds) to important bolts.
Page 41 GENERAL INSTRUCTIONS Ch 0 page • Apply the lube oil or grease to the surface and chamfered edge of the shaft on which the oil seal is to be installed, so that the shaft may be smoothly inserted into the oil seal without pinching the lip and that a proper lubrication of the shaft during the break-in period of the machine is accomplished.
Page 42 Ch 0 page GENERAL INSTRUCTIONS Handling of bearings • Keep the bearings and their surroundings clean. Every dust and dirt particle, even though they are invisibly small can affect bearings. Always take sufficient care to protect bearings against dust and dirt. •...
Page 43 GENERAL INSTRUCTIONS Ch 0 page • To press-fit a small bearing having a little interference, use of a jig shown below is recommended. In this case, be careful to press only the inner race. Should the outer race be forced, dents will be produced on the sliding surfaces between the races.
Page 44 Ch 0 page GENERAL INSTRUCTIONS Note SHOP MANUAL...
Page 45 GENERAL INSTRUCTIONS Ch 0 page SHOP MANUAL...
Page 46 Engine Ch 1 page Chapter 1 Engine SHOP MANUAL...
Page 47 Ch 1 Engine page Chapter 1 Engine Index Engine identification ................7 Removal of engine assembly .............. 11 Lifting the engine .........................17 XPI Fuel system DA30/40 ..............18 Route of the fuel on 9 and 13 litre engines .................19 Fuel filter and water separation ....................20 Overflow valve ..........................21 Fuel system components ......................22 Schematic diagram of the fuel system: ..................22...
Page 48 Engine Ch 1 page Injector Scania XPI ................73 Valve adjustment DC13 with XPI ............75 Order of adjustment for 13 litre engines ..................75 Cylinder configuration, 6 cylinder engines ..................76 Valve adjustment DC9 with XPI ............77 Cylinder configuration, 5 cylinder engines ..................78 Valve adjustment DC13 with PDE ............
Page 49 Alternator 100 A ................. 163 Check ............................163 Output test ..........................164 Renewal - Bearing and carbon brushes ..................167 Oil pump, brake cooling circulate (DA40) ........171 Exploded view ...........................171 Disassemble and overhaul the oil pump ...................172 Checking and renewing parts ....................174 Oil circulate pump assemble.
Page 50 Engine Ch 1 page Technical data DC13 with PDE ............200 General data ..........................200 Technical data DC9 with PDE ............202 General data ..........................202 Troubleshooting ECOM / Canbus ............. 205 To do: ............................205 Troubleshooting, -basic info.......................205 Troubleshooting fuel system ............206 Troubleshooting Guide ......................206 Troubleshooting Manual ..............
Page 51 Structure of the Repair Manual Important information on industrial safety Generally, the persons repairing Doosan product-sets are responsible on their own for the industrial safety. The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to per- sons and to the product during maintenance and repair works.
Page 52: Engine Identification
Engine Ch 1 page Engine identification Stamped number on top of the block DC 13 77A 6690537 The engine designation indicates, in the form of a code, the type 2100 of engine, its size and applications, etc. The type designation and engine serial number are indicated on a type plate affixed to the right-hand side of the engine.
Page 53 Ch 1 Engine page PREPARING THE ENGINE FOR STORAGE If the engine is not to be used for an extended period its cooling system, fuel system and combustion chamber must be protected against rust. This also applies to the external shell of the engine. An alternative to preparing the engine for long-term storage is to start the engine and warm it up every 6 months.
Page 54 10. Drain the preservative oil from the engine. Fill with new engine oil immediately or when the engine is to be reused. (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) 11. Drain the coolant if the engine is not to be stored with coolant in the system.
Page 55 Ch 1 Engine page Batteries Remove the batteries for trickle charging at a charging station (this does not apply to batteries which are maintenance-free according to the manufacturer). The same applies to short-term storage, even if the engine has not been prepared for storage as above. WARNING Wear gloves and protective goggles when charging and handling bat- teries.
Page 56: Removal Of Engine Assembly
Engine Ch 1 page Removal of engine assembly Place the dump truck on level ground and apply parking brake. Apply articulation lock. Turn off main switch in battery case. Raise the dump body and lock it with the safety support. Raise the tiltable cab and lock it with the safety support.
Page 57 Ch 1 Engine page Left side: Disassemble the cab pump unit from the air filter stand. Remove the water hose from the pipe socket. Remove the fuel hoses (3 pcs) and Disassemble hydraulic hoses Figure 6 Right side: Unscrew the hose clamps and remove the pipe bend, filter - turbo Disconnect the oil hose from engine brake cylinder and bracket disassemble the other end at left side on the magnetic valve...
Page 58 Engine Ch 1 page Disasssemble the cable to the Air filter sensor and cable to the sensor for the cooling water expansion tank. The unit will have two sensors on T4i/stage 3B (black arrows). Figure 9 Figure 10 Slack the transmission belt. Detach the Air Cond.
Page 59 Ch 1 Engine page Disconnect the hose from the termostat housing and the pipe between the air cooler and engine air inlet. Disconnect bracket for the air pipe and bracket between engine and fan bracket Figure 12 Disconnect the outlet pipe bend from turbo, and the inlet water hose from the transmission cooler.
Page 60 Engine Ch 1 page Disconnect the cables between starter motor and the frame Figure 16 Disassemble grounding cable attached to bracket underneath the engine starter. Figure 17 Disconnect contact on the dynamo. Figure 18 Remove the cover and disconnect the electrical contact from the engine ECU -S6 control unit Unwind wires from engine to frame Figure 19...
Page 61 Ch 1 Engine page Drive shaft Remove safety archer. Remove driveshaft between transmission and engine coupling, Assembly torque: 114 Nm Assembly torque: 141 Nm Assembly torque: 141 Nm Figure 20 Front- Left and right hand side, disassemble screw on the engine mounting bracket.
Page 62: Lifting The Engine
Engine Ch 1 page Lifting the engine NOTE The engine lifting eyes are designed for lifting the engine only, not the engine together with its ancillary equipment (alternator, gearbox etc.) or fram 8394 8373 Lever block Lifting chain Figure 24 - Mount the lifting chain 8373 to the rear lifting eyes.
Page 63: Xpi Fuel System Da30/40
Ch 1 Engine page XPI Fuel system DA30/40 Scania XPI Fuel Rail Mechaniccal Dump Valve High Pressure Connectors Pressure Sensor Injector High Pressure Line Bleed Hand Pump Inlet Metering Valve Fuel Manifold Fuel Heater 350W 5-24 deg Fuel Filter 1 10 microns Fuel Filter 2 3 microns...
Page 64: Route Of The Fuel On 9 And 13 Litre Engines
Engine Ch 1 page Route of the fuel on 9 and 13 litre engines The feed pump draws fuel from the fuel tank. The fuel is taken into connection 1 and drawn through the suction filter. From the suction filter the fuel is drawn into the control unit cooler via the fuel hose 2 and then from the control unit cooler to the feed pump via the fuel hose 3.
Page 65: Fuel Filter And Water Separation
Ch 1 Engine page Fuel filter and water separation The fuel system has two fuel filters because there are very high requirements on the purity of the fuel. Both fuel filters are filter elements. Water separating suction filter The feed pump draws fuel from the fuel tank through the suction filter.
Page 66: Overflow Valve
Engine Ch 1 page Overflow valve The overflow valve controls the pressure downstream of the injector in the fuel system. The normal operating pressure downstream of the injector is 0.7 bar. The overflow valve uses a duct in the fuel manifold to recirculate return fuel to the fuel filter, which returns the fuel to the fuel tank via a duct.
Page 67: Fuel System Components
Ch 1 Engine page Fuel system components Connection Injectors Accumulator Fuel pressure sensor Safety valve Bleed nipple High pressure pump Fuel inlet metering valve Feed pump Hand pump Fuel filter, 2 off Fuel manifold for return fuel Engine control unit with control unit cooler Overflow valve Figure 35...
Page 68: Important Information About The Fuel
Engine Ch 1 page Important information about the fuel Fuel initially contains a reduced quantity of water rom the manufacturing process. The water content may in- crease, e.g. as a result of condensation, during prolonged and unsuitable storage. Small quantities of water in the fuel do not affect the engine operation. However, micro-organisms grow in the water.
Page 69: Exhaust System Xpi
Ch 1 Engine page Exhaust system XPI Introduction System overview New, more stringent requirements for exhaust emissions will come into force as of 2011. To meet these new requirements for exhaust emissions, a technology will be used which is known as SCR, Selective Catalytic Reduction.
Page 70: Control System For Exhaust Gas Aftertreatment
Engine Ch 1 page Control system for exhaust gas aftertreatment Overview - Exhaust gas aftertreatment system structure and components Exhaust gas aftertreatment is made up of the electronic control system for exhaust gas aftertreatment, EEC (Exhaust Emission Control system), with sensors and electrical components such as the reductant pump and reductant doser.
Page 71 Ch 1 Engine page 1. Control unit EEC3 (E67) The EEC3 control unit retrieves data from the system’s sensors and components. EEC3 communicates with the engine control unit EMS. EMS decides on what measures are to be executed, e.g. what quantity of reductant is to be metered to the exhaust gases, and notifies EEC3.
Page 72 Engine Ch 1 page 4. Level sensor and temperature sensor (T116) There is a level and temperature sensor in the reductant tank which measures the fluid level and fluid temperature. This sensor reports to EEC3. The sensor is located in the reductant tank.
Page 73 Ch 1 Engine page Explanation In order to reduce the concentrations of nitrogen oxide compounds (NOx) in the exhaust gases, catalytic con- verters are used and reductant (32.5% urea and the rest water) is delivered into the exhaust gases in the hydro- lysis catalytic converter.
Page 74 Engine Ch 1 page Working principle The working principle for exhaust gas aftertreatment is divided into three different operations: Starting Operation and reductant metering Shutdown Starting The reductant pump starts when the following has taken place: The engine has started, the EEC3 control unit has carried out a system check, the catalytic converters have started to heat up and have reached the correct operating temperature (200–250°C) and any heating of the reductant is finished.
Page 75 Ch 1 Engine page Starting in the cold, below -11°C Figure 43 The EEC3 control unit monitors the values and functions of all sensors The engine is started The EEC3 control unit opens the coolant valve (3) so that the coolant can heat the reductant tank (1) and re- ductant pump (11).
Page 76 Engine Ch 1 page Operation and reductant metering Figure 44 The exhaust gases are treated in a number of steps before being released via the tailpipe. These steps are based on the combustion control mode of the engine control unit. First, the exhaust gases are mixed with reduc- tant when they pass the hydrolysis catalytic converter (6).
Page 77 Ch 1 Engine page Shutdown Figure 45 When the engine is switched off the reductant pump (11) continues for a set period to deliver reductant to the reductant doser (12). However, reductant is not injected into the hydrolysis catalytic converter (6) but is returned to the reductant tank (1) and has the purpose of cooling the reductant doser.
Page 78: Control Unit Eec3
Engine Ch 1 page Control unit EEC3 Figure 46 Control unit EEC3 NOx sensor Temperature sensor Level and temperature sensor Reductant pump Reductant doser Coolant valve Electrically heated reductant hoses Figure 47 Figure 48 SHOP MANUAL...
Page 79: System Overview For Mechanics
Ch 1 Engine page System overview for mechanics Figure 49 Reductant tank Coolant hoses for heating reductant tank and reductant pump Hydrolysis catalytic converter SCR catalytic converter Electrically Right heated hoses for reductant mudguard Reductant Doser Hydrolysis catalyst Transmission Figure 50 SHOP MANUAL...
Page 80: System Overview For Electrics
Engine Ch 1 page System overview for electrics Figure 51 Control unit EEC3 NOx sensor Temperature sensor Level and temperature sensor Reductant pump Reductant doser Coolant valve Electrically heated reductant hoses Reductant tank Figure 52 Control unit EEC3 Reductant pump Level and temperature sensor SHOP MANUAL...
Page 81: Ad Blue Filter Change
Ch 1 Engine page Ad blue filter change Renewing the reductant filter Every 1,000 hours: Disassemble guard plate 1. Place a suitable container underneath. 2. Lift out filter element. 3. Renew the filter element and check the O-ring and insulation 4.
Page 82: Reductant Doser
Engine Ch 1 page Reductant doser The reductant doser meters out the quantity of reductant, which the engine control unit indicates, to the evaporator in the silencer. On industrial and marine engines the reductant is metered out to the hydrolysis catalytic converter Connection for electrical connector Reductant inlet...
Page 83 Ch 1 Engine page The reductant flows from the inlet at a pressure of about 9–10 bar and first passes the prefilter (2), fills the ducts after which the sensor (3) reads the pressure and temperature. The dosage quantity is determined by the opening time of the solenoid valve (5). It opens once per second and the amount of time that the solenoid valve is open during that second determines the dosage quantity.
Page 84: Reductant Pump, Function
Engine Ch 1 page Reductant pump, function The reductant pump sucks reductant from the reductant tank, filters and builds up pressure for the reductant which is then fed to the reductant doser. The reductant pump is an electrically driven diaphragm pump with a filter for cleaning the reductant. The reduc- tant pump is heated using the engine’s coolant at low outdoor temperatures in order to thaw frozen reductant or prevent it freezing.
Page 85: Start-Up Instruction For New Scr Pump
Ch 1 Engine page Start-up instruction for new SCR Pump If an SCR pump has not been used for a long period of time, the check valves could seize and become jammed due to crystalized urea in the valves resulting in lack of system pressure. This could also be a problem on new spare part pumps that have spent a long time in stock.
Page 86 Engine Ch 1 page Figure 64 shows a section through the valve block viewed from the side. Reductant is sucked in through the intake port (1) and via an intake valve (2) to the pump chamber, where reductant pressure is built up by means of the pump diaphragm (3). Pressurised reductant passes through the outlet valve (4) and via the port (5) to the reductant filter, which is located under the valve block.
Page 87: Fuel System Tier2 (Pde)
Ch 1 Engine page Fuel system Tier2 (PDE) Schematic diagram of the fuel system Tier2 1 Feed pump 2 Hand pump 3 EMS control unit 4 Fuel filter 5 Cylinders 6 Fuel tank 7 Return line for excess fuel A Check valve B Gear pump (feed pump) C Safety valve D Pressure relief valve...
Page 88: General
Engine Ch 1 page General Apart from fuel lines and a fuel tank, a PDE (Pumpe-Düse-Einheit) fuel system with unit injectors consists of the following items: • a feed pump • a hand pump • a fuel filter • one fuel rail. •...
Page 89: Temperature Dependency Of The Fuel
Ch 1 Engine page Temperature dependency of the Fuel At temperatures lower than those specified for the fuel, paraffin wax may precipitate from the fuel and block filters and pipes. The engine can then lose power or stop. The fuel is adapted for use in the specific climate of each country.
Page 90: Fuel Filter
Engine Ch 1 page Fuel filter Design Fuel filter are of single-mounted type. The filter screw on to a retainer which is bolted to the engine. The filter consists of a metal container with a folded paper ele- ment. The filter cannot be dis mantled but must be changed as a complete unit.
Page 91: Water Separating Prefilter Xpi
Ch 1 Engine page 7. Fit the filter element and cover in the filter housing. Tighten the cover to 25 Nm (18.4 lbf.ft). 8. Bleed the fuel system after renewing the water separating filter. CAUTION Fit the filter elements in the filter covers before placing them in the fuel filter housings or the filter elements may be dam- aged.
Page 92: Bleeding The Fuel System
Engine Ch 1 page Bleeding the fuel system 1. Connect a transparent plastic hose to the bleed nipple on fuel filter housing 1. Place the end of the plastic hose in a container with a capacity of at least 3 liters (0.8 US gallons).
Page 93 Ch 1 Engine page Feed pump renewal Temperature dependence of diesel fuel At temperatures lower than those specified for the diesel fuel, paraf- Clean the outside of the feed pump. fin wax may precipitate from the fuel and block filters and pipes. The Remove the suction and pressure engine can then loose power or stop.
Page 94: Feed Pump
Engine Ch 1 page Feed pump The feed pump 1 draws fuel from the fuel tank and forces it through the fuel filter 11 and into the fuel rail 4. On the feed pump there is a hand pump 10 The hand pump is used to vent air from the fuel system.
Page 95: Diagnostic Prosedure
Ch 1 Engine page Diagnostic prosedure Use of diagnostic kit, Tier 2 Disassemble cover inside cab right side rear for connection point Connection point Can pc VCU + Testman Figure 77 Connect VCU testcabel to laptop Can bus overview Figure 78 EMS- S8/S6 Can1...
Page 96: Connection Point Sdp3 Scania Dagnostic
Engine Ch 1 page Connection point SDP3 Scania dagnostic On left side of the engine there is the con- nection point for Scania SDP3 Figure 80 Install the VCI 1. Switch on the laptop. 2. Connect the cabelend (2) to the engine testport 3.
Page 97: Renewing The Control Unit
Ch 1 Engine page Renewing the control unit Tightening torques Control unit, screws 22 Nm Work description CAUTION The control unit may suffer damage if it is powered when you unplug it. Before removing the control unit you must switch off the power with the starter key and wait for the EMS warning lamp to go out.
Page 98: Removing The Ecu Wiring Tier2
Engine Ch 1 page Removing the ECU wiring Tier2 Drain the coolant from the engine as described in the work de- scriptions for the cooling system. 2. Wash clean the rocker covers and the area around them. 3. Remove the inlet pipe between the turbocharger and the air cleaner.
Page 99 Ch 1 Engine page Fitting the wiring Tier2 Tightening torques: Unit injector solenoid valves, screws: 2,0 +/-0,2 Nm 512562 Torque screwdriver CAUTION Figure 86 If the screws are tightened too tight, there is a risk that they may break. If this happens, the entire unit injector must be replaced.
Page 100 Engine Ch 1 page Work description: 1. Make sure that the inlet pipe between the turbocharger and the air cleaner has been removed. 2. Fit the cable ducts. Sche- matic illustrations of the location of the cable ducts and their components are shown below Figure 87 1 Cylinder 1–6...
Page 101 Ch 1 Engine page 4. Press the cables into the groove in the lower rocker cover. See the illustration about Fitting the wiring. NOTE Take care when tightening the cable connection screws on the unit injector. If a screw breaks, the unit injector must be replaced.
Page 102: Cylinder Head - Pde System Tier2
Engine Ch 1 page Cylinder head - PDE System Tier2 Cylinder head, parts view. PDE Tier2 Figure 92 31. Gasket 1. Valve bridge 17. Bearing bracket 32. Exhaust valve 2. Pin 18. Rocker arm for unit 33. Valve seat insert 3.
Page 103: Special Tools
Ch 1 Engine page Special tools 8049 8029 512256 Slide hammer 512256 8019 8049 Impact drift 8029 Extractor for injectors 8019 Compression tester 8386 Sleeve for injectors 8386 8387 8406 8407 8405 Tool for turning flywheel 8405 8387 Socket 8406 Press drift 8407 Assembly drift...
Page 104: Valve Mechanism
Engine Ch 1 page Valve mechanism The purpose of the valve mechanism is to actuate the valves, causing them to open and close at the right times in relation to the position of the crank shaft and piston. The camshaft is located high up and driven by the timing gears at the rear end of the engine so that it rotates at half the speed of the crankshaft.
Page 105 Ch 1 Engine page 1.Open the bleeder nipple and drain the fuel system by undoing the banjo screw on the back of the fuel manifold. Figure 97 1. Bleeder nipple 2. Banjo screw WARNING The fuel system must be empty or fuel may run down into the cylinders, which will result in a great risk of liquid hammering.
Page 106 Engine Ch 1 page WARNING Do not lean over the engine when removing the rocker arm shaft. The unit injector spring is pre-tensioned and can come loose, causing personal injury. Figure 100 NOTE If the spring comes loose from the unit injector, the unit injector must be renewed.
Page 107 Ch 1 Engine page Remove the fork clamp bolt holding the unit injector in place. Figure 102 1. Fork clamp 2. Fork clamp bolt 3. Unit injector Detach the cables on the unit injector. The screws cannot be removed but undo them as far as possible.
Page 108 Engine Ch 1 page 13. It is easier to position the slide hammer if one of the lower rocker cover bolts is removed. 14. Withdraw the unit injector. If the unit injector Figure 105 is stuck, tap carefully with a rubber mallet on the solenoid valve housing.
Page 109: Dismantling
Ch 1 Engine page Dismantling 1. Remove collets, valve spring collars, springs and valves. Press the spring down using tool 8406 in a press so that the collets can be removed. 8406 2. Mark and place the valves in a rack so that they can be refitted in the same position in the cylinder head.
Page 110: Replacement Of Valve Seats
Engine Ch 1 page Replacement of valve seats 1. Remove the valve seat inserts. Use a discarded valve that has been ground so that the diameter of the disc is slightly smaller than the inside diameter of the seat. 2. Fit the valve and weld around it with an electric welder. Cool with water.
Page 111: Machining The Valve Seats Insert
Ch 1 Engine page Machining the valve seats insert Machining values Figure 113 Figure 114 Inlet valve Exhaust valve A = 1,9 - 2,6 mm A = 1,8 - 2,6 mm B = 0,75 - 1,8 mm B = 0,66 - 1,8 mm C = diameter 39,8 +/- 0,5 mm C = diameter 37,9 +/- 0,5 mm (setting value for machining tool)
Page 112 Engine Ch 1 page 3. Select and fit the cutter. 4. Release the quick-action lock and move the Figure 116 pivot plate to the upper position with the adjusting screw. 5. Set up the dial on the cutter adjuster using a valve.
Page 113: Renewing The Valve Guides
Ch 1 Engine page 10. Machine the valve seat by cranking clockwise while turn- ing the feed screw. Never crank counterclockwise, as this could damage the cutter. Lubricate with cutting oil during the procedure. 11. When the machining of the valve seat is completed, reduce the cutting pressure by turning the crank 23 turns without feeding.
Page 114: Renewing Pde Unit Injector Sleeves
Engine Ch 1 page Renewing PDE unit injector sleeves The cylinder head must be removed when renewing the injector sleeve. The valves do not need to be removed. The illustration shows the cylinder head with valves removed to demonstrate clearly the work described.
Page 115: Assembly
Ch 1 Engine page Assembly NOTE There are different versions of the combination valve - valve spring collar - split collet. Parts from the different 8406 versions must not be mixed on the same valve. 1. Lubricate all parts well with engine oil before assembly.
Page 116: Common Rail Injectors Tier4/Xpi
Engine Ch 1 page Common rail Injectors Tier4/XPI Figure 129 Figure 130 Figure 131 Low-pressure pump Fuel filters with water separator Inlet metering valve High pressure pump Rail (accumulator) Rail Pressure sensor Machanical dump valve Return rail Electronically controlled fuel injector Figure 132 SHOP MANUAL...
Page 117: Cylinder Head - Xpi System Tier4
Ch 1 Engine page Cylinder head - XPI system Tier4 Cylinder head, parts view. XPI system Tier4 Cylinder head Sleeve Core plug Rivet Valve guide Valve seat insert Valve seat insert Cylinder head gasket Seal Intake valve Valve spring Valve spring collar Exhaust valve Valve spring Valve spring...
Page 118: Injector Scania Xpi
Engine Ch 1 page Injector Scania XPI There is one injector for each cylinder. The injector is controlled electrically by the engine control unit. The injector operates in two phases. One phase is when no power is supplied to the injector and it is closed. The other phase is when power is supplied to the injector and it is open.
Page 119 Ch 1 Engine page Phase 2, power to the solenoid valve in the injector Power is supplied to the injector solenoid valve which then opens, so that the fuel flows up into the valve part. The pressure difference which arises in the injector means that the piston is drawn upwards and fuel is injected into the cylinders.
Page 120: Valve Adjustment Dc13 With Xpi
Engine Ch 1 page Valve adjustment DC13 with XPI Order of adjustment for 13 litre engines Rotate the flywheel in the engine’s normal direction of rotation using turning tool MX no.531447 . Read the mark on the flywheel visible in the upper window of the flywheel housing. Engines equipped with flywheel with marking TDC Up: Fit turning tool 531447 in the holes of the upper window.
Page 121: Cylinder Configuration, 6 Cylinder Engines
Ch 1 Engine page Cylinder configuration, 6 cylinder engines It is not possible to read the flywheel position on the lower part of the flywheel housing. To read, use the TDC top inspection hole, the cab must be tilted up. NOTE Use the cab support when reading of marks on the flywheel Set cylinder 1 exactly at TDC after the compression stroke.
Page 122: Valve Adjustment Dc9 With Xpi
Engine Ch 1 page Valve adjustment DC9 with XPI Check and adjust the valve play with the engine cold. Play for the intake valves should be 0.45 mm and for the exhaust valves 0.70 Rotate the flywheel in the normal direction of rotation using turning tool MX no.
Page 123: Cylinder Configuration, 5 Cylinder Engines
Ch 1 Engine page Cylinder configuration, 5 cylinder engines Rev- Valve Adjust intake Mark on fly- olu- change and exhaust wheel. Read- tion on cylin- valves on cyl- ing in the up- inder per window TDC Up 252/612 324/684 36/396 108/468 TDC Up 252/612...
Page 124: Valve Adjustment Dc13 With Pde
Engine Ch 1 page Valve adjustment DC13 with PDE CAUTION Use torque screwdriver 512562 to avoid the risk of shearing off the screws. The entire unit injector must be renewed if the screws shear off. 9. Refit the upper rocker cover and torque tighten the bolts to 18 Nm.
Page 125 Ch 1 Engine page WARNING Take care when carrying out the adjustment if the dimension is well outside the adjustment dimension. The spring is pre- tensioned and can cause personal injury if it is released. PDE32 512264 See note previous side. 1.
Page 126: Adjusting The Valve Clearance And Unit Injectors
Engine Ch 1 page Adjusting the valve clearance and unit injectors 1. Fit the unit injector according to the section Fitting the PDE injector, steps 1-11. 2. Fit the pushrods. 3. Fit the bearing bracket and torque tighten the bolts to 115 Nm. 4.
Page 127: Checking, Adjusting The Pde Injector And Rocker Arms
Ch 1 Engine page Checking, adjusting the PDE injector and rocker arms 3. Adjust the unit injector for cylinder No. 5. See Adjusting unit injectors. 4. Rotate the flywheel 1/3 turn at a time using tool 8405 and repeat steps 1 - 3 and adjust as per the order of adjustment below.
Page 128: Valve Adjustment Dc9 With Pde
Engine Ch 1 page Valve adjustment DC9 with PDE Checking, adjusting the PDE32 injector and rocker arms (I) If reading cannot be taken from underneath: Mx No. 531447 Disassemble the upper inspection coverplate. Turn the flywheel with tool Mx no 531447 to valve overlap on cyl- inder 1 (which corresponds to TDC up (0°) in the upper opening).
Page 129: Turbocharger
Ch 1 Engine page Turbocharger The purpose of the turbocharger is to increase the volume of air entering the engine’s cylinders. With more air the engine can burn more fuel and so develop more power and achieve cleaner com bustion than a corresponding engine without supercharg- ing.
Page 130: General
Engine Ch 1 page General Foreign bodies NOTE Foreign bodies, such as grains of sand or metal fil- ings, in the turbine or compressor will damage their Whenever working on the turbo charger, observe blades. utmost cleanli ness. The oil intake and outlet con- nections must never be left open.
Page 131: Changing Oil Filter
Engine page Changing oil filter NOTE Only use a DOOSAN oil filter. 1. Unscrew the filter cover with a closed tool with 36 mm socket. 2. Lift out the filter housing cover with filter. The filter housing will drain automatically once the filter has been removed.
Page 132: Oil Analysis
Engine Ch 1 page Oil analysis Oil analysis may be necessary to determine a different oil change interval from that recommended here. Oil companies can offer analysis of the engine oil. Such analysis measures the oil’s TBN (Total Base Number), TAN (Total Acid Number), fuel dilution, water content, viscosity and the quantity of particles and soot in the oil.
Page 133: Changing The Oil
Ch 1 Engine page Changing the oil NOTE Renew the oil filter and clean the centrifugal oil cleaner when changing oil. WARNING AVOID DEATH OR SERIOUS INJURY • Hot oil can cause burns and skin irritation. Wear protective gloves and goggles when changing hot oil. •...
Page 134: Special Tools
Engine Ch 1 page Special tools Figure 170 8014 8388 8389 8391 8014 Dial gauge 8388 Filter wrench 8389 Deflection gauge 8391 Stand 1. Lubrication oil pipe 2. Ferrule 3. Union nut 4. Straight union 5. Seal 6. Straight union 7.
Page 135: Measuring Radial Clearance And Axial Clearance
Ch 1 Engine page Measuring radial clearance and axial clearance Measuring radial clearance and axial clearance does no usually give any indication of the remaining service life of the turbocharger. When the turbocharger is not working correctly or sounds abnormal, measuring charge pressure or measuring radial clearance or axial clearance can show that the turbocharger is defective.
Page 136 Engine Ch 1 page Axial clearance 1. Place the tip of the dial gauge 8014 against the end of the shaft. 2.Press the shaft forwards and backwards and read the dial at the end positions. The differ ence between readings is axial clearance.
Page 137: Renewing The Turbocharger
Ch 1 Engine page Renewing the turbocharger NOTE When renewing the turbocharger, all gaskets and the oil filter must be changed and the centrifugal cleaner must be cleaned. Removal 1. Detach the delivery and return oil lines from the turbocharger. 2.
Page 138: Pistons And Cylinder Liners
Engine Ch 1 page Pistons and cylinder liners 1. O-ring 3. Cylinder liner for steel piston 5. O-ring 6. Compression ring 7. Compression ring 8. Oil scraper ring 9. Circlip 10. Steel piston 12. Gudgeon pin 13. Circlip 14. Bearing bushing 15.
Page 139: Special Tools
Ch 1 Engine page Special tools Figure 176 8004 Rule for dial gauge 8005 Drift 8014 Dial gauge 8224 Piston ring compressor 8028 Pressing tool 8036 Hydraulic cylinder 8215 Puller for cylinder liner 8049 Impact drift 8401 Dismantling tool 8409 Assembly tool 8390 Test apparatus for connecting rods...
Page 140: Connecting Rods
Engine Ch 1 page Connecting rods The connecting rod and big-end cap consist of a single casting which is split during the machining operation. To prevent the big-end cap from being displaced in relation to the connecting rod, the contact surfaces are provided with grooves and guide pins.
Page 141: Removing And Dismantling Connecting Rods And Pistons
Ch 1 Engine page Removing and dismantling connecting rods and pistons 1. Remove the cylinder head and oil sump. 2. Remove the piston cooling nozzle in the cylinder block. NOTE The piston cooling nozzle must not be damaged. The oil jet must hit the piston precisely.
Page 142 Engine Ch 1 page Checking connecting rods Check the connecting rods using tool 587 110. Proceed as follows: 1. When the gudgeon pin bushing has been checked, insert the bearing cap as marked and tighten the bolts to full torque. 2.
Page 143: Renewal Of Bearing Bushing In Connecting Rod
Ch 1 Engine page Renewal of bearing bushing in connecting rod Use tool 512564 when renewing the bearing bushing. The tool comprises three parts: 1. Pressplate with guide pin 2. Press drift 3. Supports There are different supports, depending on the engine type.
Page 144 Engine Ch 1 page 3. After pressing in a new bearing bush- ing, it must be finish-turned. This requires special equipment. Refer to figure 189 for the dimensions required. Diameter, d = 54.030 - 54.043 mm Surface quality = 0.6 Ra Figure 189 SHOP MANUAL...
Page 145: Pistons
Pistons The pistons which are used in DA40 engine is of type; articulated pistons. Articulated pistons are split and have an aluminium skirt and a steel crown. (For the aluminium piston to resist the high pressure and high temperature prevailing in the com- bustion chamber, the material is thicker at the piston crown and piston ring grooves than in the remainder of the piston.)
Page 146 Engine Ch 1 page The bowl-shaped combustion chamber in the piston crown has a protuberance in the centre. The design of this pro- tuberance ensures that the fuel injected at the end of the compression stroke is quickly mixed with the air in the com- bustion chamber.
Page 147: Assembling Piston And Connecting Rod
Ch 1 Engine page Assembling piston and connecting rod 1. Clean the piston and its rings thoroughly without scratching the sides of the ring grooves. The oil holes in the piston should be cleaned using a suitable drill. 2. Make sure the piston ring gaps do not exceed the permitted limit.
Page 148: Cylinderblock
Engine Ch 1 page Cylinderblock The cylinder block is a one-piece casting. It has 6 cylinder bores. There is a separate cylinder head for each cylinder. The seal between cylinder block and cylinder head consists of a steel/elastomer gasket. Seals are bonded in place at the oil and coolant passages.
Page 149 Ch 1 Engine page The inside of the cylinder liner is machined by what is known as plateau honing. This type of machining leaves a fine pattern of grooves which ensures that the oil needed for lubrication between piston rings and liner remains on the wall of the liner.
Page 150: Removing The Cylinder Liners
Engine Ch 1 page Removing the cylinder liners 1. Mark the liners with the numbers 1-6. The mark is necessary so that the liners can be refitted in the same place and position as previously. Figure 201 NOTE The mark must be made only on the surface indicated in figure 201.
Page 151: Measuring The Cylinder Liner Height
Ch 1 Engine page Measuring the cylinder liner height 1. Thoroughly clean the cylinder block liner shelf, the face around the cylinder, the cylinder liner shelf and the upper face of the cylinder liner. 2. Fit the cylinder liner without O-rings and twist down by hand into position.
Page 152: Fitting The Cylinder Liners
Engine Ch 1 page Fitting the cylinder liners 1. Check cylinder liner height as described in the section entitled Measuring the cylinder liner height. 2. Make sure the interior of the cylinder block is clean. Clean the O-ring surfaces. 3. Check that the holes for coolant going to the cylinder head and cylinder liner are not clogged.
Page 153: Fitting The Piston And Connecting Rod
Ch 1 Engine page Fitting the piston and connecting rod 1. Lubricate the piston, piston rings, cylinder liner and piston ring compressor with engine oil. 2. Remove the protection on the connecting rod journal and lubricate the journal. 3. Turn the piston rings so that the ring gaps are evenly distributed round the piston.
Page 154 Engine Ch 1 page 11. Fit the lower connecting rod bearing shell into the cap and lubricate the bearing surface. Fit the cap. Check that the connecting rod and cap have the same marking and that they are opposite each other. 12.
Page 155: Flywheel And Flywheel Housing
Ch 1 Engine page Flywheel and flywheel housing Figure 210 NOTE 23.Timing gear plate, engines with PDE unit injectors 1. Flywheel housing 15. Stud 27. Cover 2. Seal 16. Rotation speed sensor 28. O-ring 3. Bolt 17. Contact housing 29. Crankshaft gear PF 4.
Page 156: Special Tools
Engine Ch 1 page Special tools Figure 211 8006 Puller bolts 8432 Assembly tool Not illustrated: 8410 Drift 512556 Assembly tool 8412 Guide pins 512555 Assembly tool 512559 Air powered sprayer 512557 Cartridge adapter 512558 Nozzle Removing the flywheel 8006 1.
Page 157 Ch 1 Engine page Renewing support bearing 1. Remove the retaining rings on both sides of the support bearing. 2. Knock out the support bearing from the flywheel using drift 8410. 3. Fit the inner retaining ring and fit the new support bearing with drift 8410.
Page 158: Renewing The Rear Crankshaft Seal
Engine Ch 1 page Renewing the rear crankshaft seal 1. Remove the crankshaft seal using a screwdriver. Take care not to scratch the sealing surfaces on the crankshaft and the flywheel housing. NOTE Figure 214 The crankshaft seal must be fitted dry and must not be lubricat- ed.
Page 159: Fitting Flywheel Housing
Ch 1 Engine page Fitting flywheel housing Remove all old sealing compound on the sealing surfaces of the timing gear casing and timing gear plate. Clean off any oil and grease using an alcohol based cleaning agent. NOTE Figure 217 The sealing surfaces must be absolutely clean and free from grease.
Page 160 Engine Ch 1 page 4. Torque tighten the M12 bolts to 90 Nm and the M10 bolts to 50 Nm. Figure 220 5. Fit the power steering pump. 6. Fit the starter motor. Figure 221 7. Fit the flywheel, see Fitting of flywheel. Figure 222 SHOP MANUAL...
Page 161: Fitting The Flywheel
Ch 1 Engine page Fitting the flywheel 1. Fit two guide pins 8412 in the crankshaft flange. 2. Fit the flywheel on the crankshaft. NOTE Figure 223 Always use new bolts and washer. 3. Lock the flywheel using tool: - 512563 for engines with unit injector. 512563 99 411 4.
Page 162: Timing Gear, 13 Litre With Unit Injector
Engine Ch 1 page Timing gear, 13 litre with unit injector Gear drive The crankshaft gear drives two intermediate gears and the oil pump gear. One intermediate gear drives the camshaft, air compressor and hydraulic pump. The other intermediate gear drives the power take-off and on buses it also drives a hydraulic pump which in turn drives the fan motor.
Page 163: Belt Drive Collant Pump, Generator And Ac Compressor
Ch 1 Engine page Belt drive collant pump, generator and AC com- pressor The coolant pump and alternator are driven by the belt drive, as also is the A/C compressor. (The fan is mounted on a special bracket and is driven by the hydraulic system.
Page 164: Checking The Drive Belt
Engine Ch 1 page Checking the Drive Belt CAUTION Disconnect the cable terminal prior to charging to pre- vent control unit damage. Avoid boost charging as this damages the battery over time. Check the drive belt thoroughly, particularly at the idler rollers. Figure 229 Check the drive belt for cracks.
Page 165: Check For Leaks
• Check whether the drain hole on the coolant pump is blocked. If there is a leak, renew the seal in the pump or the complete coolant pump. NOTE If serious leakage occurs, contact your nearest DOOSAN work- shop. SHOP MANUAL...
Page 166: Renewing The Seal In The Front Cover
Engine Ch 1 page Renewing the seal in the front cover 1. Remove the fan ring and the fan. Thermostatic fan: Store it upright (vertical). 2. Remove the belt(s), crankshaft damper and belt pulley. 3. Remove the driver bolts and withdraw the driver.
Page 167: Crankshaft Damper
Ch 1 Engine page Crankshaft damper Figure 235 Figure 236 The power impulses from the connecting rods give rise to torsional oscillation in the crankshaft. These oscillations are severest at certain engine speeds which vary with the design of the engine, how it is loaded, etc. Torsional oscillation is characterised as follows: The flywheel (at the “rear”...
Page 168: Timing Gear, View Exploded
Engine Ch 1 page Timing gear, view exploded Figure 237 1. Camshaft 13. Intermediate gear 25. Roller tappet 2. Pin 14. Ball bearing 26. Circlip 15. Snap ring 3. Camshaft bearing 27. Flange bolt 4. Guide flange 16. Spacing sleeve 28.
Page 169: Special Tools
Ch 1 Engine page Special tools Special tools, gear 8413 Drift 8133 Drift 8049 Impact drift 8414 Support drift 8413 8133 8049 8405 Flywheel turning tool 8414 8405 Figure 238 Special tools, replacement of camshaft bearing 8036 8467 8037 Figure 239 8467 Tool for replacing camshaft bearing 8036 Hydraulic hole cylinder 8037 Compressed air powered hydraulic pump...
Page 170: Intermediate Gear
Engine Ch 1 page Intermediate gear Intermediate gear Removal - The timing gear has two intermediate gears. - One for the camshaft and pump drive and one for driving the compressor. - Both these gears should be removed in the same manner.
Page 171 Ch 1 Engine page 1. Press the shaft out of the bearing. 2. Press the bearing inner race shell from the shaft and remove the retaining ring. 3. Place the removed bearing inner race in the bearing and press out the bearing using drift 8413 4.
Page 172 Engine Ch 1 page Fitting 1. Check that cylinder number 1 is close to TDC. The markings on the camshaft gear and crankshaft gear must point towards the centre of the intermediate gear. 2. Lubricate the bearing surfaces. 3. Fit the intermediate gear against the camshaft gear and the crankshaft gear so that the markings point towards each other.
Page 173: Camshaft Gear
Ch 1 Engine page Camshaft gear Removal 1. Turn the crankshaft so that cylinder number 1 is close to TDC. Use tool 8405 and ratchet handle on the flywheel starter ring gear. 2. Remove the flywheel as described in the section Removing the flywheel.
Page 174: Crankshaft Gear
Engine Ch 1 page Crankshaft gear Removal 1. Turn the crankshaft so that cylinder number 1 is close to TDC. Use tool 8405 and ratchet handle on the flywheel starter ring gear. 2. Remove the flywheel as described in the section Removing the flywheel.
Page 175: Camshaft
Ch 1 Engine page Camshaft Removal 1. Remove the flywheel as described in Removing the flywheel. 2. Remove the flywheel housing as described in Removing the flywheel housing. 3. Remove rocker arms, pushrods and valve bridges. 4. Remove the camshaft gear. 5.
Page 176: Replacement Of Camshaft Bearing
Engine Ch 1 page Replacement of camshaft bearing Work description 1. Remove the camshaft according to the section Camshaft, removal. 2. Remove the camshaft cover at the front end of the engine. NOTE Wipe around the edges and the bearing seat surfaces around the Figure 256 old bearings to avoid damaging the contact surfaces when fitting the new bearings.
Page 177 Ch 1 Engine page 6. Take the threaded stem and insert the end with flange nut number 1 from the rear edge of the engine past the rearmost bearing seat. Insert it further through the bearing seats and the new bearings until flange nut 1 protrudes from the front of the engine.
Page 178 Engine Ch 1 page 10. Hang a new bearing on the stem at the front of the engine. 11. Place the press drift on the threaded stem and place the bearing on the drift. NOTE Figure 261 The recess in the bearing joint must be turned towards the flange on the press drifts.
Page 179 Ch 1 Engine page NOTE The new bearing is in the correct position before the old bear- ing is completely released. The new bearing has the correct position when the distance from the front edge of the cylinder block to the front edge of the press drift has a permitted value according to the table.
Page 180 Engine Ch 1 page 16. Check that the bearing oil hole is opposite the cylinder block oil ducts. NOTE The seats for camshaft bearings 2, 4 and 6 have two oil ducts. The others only have the lower one. 17. Repeat the procedure for the remaining bearings. 18.
Page 181 Ch 1 Engine page Fitting 1. Fit the camshaft. Take care not to damage the cams and bearings. 2. Lubricate with engine oil and fit the valve tappets in the same places as they were before removal. Tighten the banjo bolts to 32 Nm. Figure 269 4.
Page 182 Engine Ch 1 page 7. Fit the timing gear plate on the engine block. Tighten the bolts to 63 Nm. 8. Fit the intermediate gear as described in Intermediate gear, fitting. 9. Ensure that the markings on the camshaft gear point towards the centre of the intermediate gear.
Page 183: Crankshaft
Ch 1 Engine page Crankshaft Each compression stroke ”brakes” the crankshaft and each com- bustion stroke attempts to increase the speed of rotation of the crankshaft. The pistons and connecting rods change their direction of travel twice during each rotation of the crankshaft. This exposes the crankshaft to numerous power pulses during each revolution.
Page 184: Removal
Engine Ch 1 page Removal 1. Remove the crankshaft gear as described in Removing the crankshaft gear. 2. Remove the crankshaft pulley as described in the work descrip- tion Removing the pulley. 3. Remove the oil sump, oil suction pipe with strainer and the oil pump.
Page 185 Ch 1 Engine page - When regrinding, stated undersizes must be complied with. Suitable bearings are available for these sizes. - Refer to the next page for the diameters required for different undersizes. - It is important that the fillet radius of the journals is correct.
Page 186 Engine Ch 1 page Dimensions when regrinding Main bearing journals Standard, diameter 107.978-108.000 mm Undersize 1, diameter 107.728-107.750 mm Undersize 2, diameter 107.428-108.500 mm Undersize 3, diameter 107.228-107.250 mm Undersize 4, diameter 106.978-107.000 mm Hole recess radius 4.75-4.85 mm Surface quality 0.25 Ra Connecting rod journals Standard, diameter...
Page 187: Fitting
Ch 1 Engine page Fitting 1.Place the bearing shells in the main bearing seats in the cylinder block and in the main bearing caps. Then lubricate the bearing surfaces with engine oil. 2. Lift in the crankshaft. NOTE The outside of the bearing shells must not be lubricated. Figure 281 3.
Page 188: Adjust - Machining The Crankshaft
Engine Ch 1 page NOTE the machine serial number! Machine 810001 - 810108 Tighten the bearing cap bolts to 50 Nm + 90°. Machine 810109 (Tier3) - Tighten the bearing cap bolts to 200 Nm + 90°. Figure 284 6. Fit the pistons with connecting rods as described in Fitting the connecting rod and 200 Nm +90°...
Page 189: Lubrication System
Ch 1 Engine page Lubrication system Oil pump An oil pump, driven by the crankshaft gear, gener ates the circulation required to provide lubrication oil to all lubrication points so that it flows through the oil cleaner and oil cooler. The lubricating oil is sucked from the sump through a strainer in the oil pump.
Page 190: Lubrication Oilways
Engine Ch 1 page Lubrication oilways The lubrication oil passes through channels in the cylinder block to reach the camshaft bearings and the crankshaft main bearing. Channels in the crankshaft feed the oil on to the connecting rod bearings. Lubrication oil for the rocker arms is led via a direct channel from the main oilway. The channel is constantly pressurised.
Page 191: Oil Pressure
Ch 1 Engine page Oil pressure NOTE Max. oil pressure: High lubricating oil pressure (above Warm engine running at a speed above 800 rpm 6 bar 6 bar) is normal when starting a cold engine. Normal oil pressure: Warm engine running at an operating speed of 3 - 6 bar Min.
Page 192: Oil Cooler, Engine
Engine Ch 1 page Oil cooler, engine From the oil pump, the lubricating oil flows via passages in the block to the oil cooler located inside the front side cover on the right-hand side of the block. The oil cooler is a plate heat exchanger. All the oil flows through the cooler where it is cooled by the cool- ant from the cooling system.
Page 193: Oil Cooler View Se 010009
Ch 1 Engine page Oil cooler view Se 010009 1. Oil cooler 2. O-ring 3. O-ring 4. Flange bolt 5. Oil cooler cover 6. Core plug 7. Cover 8. Gasket 9. Bolt 10. Piston 11. Spring 12. Plug 13. Gasket 14.
Page 194: Renewing Seals And Leakage Testing
Engine Ch 1 page Renewing seals and leakage testing 1. Remove the side cover and oil cooler from the block. Figure 295 2. Remove the 4 bolts securing the oil cooler to the side cover. Figure 296 3. Remove the oil cooler. 4.
Page 195: Oil Filter
Ch 1 Engine page Oil filter From the oil cooler, the oil passes through a large-capacity full- flow filter of paper. This filter also cleans the oil to the turbocharger. The oil filter has an overflow valve which opens if the filter be- comes clogged.
Page 196: Centrifugal Oil Cleaner
Engine Ch 1 page Centrifugal oil cleaner Some of the oil passes from the main passage in the oil cooler cover to the centrifugal cleaner and then, after cleaning, flows back to the sump. Surplus oil is drained back to the sump via an overflow valve.
Page 197: Dismantling And Assembly
Ch 1 Engine page Dismantling and assembly - During routine cleaning of the oil cleaner, there should be a certain amount of dirt deposits in the rotor bowl. - If this is not the case, it indicates that the rotor is not spinning.
Page 198 Engine Ch 1 page 6. Grasp the rotor bowl and tap lightly with your hand or carefully use a screwdriver between the rotor bowl and the strainer so that the rotor bowl comes loose from the rotor. NOTE Never strike on the rotor directly as this may damage its bearings.
Page 199 Ch 1 Engine page 12. Position the O-ring in the lid. Renew the O-ring if it is at all damaged. 13. Assemble the parts and tighten the rotor nut by hand. 14. When tighten the rotor axle (point 15) its neccesarry to Figure 308 modified the Socket spanner 8023 with to weld nut M20 without threads,...
Page 200 Engine Ch 1 page 14. Make sure the shaft is not loose. If it is, it can be locked using screw locking compound. First clean thoroughly using a suitable solvent. 15. Tighten the rotor shaft using socket 8023. Tightening torque 34 Nm. 16.
Page 201: Oil Mist Separator
Ch 1 Engine page Oil mist separator General A certain amount of oil is always found in the crankcase gases, and this is normal. The amount of oil mist in- creases with the engine’s operating time. The closed crankcase ventilation system is very sensitive to changes in the flow of crankcase gases in the engine.
Page 202 Engine Ch 1 page Componenet Cause Affects The vacuum in the engine increases, but this does not Air filter Blocked filter result in increased crankcase gases. Increased flow of crankcase gases, which also leads to Internal exhaust leakage in Turbocharger, exhaust brake increased amounts of oil turbocharger.
Page 203: Crankcase Pressure Measurement
Ch 1 Engine page NOTE The vehicle’s operating profile and area of usage also affect the crankcase gases and oil mist in the engine. Operating profiles which affect this include crane operation, exhaust braking, accel- eration, and rapid throttle actuation. Crankcase pressure measurement The measurement should be carried out with a laden vehicle.
Page 204: Oil Mist Separator Exploded View
Engine Ch 1 page Oil mist separator exploded view The oil mist separator is driven by oil from the lubrication system. The oil flows into the oil mist separator and is sprayed onto the turbine located on the rotor shaft. The oil then flows out and back to the oil sump. The rotor consists of a number of tapered plastic plates which are located on top of one another.
Page 205: Oil Mist Separator Disassemble
Ch 1 Engine page Oil mist separator disassemble Remove the oil mist separator from the engine before it is dismantled. If the engine has an exhaust brake: Remove the exhaust pipe between the exhaust brake and silencer. Undo the V-clamp between the turbocharg er and exhaust brake.
Page 206 Engine Ch 1 page Oil mist separator housing (different version for closed crankcase ventilation) O-ring Nipple Heat shield Screw Diaphragm (not used on oil mist separator for closed crankcase ventilation) Diaphragm spring (not used on oil mist separator for closed crankcase ventilation) Cover (different version for closed crankcase ventilation)
Page 207: Check - Rotational Speed On Oil Mist Separator
Ch 1 Engine page Check - Rotational speed on oil mist separator An angled ABS sensor should be used to measure the rotational speed on the oil mist separator. Cut the electrical cables and fit 2 switches suitable for a multimeter which can measure Hz, see figure 316 Cold engine at idling speed, oil temperature of 20–50°C 120 +/-50 Hz...
Page 208: Alternator 100 A
Engine Ch 1 page Alternator 100 A Check CAUTION Make sure that you never run an alternator without the batteries connected! This may cause the rectifiers and/or charge regula- tor to be overloaded and damaged. NOTE To obtain a correct result, the alternator should be kept at a temperature of 20-25°C.
Page 209: Output Test
Ch 1 Engine page Output test 1. Connect an ammeter and a voltmeter to the batteries as illus- trated. Figure 319 Connection to batteries 2. Start the engine and run it at idling speed for a few minutes. Then note how much current is supplied from the alternator to the batteries.
Page 210 Engine Ch 1 page Connection to central electric unit 4. Hold the engine speed at 500 rpm and apply loads to the system by using the vehicle’s current consumers in accordance with the test report, column Check value. See below for examples of current consumers. Add the current you read at the batteries to the sum of the loads you are applying.
Page 211 Ch 1 Engine page Length of brushes Check that the length of the carbon brushes does not fall below the permitted length, see specification. Slip rings/Rotor resistance/Overcharging The charge regulator must be removed in order to check the slip rings. 1.
Page 212: Renewal - Bearing And Carbon Brushes
Engine Ch 1 page Renewal - Bearing and carbon brushes Specification Bosch 100 A Designation NCB2 28V 40/100A Output power at 6000 rpm 2800 W Resistance in rotor 8.5 ohm +/- 5% Brush length >1 mm Engine speed (rpm): Bosh 100A 1500 Max alternator current at an alternator temperature of 20-25 °C 1.
Page 213 Ch 1 Engine page 3. Remove the 4 screws which hold the alternator together Figure 325 4. Separate the alternator. The stator winding should remain in the rear housing. 5. Remove the rotor from the rear housing as follows: Refit the Figure 326 nut on the rotor shaft.
Page 214 Engine Ch 1 page 7. Press on the new bearing. Figure 329 8. Remove the screws and the washer securing the bearing in the front housing. Figure 330 9. Put a sleeve on the bearing and tap out the old bearing from the front housing.
Page 215 Ch 1 Engine page 11. Assembly: Fit the rotor in the rear housing. Remember to fit the spacing washer between the rotor and bearing in the front housing. Fit the front housing. Important! Check that the marks on the housings are aligned. 12.
Page 216: Oil Pump, Brake Cooling Circulate (Da40)
Engine Ch 1 page Oil pump, brake cooling circulate (DA40) Exploded view Pump housing Bolt, 4 off Washer, 4 off O-ring, 2 off Support ring, 2 off Plug O-ring Compression spring Control valve Pressure plate Rotor housing Rotor Vanes Wear plat15e...
Page 217: Disassemble And Overhaul The Oil Pump
Ch 1 Engine page Disassemble and overhaul the oil pump Brake oil pump is located on the engine’s fly- wheel house on the left. Lift the cab and secure with safety device. Drain the oil from the steering system. Place a receptacle under the fluid reservoir.
Page 218 Engine Ch 1 page 4. Remove the plug 6, compression spring 8 and control valve 9. NOTE The plug is spring loaded and might fly off. 5. Remove the bolts 2 holding together the pump housing and end plate. Remove the end plate. Figure 338 6.
Page 219: Checking And Renewing Parts
Ch 1 Engine page Checking and renewing parts Clean and check the following parts: Half shaft 22. Especially check the sealing surface of the sealing ring 20 and the bearing surface of the slide bearing. Slide bearing in end plate. Plunger 9 in the control valve.
Page 220: Oil Circulate Pump Assemble
Engine Ch 1 page Oil circulate pump assemble. 1. Lubricate the component parts with automatic transmission fluid. 2. Turn the sealing ring as illustrated. Figure 344 532340 3. Press on the sealing ring using drift 99 255 and shank 98 450. 532339 4.
Page 221 Ch 1 Engine page 11. Fit the pressure plate 10 with oil channel C facing the rotor housing. Figure 348 12. Fit new O-rings 4 and oil channel support rings in the pump housing. 13. Assemble the housing and the end plate. Make sure that the oil channels and the O-rings are lined up.
Page 222 Engine Ch 1 page 14. Renew the O-ring 7 on the hexagonal plug. Fit the valve insert and spring and screw in the plug. NOTE Make sure the control valve is turned as illustrated. Important! The shaft end and the gear must be degreased and free of oil and grease before fitting.
Page 223: Renewing The Gasket
Ch 1 Engine page Renewing the gasket Important ! Use only Loctite 406 when fitting the gasket. Loctite 406 does not contain any solvents that will damage the gasket NOTE Cleanliness when fitting the gasket is essential for the flange to be tight. Keep the surfaces around and on the flange clean and free from dirt.
Page 224: Cooling Fan
Ch 1 page Cooling fan The fan is driven by the hydraulic system and is moved to the hydraulic chapter. Look in the Hydraulic chapter 5. View of the radiator system DA40 Water cooler Air cooler Front brake condenser oil cooler...
Page 225: Cooling System
Ch 1 Engine page Cooling system Principal view of the cooling system To the From the cab heater. heater. LHS. Figure 356 SHOP MANUAL...
Page 226: Circulation
Engine Ch 1 page Circulation From the pump, the coolant is carried into the cyl¬inder block’s longitudinal distribution ducting and then through holes in the cylinder block, washes round the cylinder liners and flows up to the cylinder heads. The coolant is also forced directly up into the cyl¬inder heads from the distribution ducting via pas-sages which leads to the injectors and exhaust valves.
Page 227: Coolant
Ch 1 Engine page Coolant NOTE Coolant additives must be as follows: • An antifreeze content of minimum 35 and maximum 60 percent by volume when there is a risk of freezing Coolant, Resistance to Cold The following example shows coolant properties with 30 percent by volume of antifreeze: •...
Page 228: Checking Coolant Level
Engine Ch 1 page Checking Coolant Level WARNING Never open the coolant filler cap when the engine is hot. Hot coolant and steam may spray out and cause burns. If the cap has to be opened do it slowly and carefully to release the pres- sure before removing the cap.
Page 229: Checking The Antifreeze Level
Ch 1 Engine page Checking the Antifreeze Level NOTE Use only pure fresh water that is free from particles, sludge and other impurities 1. Pour a small amount of coolant into a container and check that the coolant is pure and clear. 2.
Page 230 Engine Ch 1 page • If ice forms in the coolant, there are disruptions initially, but there is no immediate risk of damage. The engine should not be subjected to heavy loads when ice starts to form. NOTE Mix the coolant as specified under the section Coolant. 1.
Page 231: Cleaning The Cooling System
Ch 1 Engine page Cleaning the Cooling System NOTE Clean the cooling system more often if necessary. NOTE Do not use caustic soda or other alkaline cleaning agent as this could damage the aluminium. Cleaning the Radiator and Charge Air cooler (Outer) 1.
Page 232: Disassemble The Cooling Unit
Engine Ch 1 page Disassemble the cooling unit 1. Drain the coolant and transmission oil. First, remove both cover on the underside front frame left and right side. On left side of the transmission cooler unscrew the plug (Nv 13 mm) and drain the coolant from the engine and radiator.
Page 233 Ch 1 Engine page 6. Disassemble the Air Condition hose clamp and the condenser at the front from cooling pack. Place the condenser and the dryer filter on the left side of the engine. NOTE Do not disassemble the Air Condition hoses from the con- denser filter or the compressor.
Page 234: Thermostat And Thermostat Housing
Engine Ch 1 page Thermostat and thermostat housing The engine have a double thermostat. When a double thermostat are used they have the same open- ing temperature as standard. The thermostats use wax as the temperature-sensi tive medium. At coolant temperatures below the opening tem perature of the thermostats, nearly all the coolant circulates between the engine’s coolant passages and the coolant pump without passing through the radiator.
Page 235: Thermostat
Ch 1 Engine page Thermostat Removing 1. Remove the expansion tank filler cap. Drain a sufficient amount of coolant from the system. 2. Remove the hose from the thermostat housing cover. Detach the thermostat housing cover and remove the thermostat (double thermostat). Figure 369 Fitting 1.
Page 236: Coolant Pump
Engine Ch 1 page Coolant pump The coolant pump is located at the front side of the front cover on the right-hand side of the engine. The coolant pump is driven by a multigroove belt directly from the crankshaft damper. The pump is of centrifugal type and consists of a spiral shaped pump housing with an impeller directly mounted on the driveshaft.
Page 237 Ch 1 Engine page Removing 1. Drain the cooling system through the drain taps in the block and in the pipe from the outlet on the radiator. 2. Remove any protection meshes and fan ring with sealing ring to gain access to the fan. 3.
Page 238 Engine Ch 1 page Changing the pulley 1. Remove the pulley using puller 501348 and drift 501349. 2. Press the pulley on until it is flush with the shaft end face. The pulley is removed Figure 373 The pulley is pressed on Changing the sealing ring Figure 374 If coolant has leaked out inside the housing...
Page 239 Ch 1 Engine page 4. Prise off the seal using two screwdrivers and separator plates. NOTE Do not damage the pump housing gasket surface. 5. Apply sealing agent (501350) to the inside and outside (brass sleeve) of the sealing ring. Figure 376 Make sure that no sealing agent gets onto The seal ring is removed...
Page 240: External Cleaning
Engine Ch 1 page External cleaning Radiator Check that the radiator is not clogged on the air side and that the cooling fins are not damaged. Carefully scrape the deposit off the radiator’s cooling fins. If necessary, a paraffin-based engine cleaner can be used. Bent fins can be straightened using a wire brush, for example, and exercising care.
Page 241: Technical Data Dc13 With Xpi
Ch 1 Engine page Technical data DC13 with XPI General data Number of cylinders and r t s r t s 12.7/775.0 Displacement (dm Engine direction of rotation, t a t Valve clearances, cold engine l d i – - l l Fuel Diesel Weight, without coolant an...
Page 242 Engine Ch 1 page Injection system sure Injection) t l i l i f t l i l i f Cooling system 16/4.2 /US gallons) Volume, excluding radiator (dm ° ( ° / – – , t a ° ( °...
Page 243: Technical Data Dc9 With Xpi
Ch 1 Engine page Technical data DC9 with XPI General data General data Number of cylinders and . 5 / r t s . 5 / 9.3/567.5 Displacement (dm Compression ratio 16:1 Engine direction of rotation, c i t Valve clearances, cold engine l t u Low idling speed (rpm) - l l...
Page 244 Engine Ch 1 page Injection system sure Injection) t l i l i f t l i l i f Cooling system 15/4.0 Volume, excluding radiator (dm /US gallons) ° ( ° / – – , t a ° ( °...
Page 245: Technical Data Dc13 With Pde
Ch 1 Engine page Technical data DC13 with PDE General data General data Number of cylinders and , 5 / , 5 / 12,7/775,0 Displacement (dm Engine direction of rotation, c i t Valve clearances, cold engine: , 0 / l t u , 0 / l d i...
Page 246 Engine Ch 1 page Injection system j n i t l i l i f l i f r e t l i f Cooling system 16/4,2 Volume, excluding radiator (dm /US gallons) C ° ° / – 0 1 – , t a C °...
Page 247: Technical Data Dc9 With Pde
Ch 1 Engine page Technical data DC9 with PDE General data General data Number of cylinders and r t s r t s 9.3/567.5 Displacement (dm Engine direction of rotation, t a t Valve clearances, cold engine Low idling speed (rpm) - l l Fuel Diesel...
Page 248 Engine Ch 1 page Injection system j n i t l i l i f l i f r e t l i f Cooling system 15/4.0 Volume, excluding radiator (dm /US gallons) C ° ° / – 0 1 – , t a C °...
Page 249 Ch 1 Engine page SHOP MANUAL...
Page 250: Troubleshooting Ecom / Canbus
Engine Ch 1 page Troubleshooting ECOM / Canbus To do: The troubleshooting manual is included in the machinery computer system. Please connect Scania softvare system, Troubleshooting, -basic info. Troubleshooting in electronic control systems requires access to a multimeter and/or PC and ECOM.
Page 251: Troubleshooting Fuel System
Ch 1 Engine page Troubleshooting fuel system Troubleshooting Guide The fuel system is very sensitive to dirt. It is therefore very important that everything is as clean as possible when work is carried out on the fuel system. Using the Troubleshooting Guide Start troubleshooting by looking at troubleshooting tree S-a.
Page 252 Engine Ch 1 page S-b Start up check S-b Start-up check S-b Check that there is fuel in the tank and that it does not contain water. There is fuel and There is no fuel or no water in the there is water in the tank tank...
Page 253 Ch 1 Engine page L-a Low pressure check L-a Low pressure check L-a Check the feed pump as described in L1. No fuel Fuel comes The problem may be comes out out ... between the fuel tank and during the feed pump. Renew the both The hand pump may be faulty.
Page 254 Engine Ch 1 page H-a High pressure check when the engine will start H-a High pressure check when the engine will start H-a The engine will start. Check the safety valve as The cause may be the described in H3. safety valve.
Page 255 Ch 1 Engine page H-a High pressure check when the engine will not start. H-a High pressure check when the engine will not start H-b The engine will not start. Check the fuel pressure in the accumulator (T111) with SDP3 and run the starter motor. Can build up Cannot build up and maintain...
Page 256 Engine Ch 1 page Descriptions, Low pressure check L1 – Low pressure check 1. Open the test connection on the high pressure pump. 2. Pump using the hand pump. Check that fuel comes out of the test connection. 3. Turn the engine over using the starter motor. Check that fuel comes out of the test connection. 4.
Page 257 Ch 1 Engine page NOTE Low feed pump pressure may be caused by a defective feed pump, or may be a symptom of a high pressure pump with a defective cylinder head. Note: Make sure that the battery level is high enough to run the engine at 90 rpm with the starter motor.
Page 258 Engine Ch 1 page H2 – Checking the return fuel pressure 1. Connect pressure gauge 99 362 to the test connection on the return fuel manifold and open the test connection. 2. Start the engine. Read the pressure with the engine idling. The pressure should be below 0.8 bar. If the pressure exceeds 0.8 bar the overflow valve on the return fuel manifold should be cleaned and visually inspected.
Page 259 Ch 1 Engine page H5 – Verification of a faulty injector 1. Remove the high pressure pipe to the injector which has been identified in H1. 2. Plug the outlet of the identified injector at the outlet port on the fuel accumulator using tool 99 019. If the out- let port of cylinder 1 has to be plugged, see the instructions in TI 03-08 01 28.
Page 260 After renewing an injector with internal leakage, the engine oil must be changed and the oil filter renewed. If there is internal leakage, soot quickly builds up in the engine oil. (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Tools for test pressurising the fuel system...
Page 261 Ch 1 Engine page Descriptions, High pressure check Checking for internal leaks Start the engine. Start the test "Checking for internal leaks " in SDP3. Switch off the engine. Read the pressure remaining in the accumulator using SDP3. There should be some pressure remaining.
Page 262 Engine Ch 1 page H3 - Checking the safety valve for leaks WARNING The accumulator may be under high pressure. Re- duce the pressure using SDP3 before starting work. Wear protective goggles. There is a risk of burn injuries when the safety valve is open. Remove the return pipe 2 from the safety valve 1 to the return fuel manifold 5.
Page 263 Ch 1 Engine page H4 - Checking injectors using SDP3 Check cylinder balancing at idling speed using SDP3. Note if any cylinder deviates. Perform a cylinder output test using SDP3. Note which cylinder deviates from the others by having a higher output.
Page 264 After renewing an injector with internal leakage, the engine oil must be changed and the oil filter renewed. If there is internal leakage, soot quickly builds up in the engine oil. (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Tools for test pressurising the fuel system...
Page 265 Ch 1 Engine page H9 - Renewing the cylinder head on the high pressure pump WARNING The fuel system has a very high fuel pressure of up to 3,000 bar. The fuel system must be depressurised before any work is started.
Page 266 Engine Ch 1 page Tightening torques Cylinder head bolts 68 Nm High pressure pump, banjo unions 55 Nm High pressure pipe 38 Nm Bracket for high pressure pipe 22 Nm Clean around the fuel system. Depressurise the fuel system. Use SDP3 to minimise the pressure.
Page 267 Ch 1 Engine page Clean the pump surface that faces against the cylinder head. Check that the guide pins under the roller tappets are straight and that the roller tappets are correctly positioned so that they go down completely in their seats; see illustration (figure 386). Screw the cylinder head bolts in alternately. Tightening torque 68 Nm. Figure 390 Fit the pipes (3, 4 and 5).
Page 268 Engine Ch 1 page SHOP MANUAL...
Page 269: Troubleshooting Manual
Ch 1 Engine page Troubleshooting Manual The trouble shooting schedule is intended as a guide and source of ideas for practical trou- ble shooting carried out on the spot by experienced mechanics. The schedule contains the causes of faults which they the Scania have encountered over the years and it will be ex- panded with new causes of faults as they occur and as we gather knowledge about them.
Page 270: Troubleshooting T4I Engines With High Nox Values
Engine Ch 1 page Troubleshooting T4i engines with high NOx values Sulphur poisoning If this is the root cause, the fault code is often generated alone, without other related fault codes in EMS S8 or in EEC3. Sulphur poisoning is not visible, but reduces the conversion rate of the catalytic converter and thereby leads to increased NOx values.
Page 271: Work Description
If the problem recurs often, a fuel sample must be taken to ensure that the diesel is of sufficiently high quality. For DA40: Devalidate the fault code with SPD3 and put the engine under heavy load for one hour to cause the exhaust gas tempera- ture to rise to maximum 450°C.
Page 272: The Scr System Is Unable To Build Pressure
Engine Ch 1 page The SCR system is unable to build pressure If this is the reason for the NOx fault code, then fault code DT- C20E8, required reductant pressure cannot be buildt and main- tained, will also be found in control unit EEC3. To correct this prob- lem: carry out a system test in SDP3 and use the troubleshooting guide below.
Page 273: Blocked Prefilter In The Doser
Ch 1 Engine page 3. Blocked prefilter in the doser Cause Grease or dirt has blocked the filter. Solution Clean or renew the prefilter that sits in the doser intake. Never use grease to fit hoses in the SCR system. Only soapy water is premit- ted to facilitate fitting of hoses.
Page 274: White Smoke
Engine Ch 1 page White smoke E ect Cause Trouble shooting Action - If possible: reduce engine speed or put the The white smoke starts engine under load Incompletely burnt to turn blue and disap - - Install a white smoke Cold engine fuel pears when the engine is...
Page 275: Black Smoke On Starting
Ch 1 Engine page White smoke, water vapour E ect Cause Trouble shooting Action “Adjusted” injection Check the lead seal - Test in test bench pump, attempt to boost Injection timing too late Inlet valve does not open properly. Valve adjust- ment disturbed Disconnect one delivery pi p e at a time and listen for changes in the engine sound.
Page 276: Blue Smoke
Engine Ch 1 page Blue smoke E ect Cause Trouble shooting Action Oil coating past piston rings Check for oil in the Oil leakage in turbo- intake manifold after the charger turbocharger Damaged piston cooling - Change damaged nozzles nozzles Petrol in diesel oil Fuel in the oil E ect...
Page 277: Oil In Coolant
Ch 1 Engine page Oil in coolant E ect Cause Trouble shooting Action Test pressurize the oil cooler Oil cooler leaks when Note: classed oil cooler, test pressurized: 10 bar oil engine is running on the oil side, 0.5 bar air on the water side, immersed in water 25 - 27 °...
Page 278: Low Oil Pressure
Engine Ch 1 page Low oil pressure E ect Cause Trouble shooting Action Take a reading of the oil pressure on warmed-up engine using a mechanical pressure gauge directly on the engine: Defective sensor/instru - Minimum 1 bar at 800 r/min. ment Maximum 6 bar >...
Page 279 Seizing in camshaft warning lamp will come bearings Ch 1 Engine page The engine throws out oil through the crank - case ventilation Piston cooling nozzle has come loose Oil pressure can be Seizing in the bearing on increased ~ 1 bar when engine power take-o the power take-o is ED140 (14-series engine)
Page 280: High Oil Pressure (Engine Warmed Up)
Engine Ch 1 page High oil pressure (engine warmed up) E ect Cause Trouble shooting Action Take a reading of the oil pressure on the warmed- up engine using a mechanical pressure gauge directly on the engine: Defective sensor/instru- Minimum 1 bar at 800 r/min. ment Maximum 6 bar >...
Page 281: Vibration, No Driven Components Engaged
Ch 1 Engine page Vibration, no driven components engaged E ect Cause Trouble shooting Action Wrong injection timing Broken delivery valve Disconnect one delivery pipe at a time and listen spring for changes in the engine sound. WARNING! Be careful when disconnecting the delivery Individual injectors not operating pipes as the pressure is extremely high and...
Page 282: Vibration When The Clutch Or Reverse Gear Is Engaged
Engine Ch 1 page Vibration when the clutch or reverse gear is engaged E ect Cause Trouble shooting Action Imbalance in driven unit - Balance the unit Imbalance in clutch Inadequate alignment - Carry out alignment between engine and Check alignment more accurately driven unit Unsuitable suspension...
Page 283: Engine Speed Hunting - Single-Speed Engines With Rq Governor
Ch 1 Engine page Engine speed hunting - single-speed engines with RQ governor E ect Cause Trouble shooting Action Play in exible cou- Apply a light load, at a - Change the rubber ele - pling between engine load of about 20 kW the ment/check the cou - and alternator (worn hunting disappears...
Page 284: Delivery Pipe Fractures
Engine Ch 1 page Delivery pipe fractures E ect Cause Trouble shooting Action No clamping Carelessly handled delivery pipe Internal cavitation in Fit 0-hole delivery delivery pipe valves for single-speed Note: Single-pipe sys - operation tem is not permitted External corrosion on cylinder liner E ect Cause Trouble shooting...
Page 285: Engine Difficult To Start
Ch 1 Engine page Engine difficult to start E ect Cause Trouble shooting Action Leakage in suction pipe The highest fuel level in the tank is lower than the feed pump. A longer - Install a ”daily supply standstill (days) the fuel Air in fuel system tank”...
Page 286: Fluid Stroke
Engine Ch 1 page Fluid stroke E ect Cause Trouble shooting Action Test pressure (air Leaky charge air cooler 0.5 bar, liquid 4 bar) Starter motor not Leaky cylinder head powerful enough to gasket pull the piston over If the fault is hard to trace: the compression Change all cylinder heads for exchange cylinder stroke (if the engine...
Page 287: Knocking/Noise
Ch 1 Engine page Knocking/noise E ect Cause Trouble shooting Action Timing gears incor- rectly meshed Exhaust valves close Check the valve timing, The crankshaft gear has too late and strike see “Service data, come loose the piston crowns engines” Valve mechanism not operating Disturbances in the sup -...
Page 288: High Oil Consumption
Engine Ch 1 page High oil consumption E ect Cause Trouble shooting Action Piston ring seizure Combustion tempera - Piston seizure ture too high? Cylinder seizure Liner wear Unclean intake air? Carbon polishing (in patches) Poor grade of oil? Piston ring wear Piston rings stuck Tapered piston rings t - ted wrong way...
Page 289: High Fuel Consumption
Ch 1 Engine page High fuel consumption E ect Cause Trouble shooting Action Faulty injector Low charge air pressure Check in a pump test bench that the amount Adjusted injection pump (Q-mm /stroke) corre- sponds to speci cation Manner of driving, oper - ating/load conditions Low compression E ect...
Page 290: Low Engine Output
Engine Ch 1 page Low engine output E ect Cause Trouble shooting Action Check the feed pump and over ow valve for leak - age as described in the workshop manual Low fuel supply pres- Look for leakage in the suction pipe between tank sure (below 0.3 bar) and feed pump Clogged fuel lter/Para n precipitation in fuel...
Page 291: Hot Engine
Ch 1 Engine page Hot engine E ect Cause Trouble shooting Action Check that sensor and instrument suit each other Defective sensor/instru - (120 and 150 ° C) ment Check with a separate instrument Low coolant level Clogged seawater lter - Clean the cooling sys- Clogged freshwater/sea - tem internally and...
Page 292: Cold Engine
Engine Ch 1 page Cold engine E ect Cause Trouble shooting Action Check that sensor and instrument match each other Defective sensor/instru - (120 and 150 ° C) ment Check with a separate instrument Thermostat jammed in Check operation of ther- open position mostat - Fit a thermostat fan...
Page 293: High Oil Temperature
Ch 1 Engine page Polluted coolant E ect Cause Trouble shooting Action Incorrect mixture or type - Clean the cooling sys- of glycol and/or corro - tem and ll it with Boiler scale on sion inhibitor coolant as described in engine heater Anti-freeze with phos - the maintenance...
Page 294: Low Charge Air Pressure
Engine Ch 1 page Low charge air pressure E ect Cause Trouble shooting Action Dirty/damaged turbine/ compressor wheel in tur- - Check/clean bocharger Leakage between turbo- charger and cylinder - Check/change gaskets head Bearing seizure in turbo- - Recondition/change Check bearing play charger turbocharger Check the vacuum...
Page 295: High System Voltage
Ch 1 Engine page High system voltage E ect Cause Trouble shooting Action (Normal charging Voltage regulator fault voltage: Battery charger fault 27 - 28 V) External oil leakage E ect Cause Trouble shooting Action Check “blow-by” in crankcase Crankcase pressure too Correct value for new engine: 0 - +10 mm wc high...
Page 296: External Coolant Leakage
Engine Ch 1 page External coolant leakage E ect Cause Trouble shooting Action Leakage in cylinder liner seal - Change to hoses of bet - Cold leakage ter quality (preferably silicone hoses) Defective cylinder head gasket Check at the water pump Water pump leakage housing’s telltale hole Leakage at charge air...
Page 297: Compressed Air System
Ch 1 Engine page Compressed air system E ect Cause Trouble shooting Action Too much carbon in compressor cylinder Empty the compressed head or discharge air tank, retain the air in piping connected compressed air components. - If charging time Exhaust valves leak Run the engine at exceeds speci ed val -...
Page 298 Engine Ch 1 page Note SHOP MANUAL...
Page 299 Ch 1 Engine page Note SHOP MANUAL...
Page 300 Engine Ch 1 page SHOP MANUAL...
Page 301 TRANSMISSION Ch 2 page Chapter 2 Transmission SHOP MANUAL...
Page 302 TRANSMISSION Ch 2 page SHOP MANUAL...
Page 303 TRANSMISSION Ch 2 page Chapter 2 Transmission Index GENERAL ........................ 5 Structure of the Repair Manual ....................6 Denomination of standard dimensions ..................7 Conversion table ........................7 Torque limits for screws..................8 Table ............................8 Labeling of type plate .................... 9 Information on spare parts ordering ..................9 Configuration of transmission ................
Page 304 TRANSMISSION Ch 2 page SHOP MANUAL...
Page 305: General
TRANSMISSION Ch 2 page GENERAL The Service Manual covers all works required for dismantling and the pertaining installation. When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-like manner. The transmission should only be disassembled for renewing damaged parts. Covers and housing parts installed with seals must be loosened by slight blows with a plastic mallet after screws and nuts have been removed.
Page 306: Structure Of The Repair Manual
See this chapter, 2.0 Important information on industrial safety Generally, the persons repairing Doosan product-sets are responsible on their own for the industrial safety. The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to per- sons and to the product during maintenance and repair works.
Page 307: Denomination Of Standard Dimensions
TRANSMISSION Ch 2 page Denomination of standard dimensions Note: linear density in kg/m; areal density in t/m2 Unit Character Conversion Note Mass kg (Kilogramm) Force N (Newton) 1 kp = 9,81 N Work J (Joule) 0,102 kpm = 1J = 1 Nm 1 PS = 0,7355 KW Power KW (Kilowatt)
Page 308: Torque Limits For Screws
TRANSMISSION Ch 2 page Torque limits for screws. Table TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF STANDARDS 148 Friction value: µ total= 0,12 for screws and nuts without after treatment as well as phosphatized nuts. Tightening by hand! Torque limits, if not especially indicated, can be taken from the following list: Metric ISO Standard thread Metric ISO Fine thread Size...
Page 309: Labeling Of Type Plate
TRANSMISSION Ch 2 page Labeling of type plate Transmission type Transmission number ZF parts list number Overall transmission ratio Oil filling (oil specifications) ZF list of lubricants Oil fill quantity Customer number Figure 1 Information on spare parts ordering The following information is required when ordering genuine ZF spare parts: 1 = Transmission type You will find these informations on the type plate.
Page 310: Configuration Of Transmission
TRANSMISSION Ch 2 page Configuration of transmission Transmission schematics Transmission schematics and gear schematics Legend: 2 = Engine - dependent PTO 3 = Output flange (rear axle) 4 = Emergency steering pump (option) 5 = Output flanges of LKV axle insert (front axle) 6 = Input flange Legend of letters: Figure 2...
Page 311: Measuring Points And Connections
TRANSMISSION Ch 2 page Measuring points and connections Table Take measurements when the transmission has reached operating temperature (approx. 80 - 90 °C) N° Item designation Connect Measuring points for pressure oil and temperatue Clutch - forward 16+2 bar M12X1.5 Clutch - reverse 16+2 bar M12X1.5...
Page 312: Clutch Calibration
TRANSMISSION Ch 2 page Clutch calibration Start the engine and run it on 800 - 1000 RPM. Activate parking brake and make sure the vehicle is not moving during calibration. Transmission oil temperature must be 75 degrees celsius or above. Follow instruction on display as shown below.
Page 313 TRANSMISSION Ch 2 page 3. Select transmission clutch calibration (AEB) 4. Follow the procedure described on the display screen Figure 7 When the message “CLUTCH CALIBRATION FINISHED SUCCSESSFULLY!” appears, cali- bration process i completed. Restart engine. Figure 8 SHOP MANUAL...
Page 314: Installation Sheet
TRANSMISSION Ch 2 page Installation sheet Figure 9 Detail “Y” Figure 10 SHOP MANUAL...
Page 315 TRANSMISSION Ch 2 page Specjal tools for disassembly and reassembly ZF - Ergopower L II Chapter/Fig. Cons. Figure Designation Order No. Assembly truck cpl. with tilting device MX504213 Clamping device MX531196 4/23 Adjusting screws MX504189 4/24 Socket wrench TX 27 4/35 4/33 Adjusting screws...
Page 316: Specjal Tools For Disassembly And Reassembly
TRANSMISSION Ch 2 page Specjal tools for disassembly and reassembly ZF - Ergopower L II Cons. Figure Designation Chapter/Fig. Order No. 4/34 Socket wrench TX 40 MX504254 Driver tool MX531197 6/10 Driver tool MX531198 Driver tool MX531199 Power wrench 5/10 MX533483 SHOP MANUAL...
Page 317 TRANSMISSION Ch 2 page Cons. Figure Designation Chapter/Fig. Order No. Eyebolt MX531201 SHOP MANUAL...
Page 318 TRANSMISSION Ch 2 page Commercial tools for disassembly and reassembly Cons. Figure Designation Qty. Chapter/Fig Order no. Magnetic stand Universal Dial indicator Universal Gauge blocks 70 mm Universal 100 mm Digital depth gauge 200 mm Universal 300 mm Digital caliper gauge 150 mm Universal SHOP MANUAL...
Page 319: Commercial Tools For Disassembly And Reassembly
TRANSMISSION Ch 2 page Commercial tools for disassembly and reassembly Cons. Figure Designation Qty. Chapter/Fig Order no. Torque wrench 0.6 -6.0 Nm 1.0 – 12 Nm 3.0 – 23 Nm Universal 5.0 – 45 Nm 10 – 90 Nm 80 – 400 Nm 140 –...
Page 320 TRANSMISSION Ch 2 page Commercial tools for disassembly and reassembly Cons. Figure Designation Qty. Chapter/Fig Order no. Lifting chain Universal Pry bar Universal Striker Universal Set of internal pliers I1-I2-I3-I4 Universal Set of internal pliers I11-I21-I31-I41 90° Universal SHOP MANUAL...
Page 321 TRANSMISSION Ch 2 page Commercial tools for disassembly and reassembly Cons. Figure Designation Qty. Chapter/Fig Order no. Set of external pliers A1-A2-A3-A4 Universal Set of external pliers A01-A02-A03-A04 90° Universal Two-armed puller Jaw width 80 mm Throat depth 100 mm Jaw width 120 mm Throat depth...
Page 322 TRANSMISSION Ch 2 page Commercial tools for disassembly and reassembly Cons. Figure Designation Qty. Chapter/Fig Order no. Three armed puller Jaw width 85 mm Throat depth 65 mm Jaw width 130 mm Throat depth 105 mm Jaw width 230 mm Throat depth 150 mm Universal...
Page 323: Removal Of Transmission, Disass'y
TRANSMISSION Ch 2 page Removal of transmission, disass’y NOTE Place the dump truck on level ground and apply parking brake Start with the propeller shaft in the articulation hinge. For best working, start the engine and turn the machine to full right direction. Release articulation propeller shaft from the transmission output flange.
Page 324 TRANSMISSION Ch 2 page Remove the clamp of the hinge bearing lubrication from the body heat- ing bracket. Figure 14 Disassemble the body heating (if it is assembled on machine) 04 screws in the body heating bracket. Remove 04 screws in pipe clamps attached to exhaust pipe.
Page 325 TRANSMISSION Ch 2 page Disconnect the T/M power off / rear drive shaft joint (4 screws). Tie the rear drive shaft on the frame (near the hinge point) to keep it suspended Figure 19 Remove the transmission cover (8 screws) and the bottom guard (4 screws) •...
Page 326 TRANSMISSION Ch 2 page Drain both hydraulic v reservoirs, see chapter 7 maintenance - 2000 hour service in the Operating & Maintenance Manual. Main reservoir Emergency steering reservoir (Oil capacity approx. 190-200 l.) NOTE See in the hydraulic chapter about the filling procedure. Figure 24 Draining operation Figure 25...
Page 327 TRANSMISSION Ch 2 page With the handle, pump and raise the cab. When lower the cab, turn the direction valve to the down position and with the handle lower the cab. Figure 28 Disconnect all hydraulic hoses (12 hydraulic hoses) and cabin heating hoses (02 heater hoses) between cabin / transmission and other frame components.
Page 328 TRANSMISSION Ch 2 page At the bottom of the cabin, rear side, remove the black cover. Figure 32 Disconnect the 6 connectors from left to right; (S1, S2, S3, S4, S5, S6) Figure 33 Remove “Out” A/C hose (small fitting) until the wrench toll fits, then remove the “In”...
Page 329 TRANSMISSION Ch 2 page Remove the pins Figure 36 Hang the cabin in the 04 hook points (fig.37) on the top of it and remove the cabin (fig.38) Figure 38 Figure 37 Measure distance between the rear side of T/M and the frame (use this as reference when assembling the new one) Figure 39 SHOP MANUAL...
Page 330: Disassemble The Structure Bar
TRANSMISSION Ch 2 page Release the bracket beam (04 screws – 02 in each side) from the back of the front frame and pull it towards the rear frame, to clear the way while removing the transmission. Cut the plastic clamps that hold the hoses and wires if necessary. Disconnect all the hydraulic hoses from the transmission.
Page 331 TRANSMISSION Ch 2 page Realease all the hydraulic hoses connected to the transmis- sion. Realease all of the wiring on the electrical points. (ground cabel and the electrical connections have to be dis- connected.) Figure 43 Disconnect both of the hoses and the L-nipple from the emergency steering pump from the articulated hinge side. Protect the hydraulic nipple on the pump with plastic plug or similar.
Page 332 TRANSMISSION Ch 2 page Dismount the axle catcher bow. Dismount converter prop. shaft. Front screw: M12x50 ISO4014-10.9 EL Rear screw: ½” UNF x2” NS 965--8.8 Figure 47 Disassemble the front transmission bracket attachment. If shim are assembled, use the shims at the same place when as- semblying.
Page 333 TRANSMISSION Ch 2 page Use 03 chains to hang the T/M on the 03 eye bolts. Figure 51 Check around the transmission that all connections to the front frame equipment not are connected to the transmission. Assemble the lifting device and adjust the chains to keep the transmission in balance.
Page 334: Positioning For Disassembly And Reassembly
TRANSMISSION Ch 2 page Positioning for disassembly and reassembly The adjacent figure shows the 8 EP-Series after it’s re- moval from the vehicle. This Repair Manual describes worksteps which can be per- formed in installed and removed condition. CAUTION Make sure that the transmission is sufficiently supported/se- cured by appropriate fixtures to avoid any accidents! When doing repairs on a transmission which is installed in the ve- hicle, observe the vehicle manufacturer’s safety regulations.
Page 335: Removal And Refitting Various Components
TRANSMISSION Ch 2 page Removal and refitting various components Transmission 1. Eye bolt M20 2. Breather (M10x1) • Tightening torque M = 12 Nm 3. Oil filler plug • M42x2 with O-ring 38x2.5 • Tightening torque M = 145 Nm 4.
Page 336: Removal And Refitting Of Speed Sensor N4-Output
TRANSMISSION Ch 2 page Removal and refitting of speed sensor n4-output Removal: Loosen cylindrical screws (1) and remove cover (2) with seal. Figure 59 Open the locking of plug connection for wiring harness/speed sensor (1) and disconnect the plug. Pull out the xing plate (2). Figure 60 Loosen cylindrical screw (1) and remove speed sensor (2).
Page 337 TRANSMISSION Ch 2 page Insert fixing plate (1) into the transmission housing and lock the speed sensor (2) with the wiring harness plug. Figure 63 Bring seal (1) and cover (2) into contatc positin at the transmission housing. Figure 64 Fix cover with cylindrical screws (1).
Page 338: Removal And Refitting Of Solenoid Valves Of Shifting Block Ii And Temperature Sensors
TRANSMISSION Ch 2 page Removal and refitting of solenoid valves of shifting block II and temperature sensors Removal: Loosen cylindrical screws and remove the cover (1) with seal. Loosen the screw plug (2) with O-ring. Figure 66 Open the lockings of plug connections for wiring harness/ pressure, controllers / temperature sensor (1) and disconnect the plugs.
Page 339: Retting
TRANSMISSION Ch 2 page Loosen the temperature sensors (1 and 2). Figure 70 Retting: Fit the temperature sensors (1 and 2) and close the locking of wiring harness / temperature sensors plug connection. • 1 = temperature sensor -> oil sump •...
Page 340 TRANSMISSION Ch 2 page Secure the clamping plate with cylindrical screws. Tightening torque (M6/8.8x12) MA = 9.5 Close the lockings of wiring harness / temperature sensors plug connections (1). Figure 74 Bring the seal and cover (1) into contact position at the trans- mission housing.
Page 341: Disassembly And Reassembly Of Shifting Block I And Speed Sensors
TRANSMISSION Ch 2 page Disassembly and reassembly of shifting block I and speed sensors Disassembly: Loosen the clip (1), open and separate the lockings of wiring harness (2) (bayonet locking and plug). Loosen the control unit/duct plate bolted connection (3). Figure 77 Remove the ErgoControl II unit (1).
Page 342 TRANSMISSION Ch 2 page Loosen the cylindrical screw (1) and remove the speed sen- sor (2). Figure 81 Open and separate the lockings of speed sensors (1 and 2) and differential lock solenoid valve (3) Loosen the Torx screws (4) and remove xing plate (5) with speed sensors.
Page 343 TRANSMISSION Ch 2 page Remove wiring harness (1). Loosen the cylindrical screw (2) of the dierential lock solenoid valve. Figure 85 Remove the dierential lock solenoid valve (1) with bracket (2). Loosen the duct plate/valve block screw connection (3). Remove the cylindrical screws (4) from the clamping plates. Remove valve block (1) and seal (2).
Page 344 TRANSMISSION Ch 2 page Preload all follow-on slides (see arrow) and remove the stop plates (1). Figure 89 Remove all follow-on slides consisting of: • piston (1) • compression spring (2). Figure 90 Disengage the retaining ring (1). Figure 91 Remove the pressure reducing valve consisting of: •...
Page 345: Reassembly
TRANSMISSION Ch 2 page Reassembly: Shifting block I: 1 = pressure controller with follow-on slide 2 = pressure reducing valve 3 = wiring harness ErgoControl II • A = connection of wiring harness shifting block II • B = connection of control unit (TCU) Figure 93 Insert the pressure reducing valve consisting of: •...
Page 346 TRANSMISSION Ch 2 page Preload all follow-on slides (see arrow) and x them with stop plates (1). Figure 97 Insert all pressure controllers (1) with clamping plates (2) into the valve block and fix them with the cylindrical screw (3) Tightening torque (M6/8.8x12) MA = 9.5 Nm Ensure correct installation position of pressure controllers...
Page 347 TRANSMISSION Ch 2 page Insert the dierential lock solenoid valve (1) with bracket (2) into the valve block and x it with the cylindrical screws (3). Tightening torque (M6/8.8x12) = 9.5 Nm Ensure correct installation position of solenoid valve (plug connection) - see arrow.
Page 348 TRANSMISSION Ch 2 page Fix the speed senor (2) to the fixing plate (3) using the cylidri- cal screw (1) Tightening torque (M6/8.8x12) MA = 9.5 Nm Legend of speed sensor: 2 = speed sensor – n3 secondary step. Figure 105 Bring the speed sensor into contact position with the transmis- sionscrews housing using the fixing plate (1) and fix it with the cylindrical...
Page 349 TRANSMISSION Ch 2 page Fit two adjusting screws and bring duct plate (1) into contact position with the transmission housing. (S) Adjusting screws MX504185 Figure 109 Fix duct plate / transmission housing bolted connection (1) equallywith Torx screws (1). Tightening torque (M8/10.9x35) MA = 23 Nm (S) Socket wrench TX-40 Bring ErgoControl II unit (2) into contact position.
Page 350: Removal And Refitting Of Lkv Axle Insert
TRANSMISSION Ch 2 page Removal and refitting of LKV axle insert Separation of LKV axle insert from transmis- sion: Loosen the hexagon screws. Figure 112 We recommend to loosen the bolted connection with a power wrench. (S) Power wrench Figure 113 Remove the hexagon screws (1).
Page 351: Attachment Of Lkv Axle Insert To Transmission
TRANSMISSION Ch 2 page Remove breather (1) and O-ring (2). Figure 116 Attachment of LKV axle insert to transmission Fit O-ring 180x3 (1) and grease it. Mount breather M10x1 (2). Tightening torque breather MA = 12 Nm Figure 117 Use the lifting tackle to bring the LKV axle insert into contact position with the transmission housing.
Page 352 TRANSMISSION Ch 2 page Fit hexagon screw (1) and fix the breather with clip to the transmission housing using a cylindrical screw. Tightening torque (M30/10.98x150) MA = 1900 Nm Figure 120 We recommend to tighten the hexagon screws with a power wrench. (S) Power wrench Tightening torque (M30/10.98x150) MA = 1900 Nm...
Page 353: Sealing Of Outputs Towards Rear Axle And Lkv Axle Insert
Fit the shaft seal ring 85X120X12 (1) with driver tool, with the sealing lip facing the oil chamber ( see figure 123 ) (S) Driver tool DOOSAN P/N HAVE TO BE CREATED Use of the specied driver tool (S) ensures the exact installation position!
Page 354: Fitting Of Shaft Seal Ring
Fit the shaft seal ring 100X130X12 (1) with driver tool, with the sealing lip facing the oil chamber ( see figure 128). (S) Driver tool DOOSAN P/N HAVE TO BE CREATED Use of the specied driver tool (S) ensures the exact installation position!
Page 355 Before putting the transmission into operation, fill it with oil (For fluid type and specifications, refer to the Figure 131 DOOSAN Operating & Maintenance Manual Chapter 6) / Order No.4662 700 017! Check oil level with dipstick located on hydraulic tank and make sure correct amount is filled.
Page 356: Transmission Assembly
TRANSMISSION Ch 2 page Transmission assembly NOTE Place the dump truck on level ground and apply parking brake Start with the propeller shaft in the articulation hinge. Release articulation propeller shaft from the transmission output flange. Apply articulation lock. Figure 133 CAUTION Place wheel chocks to the front wheel Figure 134...
Page 357 Figure 136 Fill front differential: 9,4 Liters - Shell Spirax S3 ALS 80W-90 (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Hook chains into the 03 eyebolts on transmission. Adjust the chains to keep transmission in level.
Page 358 Assemble the bracket between engine and transmission. Figure 139 Fix adjustment tools to align the transmission and engine. 2x DA30 531192 2x DA40 529833 One on transmission flange and one on engine flange. Tolerance for engine installation is 3,5mm 1.5 Centerline ø4...
Page 359 TRANSMISSION Ch 2 page Assemble the power drive shaft connecting engine and transmission (04 screws on engine flange 04 screws on transmission flange) with torque 114Nm. Figure 143 Adjust rear drive shaft into position on transmission flange. Assemble the rear drive shaft with 02 screws on each side (04 screws) Torque: 114 Nm Figure 144 Assemble rear bracket beam (04 screws).
Page 360 TRANSMISSION Ch 2 page Assemble the driver cabin and put the LH and RH pins to the cabin hinge with snap rings. Make sure the snap ring is placed in the pin groove. Figure 147 Figure 148 Assemble the “IN” A/C hose (large fitting), “OUT” A/C hose (small fitting), reconnect the 6 connectors from left to right (S1, S2, S3, S4, S5, S6) Figure 149 Assemble the protecion cover to original porsition.
Page 361 Connect all the hydraulic hoses from the cabin and the heating system to the cabin. Make sure you follow position markup that is applied dur- ing disassembly. Refill hydraulic tank (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Refill A/C system Figure 153 Assemble the final 02 drive shaft points on each side of transmission (LH and RH).
Page 362 TRANSMISSION Ch 2 page Assemble the body heating assemble (if it was assembled on the ma- chine) Assemble 04 screws on exhaust pipe clamps Figure 157 Assemble the body heating bracket. (04 screws) Figure 158 Assemble the clamp of the hinge bearing lubrication from the body heating bracet.
Page 363 TRANSMISSION Ch 2 page SHOP MANUAL...
Page 364 DRIVE LINE Ch 3 page Chapter 3 Drive line SHOP MANUAL...
Page 365 DRIVE LINE Ch 3 page SHOP MANUAL...
Page 366 DRIVE LINE Ch 3 page Drive line Introduction ..................... 5 General ..................... 6 Structure of the Repair Manual......................7 Denomination of standard dimensions ..................8 Conversion table ...........................8 Torque limits for screws................. 9 Table ..............................9 Main drive line components ..............10 Front hub....................
Page 367 DRIVE LINE Ch 3 page Disassembling the axle housing from the tandemhousing ............112 DISASSEMBLY New Differential (mod no. 8x0660) ..............118 CONTACT PATTERN EXAMPLES OF GLEASON TOOTH SYSTEM ........140 EXAMPLE 1: Dedendum tooth position ..................141 EXAMPLE 2: Dedendum tooth position ..................141 EXAMPLE 3: „LINE“CONTACT PATTERN.................142 Assemble the tandem housing unit to the rear ................145 Rear wheel hub, ..................
Page 368: Introduction
DRIVE LINE Ch 3 page Introduction The Drive Line consists of the components transferring the power from the engine to the transmission, and from the transmission to each wheel, and also wheels, and brakes. Right Tandem Housing Rear Axle Rear Axle Differential Parking Brake...
Page 369: General
DRIVE LINE Ch 3 page General The Service Manual covers all works required for dismantling and the pertaining installation. When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-like manner. Drive line parts should only be disassembled for renewing damaged parts.
Page 370: Structure Of The Repair Manual
See this chapter Important information on industrial safety Generally, the persons repairing Doosan product-sets are responsible on their own for the industrial safety. The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to persons and to the product during maintenance and repair works.
Page 371: Denomination Of Standard Dimensions
DRIVE LINE Ch 3 page Denomination of standard dimensions Note: linear density in kg/m; areal density in t/m2 Unit Character Conversion Note Mass kg (Kilogramm) Force N (Newton) 1 kp = 9,81 N Work J (Joule) 0,102 kpm = 1J = 1 Nm 1 PS = 0,7355 KW Power KW (Kilowatt)
Page 372: Torque Limits For Screws
DRIVE LINE Ch 3 page Torque limits for screws. Table TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF STANDARDS 148 Friction value: µ total= 0,12 for screws and nuts without after treatment as well as phosphatized nuts. Tightening by hand! Torque limits, if not especially indicated, can be taken from the following list: Metric ISO Standard thread Metric ISO Fine thread Size...
Page 373: Main Drive Line Components
The rear differential is equipped with limited slip and drive shafts will then transmit the torque to the tandem housing reduction gears and to the wheels, this is to avoid wheel spin. BRAKES The Doosan dump truck have 4 independent brake systems. Service brake Parking brake...
Page 374: Front Hub
DRIVE LINE Ch 3 page Front hub Outer view and section drawing Figure 2 SHOP MANUAL...
Page 375 DRIVE LINE Ch 3 page 1 = Connection external cooling from pump 2 = Connection external cooling to pump 3 = Oil drain - Cooling brake 4 = Brake chamber 5 = Bleeder Figure 3 \W1.00;B 00;48685 0 0 ; 6 7 3 9 0 00;48620 0 0 ;...
Page 376: Tools For Wdb
DRIVE LINE Ch 3 page Tools for WDB 504210 505755 514653 505760 505766 505767 5870 345 071 5870 050 008 5870 260 004 5870 230 006 5870 610 002 5870 610 010 0 - 100 N M22x1,5 5870 051 004 505756 504175 5870 200 072...
Page 377 DRIVE LINE Ch 3 page 504210 5870 345 071 5870 345 106 514662 5870 705 011 514668 5870 900 016 504232 5870 900 051 514669 514644 514673 514663 5870 204 002 504182 5870 281 047 504198 5870 654 047 514667 5870 080 055 5870 970 029 5870 510 041...
Page 378: Disassembly: Front Wheel Hub
DRIVE LINE Ch 3 page Disassembly: front wheel hub NOTE Look in the section; Safety precautions before starting disas- sembly of hub. When disassembly the WDB-hub it is from starting 2 ways for this: To disassemble the unit complete, use descripotion 1 To disassemble inside parts use discription 2 Disassemble the propeller shaft from transmission flange shaft connection.
Page 379 DRIVE LINE Ch 3 page Figure 2 Brake (see Fig. 11) Loosen screw plug (1) and drain oil. Wheel head Loosen screw plug (2) and cap screw (3) and drain oil. Remove screw plug (4). Also drain oil in axle insert. Figure 11 Loosen the bolt connection (1) planet carrier/hub.
Page 380 DRIVE LINE Ch 3 page By means of lifting device separate the planet carrier (1) from hub. Pay attention to the released sun gear shaft (2)! (S) Lifting chain 504198 (S) Lifting tackle 514658 Figure 13 Remove O-Ring (1). (S) Set of external pliers 504231 (S) Two-armed puller 504731...
Page 381 DRIVE LINE Ch 3 page Pull the stub shaft (1). Left and right stub shaft have different length! Figure 17 Loosen both hexagon screws (1) and remove the lock plate. Figure 18 Loosen slotted nut. Loosening torque of slotted nut is over 2000 Nm. (S) Slotted nut wrench 505764 (S) Centering bracket...
Page 382 DRIVE LINE Ch 3 page Remove the hub. Figure 21 Remove the ring gear (1) from the hub (2). Figure 22 Unsnap circlip (1) and separate the ring gear carrier (2) from ring gear (3). Figure 23 By means of lever action press shaft seal (1) out of the hub bore (3) and remove ring (2).
Page 383: Disassemble The Wdb-Brake Housing
DRIVE LINE Ch 3 page By means of lever action press slide ring seal (1) out of the hub (2). (S) Resetting device 504210 Disassemble the WDB-brake housing Figure 25 Loosen hexagon screws (3) and separate the sealing holder (2) from the brake housing (1). Install adjusting screws.
Page 384 DRIVE LINE Ch 3 page Remove disc set (1) from the brake housing (2). Figure 29 By means of the lifting tackle separate the brake housing (1) from the brake carrier (2). (S) Eyebolts assortment 504182 (S) Lifting chain 504198 Figure 30 Drive back the slotted pins (3) to be flush and unsnap the circlip (1)
Page 385 DRIVE LINE Ch 3 page Expel the slotted pins (1) from the support shim. Figure 33 Preload the cup springs by means of a press and unsnap the circlips. (S) Clamping pliers 514669 (S) Assembly fixture 514662 Figure 34 Pull pin (1) out of support shim and remove the released cup springs (2).
Page 386 DRIVE LINE Ch 3 page By means of compressed air press the piston out of the brake housing (1). By means of the lifting tackle rotate the brake carrier by 180°! See the sketch for connections (2)! Cover the bore (1) with the hand (pressure build-up)! Figure 37 Remove the guide ring, the support rings and U-rings from the annular grooves of the brake housing.
Page 387 DRIVE LINE Ch 3 page By means of the lifting tackle separate t he hub carrier (1) from axle casing. (S) Lifting strap 514655 Figure 41 By means of the lifting tackle separate the brake carrier (1) from the axle casing. (S) Eyebolts assortment 504182 (S) Lifting chain...
Page 388: Reassemble
DRIVE LINE Ch 3 page Reassemble Assemble of the complete hub unit . Clean the connection surface (1) Install the slots of slotted pins in direction of force and by 180° turned to each other. 1 = Slotted pin S 25x70 2 = Slotted pin S 15x70 Figure 44 Power bearing...
Page 389 DRIVE LINE Ch 3 page Assemble of the separated parts Preassemble the slotted pins in the hub carrier and the brake anchor plate before assembling to the axle arm Power bearing Figure 49 Clean the connection surface (1) Install the slots of slotted pins in direction of force and by 180°...
Page 390 DRIVE LINE Ch 3 page Mount the hub carrier by means of the lifting tackle. Observe the radial installation position of the hub carrier! (S) Lifting strap 514655 Figure 53 Figure 54 Wet thread of hexagon screws with Loctite type no. 262. Tighten the bolt connection with hexagon screws (1).
Page 391: Adjust The Rolling Resistance Of The Wheel Bearing
DRIVE LINE Ch 3 page Adjust the rolling resistance of the wheel bearing Press both bearing outer rings into the hub until contact. (S) Mounting tool 505755 (S) Handle 504256 Figure 57 Mount the bearing inner ring (1) onto the hub carrier. By means of the lifting tackle locate the hub (2) cautiously until contact is obtained.
Page 392 DRIVE LINE Ch 3 page Insert the ring gear carrier (1) into the ring gear (2) and fasten it by means of the retaining ring (3). Figure 61 Insert the cpl. ring gear (1) and screw on the slotted nut (2). Mount the chamfer showing to the outside! Figure 62 Tighten the slotted nut.
Page 393: Installation Of The Wet Multi-Disc Brake
DRIVE LINE Ch 3 page NOTE In case of reusing bearings which had already been run- ning, reduce the torque by 50%: Torque T = 4 - 7 Nm Tensile force F min = T: r = 4 Nm : 0.222 m = 18 N Tensile force F max = T: r = 7 Nm : 0.222 m = 31 N Figure 65 Loosen the slotted nut.
Page 394: Pre-Assemble The Return Mecanism
DRIVE LINE Ch 3 page Legend to the sketch: 1 = Brake housing 2 = Guide ring 3 = Backup ring 4 = U-ring 5 = U-ring 6 = Backup ring 7 = Pressure connection Figure 69 Insert the piston (1) into the brake housing (2). Apply sufficiently oil onto the sliding surfaces of the piston or backup rings, U-rings and guide ring (use W-10 oils)!
Page 395 DRIVE LINE Ch 3 page Press 4 gripping rings (1) onto the pins until contact on the assembly fixture (S). The exact installation dimension (see Sketch, Fig. 75) of the gripping rings is obtained when using the speci fied assembly fixture! Observe the installation position, install gripping rings with the orifice offset by 180°...
Page 396 DRIVE LINE Ch 3 page Insert the preassembled support shim (1) into the piston and fasten it by means of the circlip (2). Figure 77 Drive 6 slotted pins (1) for locking of the circlip into the bore holes of the support shim. (S) Drift mandrel 514668 Wet the slotted pin at extremities with grease!
Page 397 DRIVE LINE Ch 3 page By means of the lifting tackle locate the brake carrier (1) until contact is obtained. Observe the radial installation position of the hub carrier! Figure 81 Fasten the brake carrier by means of three hexagon screws (1) provisionally to the brake carrier.
Page 398 DRIVE LINE Ch 3 page Determination of the clearance for new lined discs (inner discs): Example: X ……………………….. = 28.00 mm Y ……………………….. = 26.60 mm Clearance = - 1.40 mm If required, correct the clearance with an adequate outer disc. 1.3 + 0.3 mm Max.
Page 399: Installation Of The Wheel Head
DRIVE LINE Ch 3 page Mount the sealing holder (1) onto the brake housing until contact is obtained and fasten it with hexagon screws (2). Tightening torque ........MA = 390 Nm (S) Adjusting screws 514650 Figure 89 Install the bleeder valve (1). Tightening torque/Screw neck…....
Page 400 DRIVE LINE Ch 3 page Thereupon snap new slide ring seal (1) into sealing ring holder. Pay attention that sealing surface is in parallel to the housing surface! The O-rings must be mounted evenly in the locating hole and must not bulge out of the hole. The surface of the slide ring seal may not have any grooves, scratches or other kind of damage! For the installation position of the slide ring seal please...
Page 401 DRIVE LINE Ch 3 page Mount inner installer (S) on hub carrier (S) Inner installer 514666 Figure 97 Mount hub by means of a lifting tackle. Careless handling might damage the shaft seal (1) of the inner installer (see arrow). Carefully instal the wheel head on the inner installer.
Page 402 DRIVE LINE Ch 3 page Heat the inner diameter of the bearing inner ring (approx. 120 °C). (S) Hot-air blower 230 V 504193 (S) Hot-air blower 115 V 504194 Figure 101 Mount ring (1) and bearing inner ring (2) onto the hub carrier until contact is obtained.
Page 403 DRIVE LINE Ch 3 page Install the lock plate (1) and fasten it by means of locking bolts (2). Tightening torque ........M = 86 Nm Always use new locking bolts! Prior to install the locking bolts, the leakage test of the brake chamber/wheel head (see 1.2.5) and of the brake hydraulics (see 1.2.6) can already be carried out! Figure 105...
Page 404 DRIVE LINE Ch 3 page Heat the inner diameter of the roller bearing at the preassembled planetary gear (approx. 120 ° C). (S) Hot-air blower 230 V 504193 (S) Hot-air blower 115 V 504194 Figure 109 Mount the planetary gears (1) until contact and fasten them by means of the retaining ring (2).
Page 405 DRIVE LINE Ch 3 page Example: Dim. I e.g..…........9.40 mm Dim. II e.g......... - 4.00 mm Difference ........= 5.40 mm required axial clearance .....e.g. - 0.40 mm Result = Thrust washer s = 5.00 mm Fix the thrust washer (1) with grease into the planet carrier.
Page 406 DRIVE LINE Ch 3 page Attach the cap screw (5) in the through hole. Wet the thread of the cap screw with sealing compound (Loctite, Type No. 574)! Then fasten the planet carrier by means of hexagon screws (4). Tightening torque (M16/10.9) ....M = 280 Nm Figure 117 Mount screw plugs (1) and (2) with new O-ring.
Page 407: Check The Brake Chamber/Wheel Head For Leak Tightness
DRIVE LINE Ch 3 page Check the brake chamber/wheel head for leak tightness The brake chamber is to be pressure tested with 0,4 – 0,5 bar compressed air for approx. 5 min. No pressure loss is allowed. (S) Air connection with pressure gauge and pressure release valve 514660 Air pres...
Page 408: Leakage Test Of Brake Hydraulics
DRIVE LINE Ch 3 page Leakage test of brake hydraulics Prior to start the test, ventilate the brake hydraulics completely! 1. Open the bleeder. 2. Actuate the HP-pump slowly until oil gets out of the bleeder. 3. Close the bleeder again. 4.
Page 409: Wdb Cirquit Front Brake
DRIVE LINE Ch 3 page WDB cirquit front brake Front brake cirquit Brake valve Hub Rhs 6040 Oil reservoir Front 6140 Circulation pump Rear service brake service brake 6220 Filter (No Bypass) valve 6300 Temp sensor block 6660 Oil cooler unit 6660 6780 Test connector 6800 Non return valve...
Page 410: Drive Shafts
DRIVE LINE Ch 3 page Drive shafts Front frame Figure 123 Cardan Shaft, Engine -Transmission Rubber coupling Figure 124 Pos. Quantity Part Rubber coupling ass'y •Element •Friction washer •Friction ring •Adapter •Screw •Screw Figure 125 Cardan Shaft (LH and RH) Figure 126 SHOP MANUAL...
Page 411: Rear Frame
DRIVE LINE Ch 3 page Rear frame Figure 127 SHOP MANUAL...
Page 412: Mounting The Bearings On The Intermediate Shaft (B)
DRIVE LINE Ch 3 page Mounting the bearings on the intermediate shaft (B) Clean the ends of the intermediate shaft where the bearings will be installed. Place the intermediate shaft in the two pieces of wood or similar, to have easy handling on the shaft. Figure 128 Heat the inner diameter of the spacer sleeve (inner) with electrical heater, Hot oil or Hot air blower...
Page 413 DRIVE LINE Ch 3 page Place the installation device the end of the interme- diate shaft, in front of the spacer sleeve(inner), and press it against the spacer slevee without hit on it. Figure 132 Now, use a nylon hammer to hit the device installa- tion against the spacer sleeve (inner) until the spacer sleeve touches the end of the machined body of the intermediate shaft.
Page 414 DRIVE LINE Ch 3 page Instal the support ring in front of the rubber seal. Make sure that the concave side is toward to the rubber seal. Figure 136 Place the support ring on the end of the spacer sleeve (inner), covering the rubber seal.
Page 415 DRIVE LINE Ch 3 page Heat the inner diameter of the spacer sleeve (out- er) with electrical heater, Hot oil or Hot air blower Temp 75 - 120°C (167 - 248°F) (S) Hot-air blower 230 V 504193 (S) Hot-air blower 115 V 504194 CAUTION Be aware of personal injury.
Page 416 DRIVE LINE Ch 3 page Place the rubber seal on the splined yoke. Figure 144 Make sure that the lips of the rubber seal are to- wards to the shaft direction. Lubricate the striated part of the splined yoke with grease.
Page 417 DRIVE LINE Ch 3 page Align the arrow on the splined yoke with the arrow on the intermediate shaft and mount the splined yoke on the intermediate shaft. Check if the splined yoke is completed mounted at Figure 148 the end. Figure 149 Tied the nut.
Page 418 DRIVE LINE Ch 3 page CAUTION The mounting and dismounting of rolling bearings involve the handling of sometimes heavy weights, the use of tools and other devices, and in some cases the use of high pres- sure oil. In order to avoid accidents, injuries or damage to property please follow carefully the prescribed methods.
Page 419 DRIVE LINE Ch 3 page Carefully align the housing base. Vertical markings at the middle of the side faces and ends of the housing base can facilitate this. Then lightly tighten the attachment bolts. Figure 154 The housing cap should be placed over the base and the cap boltas (to join cap and base) tightened to the torque according to the torque table.
Page 420 DRIVE LINE Ch 3 page Finally, push the V-rings seal into their correct position. This can be done using a screwdriver at the same time as the shaft is turned. Figure 157 “F” Articulation bearing end Parking brake end Figure 158 On intermediate shafts with identical flanges, the bearing housing to the parking brake disc should have lock ring installed and be marked with “F”.
Page 421: Front Differential And Transmission
DRIVE LINE Ch 3 page Front differential and transmission Also see chapter 2. Schematic view Legend of numbers: 2 = Engine - dependent PTO 3 = Output flange (rear axle) 4 = Emergency steering pump (option) 5 = Output flanges of LKV axle insert (front axle) 6 = Input flange Legend of letters: •...
Page 422: Brakes
DRIVE LINE Ch 3 page Brakes Service brakes MEASURING BRAKE FLUID PRESSURE Stop the machine on level ground and apply the parking brake. Connect a pressure gauge to the test point rear frame. (See figure 162) Depress brake pedal fully down. *STANDARD VALUE: Front 62,1±5 bar Rear 62,1±5 >...
Page 423: Service Brake Description
DRIVE LINE Ch 3 page Service brake description The service brake consist of: Hydraulic pump, Accumulators, Accumulator valve, Brake pedal, Control valve, and calippers. See the Shop Manual: Chapter 5 Figure 163 Hydraulic pump Figure 164 Accumulator Valve Accumulators Left Right hand hand...
Page 424: Testing Of Parking Brake
DRIVE LINE Ch 3 page Testing of parking brake Stop the machine on a level ground. Charge brakes to specified pressure. Warm up engine to 70°C, transmission oil to 80 - 95°C and hydraulic oil to 40 - 70°C. Apply parking brake. Place gear shift lever in the 1st gear.
Page 425: Remove The Linings
DRIVE LINE Ch 3 page Remove the Linings WARNING To prevent serious eye injury, always wear proper protection when you perform vehicle maintenance or service. Do not work under a vehicle supported only by jacks. Jacks can slip or fall over and cause serious personal injury. Support the vehicle with safety stands.
Page 426 DRIVE LINE Ch 3 page Remove the stabilizer bar cotter pin and retainer pin. Hinge the stabilizer bar so it is out of the way. Figure 172. Lift the inner lining out of the caliper assembly. If you plan to reuse the lining, mark the lining INBOARD.
Page 427: Disassembly The Park Brake Unit
DRIVE LINE Ch 3 page Disassembly the park brake unit Block the wheels to prevent the machine from moving. Set the park brake in position OFF, (Hydraulik press on the cylinder is no ON) Remove the adjuster plug. Figure 170 Use a 6 mm Allen wrench, turn the adjuster screw 3 turns backwards, (out).
Page 428: Assembly The Park Brake Unit
DRIVE LINE Ch 3 page Secure the brake unit with lifting device. CAUTION Do not use the stabilizer bar to lift the caliper on or off of the vehicle. Damage to the stabilizer bar can result. Unfasten the bracket f/parking brake. Screw M16x50 ISO4017-10.9 EL Figure 175 Lock washer M16 (Nord-lock)
Page 429: Adjust The Initial Caliper Clearance
DRIVE LINE Ch 3 page Adjust the Initial Caliper Clearance 1. Adjust the caliper by reducing the caliper-to-disc clearance to ZERO. Refer to Table A for the adjusting direction. 2. Check that the load plate fully contacts the lining backing plate. 3.
Page 430: Park Brake Maintenance
Hydraulic Fluid WARNING Use only the type of hydraulic fluid specified In the Doosan Operating & Maintenance Manual. Do not use different types of hydraulic fluid. Using incorrect hydraulic fluid will damage the rubber parts of the caliper. Component damage, loss of braking and serious personal injury can result.
Page 431: Troubleshooting Park Brake
Troubleshooting Park brake Figure 181 Inspect the Brake Components WARNING Use Doosan parts only. Do not use parts manufactured by other suppliers. Use of non-Doosan parts can cause damage, loss of braking and serious personal injury. Lining Thickness Lining material thickness must not be less than 0.200-inch (5.1 mm). Replace the linings before the lining material thickness reaches this specification.
Page 432 DRIVE LINE Ch 3 page Disc CAUTION You must always replace a damaged disc. When you inspect the brakes, inspect both sides and the outer diameter of the disc for the following conditions: • Cracks • Heat checking • Grooves or scoring •...
Page 433 DRIVE LINE Ch 3 page Measure Disc Thickness Measure the thickness of the disc when you reline the brakes. The disc must be at least 0.866-inches (22.0 mm). Figure 186. If the disc thickness is outside specification, replace the disc. Caliper Assembly The caliper and saddle assembly are not serviceable.
Page 434 DRIVE LINE Ch 3 page Hydraulic Release Parking Disc Brake Troubleshooting Park brake Conditions : Possible Cause(s): What to Check : Corrections : À Chamber exceeds Incorrect initia l Check the chamber stroke If the air chamber stil l two-inch maximum adjustment or after 20 brake overstrokes, replace th e...
Page 435: Rear Differential
DRIVE LINE Ch 3 page Rear differential Figure 187 Figure 188 SHOP MANUAL...
Page 436: General Function
DRIVE LINE Ch 3 page General function The differentials transmit the torque of the transmission output propeller shafts to the wheels. The differential contains one crownwheel and one pinion, as well as a differential gear. The teeth of the crownwheel and pinion are cut in a special way to provide proper mesh and high strength.
Page 437 DRIVE LINE Ch 3 page Although the wheels have different distances to roll when negotiat- ing bend and thereby different rotation speed, exactly the same drive torque has to be transmitted to both sides. This torque distribution takes place in the differential gear. The differential gear consists of four taper gear wheels, star wheels, that run on a differential spider.
Page 438 DRIVE LINE Ch 3 page To avoid wheel spin, the two differentials each have a differential brake with a locking value of 45%. When the differential brake is activated, the drive wheel is forced to roll at the rotation speed decided by the locking value.
Page 439: Illustrated Tables - Special Tools
DRIVE LINE Ch 3 page Illustrated tables - Special tools 509157 509109 504195 504198 504731 DIFF .CARRIER. 153441 Page: 1/3 509110 504173 504185 504170 505759 504175 504171 509111 504172 230 V 115 V 504209 504193 504194 509112 505155 504196 505158 504175 504231 505770...
Page 440: Disassemble The Tk-Differential
DRIVE LINE Ch 3 page Illustrated tables - Special tools 532218 532234 532233 504256 DIFF.CARRIER. 153441 Page: 3/3 532220 532227 532226 532228 532229 532231 504247 532232 Figure 200 Disassemble the TK-differential Safety precautions. Differensial “TK new” i=4,375 (UNF) WARNING Connect the articulation lock to front frame. WARNING Be aware of personal injury.
Page 441: Disassemble The Differentilal From The Axle Housing
DRIVE LINE Ch 3 page Disassemble the differentilal from the axle hous- DANGER Secure the machine with wheel chocks on the front wheel. Drain the oil from axle housing. Figure 202 NOTE Draining oil from tandem housing is not necessary if removal takes place just for work on the tandem bearing.
Page 442 DRIVE LINE Ch 3 page Remove the cover. Use chisel and hammer. Be aware not to damage the cover Figure 205 Remove the snap ring for the thrust washer Figure 206 Pull out the thrust washer Use screw M16x220 060583 Pull out the shaft.
Page 443 Ch 3 page Lift the body in safe position and welding a bracket under the body bottom. The bracket is not Doosan part. NOTE When welding on machine, place the welding ground cable to the same object and close the welding point as possible.
Page 444: Disassemble The Boggi Unit From Frame
DRIVE LINE Ch 3 page Disassemble the boggi unit from frame Disassemble brake hoses from Tandem housing LHS and RHS Disassemble lubrication hose from Tandem housing LHS and RHS Disassemble axle housing screws (4 in each side). Screw M24x380 DIN931-10.9 Figure 213 WARNING Be aware of personal injury.
Page 445 DRIVE LINE Ch 3 page By crane, turn the axle housing 90° Figure 216 Assemble 2 pcs. M16 eye bolt to the M16 threaded hole in the bearing housing Figure 217 Disassemble screws from the differential flange Figure 218 By crane, carefully lift the differential out from the axle housing Figure 219 SHOP MANUAL...
Page 446 DRIVE LINE Ch 3 page Fasten differential carrier on the assembly car. (S) Assembly car 504213 (S) Support 509253 Figure 220 Loosen hex. head screws and remove both lock plates Figure 221 Loosen both adjusting nuts. (S) Pry bar 504209 Figure 222 SHOP MANUAL...
Page 447 DRIVE LINE Ch 3 page Mark installation position of the bearing brackets with the axle drive housing, see Arrows ! Figure 223 Loosen hex. head screws and remove both bearing brackets, adjusting nuts and bearing outer races. Hex. head screws are secured with Loctite ! Heat axle drive housing in the area of the tapped holes ! (S) Hot-air blower 230 V 504193...
Page 448: Dismantle Differential
DRIVE LINE Ch 3 page Dismantle Differential Pull off both bearing inner races (differential bearing). (S) Quick-acting grip 509254 (S) Quick-acting grip 509255 (S) Basic tool 504243 Figure 227 Loosen hex. head screws, remove housing, cover and disasssemble components. Figure 228 If necessary, loosen screw connection (Figure 229), resp.
Page 449: Disassemble Drive Pinion
DRIVE LINE Ch 3 page Disassemble Drive pinion Unlock and loosen castle nut. Do not remove the castle nut ! (S) Clamping yoke 509110 Pipe KM 509157 Figure 230 Mark the radial installation location of sealing cap and bearing bush with the axle drive housing, see Arrows ! Loosen hex.
Page 450 DRIVE LINE Ch 3 page Demount sealing cap and disassemble shaft seal. Figure 234 Press drive pinion out of the bearing bush. Pay attention to released components! Figure 235 Remove adjusting ring. Figure 236 Pull off bearing inner race from the drive pinion. (Bearing) 532767 (S) Grab sleeve...
Page 451 DRIVE LINE Ch 3 page Squeeze circlip out. (S) Set of external pliers 504231 Figure 238 Pull off roller bearing. (S) Two-leg puller 505770 Figure 239 SHOP MANUAL...
Page 452: Assembly
DRIVE LINE Ch 3 page ASSEMBLY If the crown wheel or drive pinion are damaged, both parts must be changed together ! Pay attention to equal mating numbers ! Clean tapped holes of the bearing bracket screw connection from Loctite residues ! Figure 240 DRIVE PINION Adjust Contact pattern - Bevel gear set, see Figure 241 (Draft) to...
Page 453 DRIVE LINE Ch 3 page Locate both bearing brackets provisionally by means of hex. head screws. Insert fitting pieces into the bearing bores and introduce meas- uring shaft, see also Figure 241/Page 89! (S) Fitting pieces 509257 (S) Measuring shaft 505158 Figure 242 Tilt axle drive housing 180°.
Page 454 DRIVE LINE Ch 3 page Read Dimension d (pinion dimension). +0,1 + 0,1 Dimension d e.g. (197 + 0,1 mm) ....197,10 mm Example „A2„: Dimension c (Figure 245)......... 53,60 mm Dimension d ........+ 197,10 mm gives Dimension Y (install. Dimension) 250,70 mm Figure 246 Example „A3„:...
Page 455 DRIVE LINE Ch 3 page Line up the bearing bush. Figure 249 Press bearing inner race against shoulder. Figure 250 Press dust cap over the input flange until contact is obtained. Figure 251 Heat input flange and line it up until contact is obtained. CAUTION Use protective gloves! Figure 252...
Page 456 DRIVE LINE Ch 3 page Line up the disc and tighten castle nut. Torque limit ....... 1300 Nm During the tightening, rotate the drive pinion several times in both directions ! (S) Clamping yoke 509110 Figure 253 Check Bearing torque 1 ... 2 Nm ! In case of deviations from the required rolling moment, correct with corresponding adjusting ring (Figure 249), according to the following specification:...
Page 457 DRIVE LINE Ch 3 page Fix roller bearing by means of circlip. (S) Set of external pliers 504231 Figure 257 Install two adjusting screws and line up the shim e.g. s = 0,60 mm (see Example A3 /Figure 258). Pay attention to the overlapping of the oil ducts, see Arrows! Wet the shim(s) on both sides with the sealing compound...
Page 458 DRIVE LINE Ch 3 page L- diff Figure 261 Assemble bearing housing Torque limit (M16/10.9) ... 280Nm TK- diff Figure 262 Assemble the Sealing cap Torque limit (M8/8.8)........23Nm TK- diff Figure 263 Heat input flange and line it up. Figure 264 SHOP MANUAL...
Page 459 DRIVE LINE Ch 3 page Screw sealing cap and bearing bush together with the axle drive housing. Tilt differential carrier 90°. Wet contact face of the disc with sealing compound (Loctite, Type-No.574). Line up the disc and tighten castle nut. Torque limit ......
Page 460 DRIVE LINE Ch 3 page 1. 2.2 DIFFERENTIAL DL-1600, Interlock value 45% The following Perspective Illustration (figure 269) shows the components of the Differential and its installation location. Strain bolts Thrust ring Housing cover Side gear Thrust washer Differential bevel gear Outer plate (optional) Differential axle Inner plate...
Page 461 DRIVE LINE Ch 3 page Pre-assemble Differential (Figure 271 ... 283) NOTE Lubricate the differential components according to ZF-List of lubricants TE-ML 05 (with LS-Addi- tive) ! Insert thrust washer, with the chamfer on the outer diameter show- ing downward, into the differential housing. Figure 271 Install plate pack A, starting with one outer plate.
Page 462 DRIVE LINE Ch 3 page Insert complete differential spider. Figure 275 Introduce thrust ring. Figure 276 Introduce thrust ring. Figure 277 Install plate pack B, starting with one inner plate. NOTE Pay attention to the Note, Figure 269 Figure 278 SHOP MANUAL...
Page 463 DRIVE LINE Ch 3 page Check the Assembly play of the internal components = 0,2 ... 0,6 mm (Figure 279 ... Example B): Differential housing Measure Dimension I from the mounting face to the outer plate. Dimension I e.g......... 6,50 mm (S) Digital Depth gauge 504175...
Page 464 DRIVE LINE Ch 3 page Mount housing cover and fasten it with strain bolts. Torque limit ........105 Nm Wet thread of strain bolts with Loctite (Type-No. 262) ! Only use of new strain bolts permitted ! Figure 282 Press bearing inner race against shoulder. Install crown wheel-side bearing inner race accordingly.
Page 465 DRIVE LINE Ch 3 page Position differential by means of lifting device in the axle drive housing and install both bearing outer races. Pay attention to the position of the sliding pad ! (S) Gripper tongs 505155 Figure 286 Install both adjusting nuts. Figure 287 Mount both bearing brackets and locate them provisionally by means of hex.
Page 466: Adjust Backlash
DRIVE LINE Ch 3 page Adjust Backlash Adjust Backlash - Bevel gear set = 0,27 ... 0,33 mm Bearing torque - Differential bearing T = 3 ... 4 Nm Yoke width = 472 - 0,2 mm (Figure 290 ... 291): Determine the backlash by the alternating adjustment of the two adjusting nuts (Figure 290).
Page 467: Examples Of Gear-Tooth-Contact
DRIVE LINE Ch 3 page Examples of gear-tooth-contact. Examples of gear-tooth-contact patterns for the gleason gear-tooth system Coast side (concave) Ideal tooth-contact pattern i.e. pinion distance is correct Figure 294-1 Ideal tooth-contact pattern i.e. Drive side (convex) pinion distance is correct Figure 294-2 Pinion distance must be increased...
Page 468 DRIVE LINE Ch 3 page Figure 294-5 Pinion distance must be decreased Figure 294-6 Fix both adjusting nuts by means of lock plate (Arrow). Wet thread of hex. head screws with Loctite (Type-No. 262) ! Torque limit (M8/8.8) ....... 23 Nm Figure 294-7 Adjust Sliding pad without play and pressure: Wet some threads of the set screw in the area of the housing...
Page 469: Assemble The Tk-Diff In The Axle Housing
DRIVE LINE Ch 3 page Assemble the TK-diff in the axle housing Apply sealing compound: Loctite 574. Apply around the threaded holes. Figure 295 Assemble the differential into the axle housing. WARNING Be aware of personal injury. Figure 296 Make sure differential is in correct position Figure 297 Assemble the screws Screw: M20x90 ISO4014-10.9 2 pcs (arrow)
Page 470 DRIVE LINE Ch 3 page Torque limit 560 Nm Figure 299 Assemble shafts on both tandemhousing. Turn the input flange on the differential to line up the shaft and the spline in the differential . Figure 300 Assemble thrust washer with new O-ring. Figure 301 Assemble snap ring.
Page 471 DRIVE LINE Ch 3 page Apply sealing compound: Loctite 574. Figure 303 Apply on both sides of the holes. Figure 304 Assemble the cover. Screw: M10x40 ISO4017-8.8 fzb Locking liquid: Loctite 245 Figure 305 Torque limit 46 Nm Figure 306 SHOP MANUAL...
Page 472 DRIVE LINE Ch 3 page Turn the axle housing back to normal position. Figure 307 Assemble the wheels. Lubricate the wheel bolts, and assemble the wheels Torque limit: 450 Nm Figure 308 For tandem assembly see page 143 SHOP MANUAL...
Page 473: Disassemble The Tandem Unit From The Rear Frame
DRIVE LINE Ch 3 page Disassemble the tandem unit from the rear frame It is also possible to disassemble the tandem housing without dis- assemble the axle housing. See note on next page. Unfasten the rear propeller shaft from the differential flange M12x60 DIN912-12.9 Secure the rear propeller shaft for damage with a strop Figure 309...
Page 474 DRIVE LINE Ch 3 page NOTE If it is not possible to lift the rear frame off the tandem unit, the tandem unit could be pulled off the rear axle housing by using the arrangement as shown on the figure. Place the arrangement between the wheels.
Page 475: Disassembling The Axle Housing From The Tandemhousing
DRIVE LINE Ch 3 page Disassembling the axle housing from the tan- demhousing Lift one side of the tandem unit and place safety supports under the axle housing. Be sure that the tandem unit is safely placed at the safety support. Safeguard the tandem housing with the crane Figure 316 Disassemble wheel nuts...
Page 476 Remove articulation bearing from differential adapter. Figure 321 Secure differential properly in jigg or with safety support. Doosan jig solution used for disassembly and assembly of rear axle, see figure 322. Other secure solutions can be used. Mox no: 800493...
Page 477 DRIVE LINE Ch 3 page Axle drive housing Disassembly Only on model 8X0660 ---> Fix axle drive housing to assembly truck. Assembly truck: 504213 Fixtures (2x) 532217 Figure 325 Loosen cylindrical screws and remove the releasing bearing housing with a lifting device. (S) Inner extractor 532218 (S) Eye nut...
Page 478 DRIVE LINE Ch 3 page Disassembly Pull the bearing outer ring (see arrow) out of the bearing hole and remove the shim behind. Figure 329 Heat slotted nut by means of hot-air blower. Slotted nut is secured with Loctite (Type no.: 262)! Figure 330 Loosen slotted nut and remove the shim behind.
Page 479 DRIVE LINE Ch 3 page Disassembly Use a two-armed puller to press the input pinion out of the axle drive housing and remove the releasing tapered roller bearing. Figure 333 Remove the spacer and pull the tapered roller bearing from the input pinion.
Page 480 DRIVE LINE Ch 3 page Differentials Disassembly 2.1 Multi-disk differential lock DHL-5000 Remove axial roller cage (arrow). Figure 337 Pull both tapered roller bearings from the differential. Crown wheel side (S) Rapid grip 532230 (S) Basic tool 504246 (S) Pressure piece 532231 Opposite side: (S) Grab sleeve...
Page 481: Disassembly New Differential (Mod No. 8X0660)
DRIVE LINE Ch 3 page Disassembly DISASSEMBLY New Differential (mod no. 8x0660) Preload compression spring by means of the press and disengage the retaining ring. Then pull the sliding sleeve out of differential cover and remove the releasing compression springs. Figure 341 Remove single parts.
Page 482 DRIVE LINE Ch 3 page Disassembly Press out slotted pins (4x). Figure 345 Pull spider shafts (4x) and remove the releasing differential bevel gears with the thrust washers from the differential housing. Figure 346 Remove axle bevel gears and the shims behind. Figure 347 Support the crown wheel and press out differential housing.
Page 483 DRIVE LINE Ch 3 page Disassembly Pull both tapered roller bearings from the differential. Crown wheel side (S) Rapid grip 532230 (S) Basic tool 504246 (S) Pressure piece 532231 Opposite side: (S) Grab sleeve 504247 (S) Basic tool 504246 (S) Clamping cylinder 532226 (S) Pump 532228...
Page 484 DRIVE LINE Ch 3 page Disassembly Remove spider shafts and axle bevel gears (see Figure 353) out of the differential housing. Figure 353 Remove the second axle bevel gear. Figure 354 Lift the pressure ring out of differential housing and remove the disk package and thrust washers behind.
Page 485 DRIVE LINE Ch 3 page Differentials Reassembly 3.1 Multi-disk differential lock DHL-5000 Mount two adjusting screws (S) and press the heated crown wheel onto differential housing until contact is obtained. (S) Locating pins 504722 Figure 357 Insert disk and thrust washer into the differential housing. Figure 358 Insert axle bevel gear.
Page 486 DRIVE LINE Ch 3 page Reassembly Fix spider shafts with slotted pins (2 pieces/hole). Press the slotted pins with 180° offset openings into flush position!! Figure 361 Mount second axle bevel gear and thrust washer. Figure 362 Mount disk and fix it with hexagon screws. Tightening torque (M10/10.9) MA = 50 Nm Figure 363 SHOP MANUAL...
Page 487 DRIVE LINE Ch 3 page Reassembly Setting of disk package Premount single parts according to the adjacent sketch. 1 = Differential cover 2 = Pressure piece 3 = Disk 4 = Cage 5 = Lever (15x) 6 = End plate 7 = Outer disks (optional) 8 = Inner disks Figure 364...
Page 488 DRIVE LINE Ch 3 page Reassembly Insert the premounted disk carrier onto the axle bevel gear. Figure 368 Mount outer and inner disks. For the number of disks and disk arrangement please refer to the relating spare parts list! Pay attention to the radial installation position of the disk package, as shown on the adjacent Figure! Figure 369 Insert end plate.
Page 489 DRIVE LINE Ch 3 page Reassembly Insert pressure piece (see arrow) and install disk. Figure 372 Insert compression springs (6x) into the differential cover. Figure 373 Insert sliding sleeve. Figure 374 Preload the compression springs by means of the press and engage the retaining ring into the annular groove of the sliding sleeve.
Page 490 DRIVE LINE Ch 3 page Reassembly Mount two adjusting screws (S) and insert the differential cover by means of the lifting device. (S) Locating pins 504722 (S) Inner extractor 532218 (S) Eye nut 532220 Figure 376 Preload the differential by means of the press and bolt with new locking screws.
Page 491 DRIVE LINE Ch 3 page Reassembly 3.2 Multi-disk differential lock DL-5000 Mount two locating pins (S) and press the heated crown wheel onto the differential housing until contact is obtained. (S) Locating pins 504722 Figure 380 Insert thrust washers into the differential housing. Figure 381 Mount outer and inner disks in alternating order, starting with an outer disk.
Page 492 DRIVE LINE Ch 3 page Reassembly Insert the axle bevel gear until contact is obtained and install the inner disks with the teeth. Figure 384 Preassemble the differential spider and insert it into the differential housing /into the pressure ring. Figure 385 Mount second axle bevel gear.
Page 493 DRIVE LINE Ch 3 page Reassembly Mount inner and outer disks in alternating order, starting with an inner disk. The installation clearance of the internal parts is corrected by mounting outer disks with different thicknesses! The difference in thickness between the left and the right disk package may only be 0.1 mm at maximum!! Figure 388 Setting of dimension „A“...
Page 494 DRIVE LINE Ch 3 page Reassembly Mount two adjusting screws (S) and insert the differential cover by means of a lifting device. (S) Locating pins 504722 (S) Inner extractor 532218 (S) Eye nut 532220 Figure 391 Preload the differential by means of the press and bolt with new locking screws.
Page 495 DRIVE LINE Ch 3 page Axle drive housing reassembly Determination of shim thickness to obtain a correct contact pattern The following measuring procedures must be carried out with utmost accuracy! Inaccurate measurements lead to an incorrect contact pattern requiring an additional disassembly and reassembly of pinion and differential! Read dimension I from the axle drive housing.
Page 496 DRIVE LINE Ch 3 page Reassembly Determine dimension III (bearing width). Dimension III e.g. 63.60 mm Make sure that the rollers are located without any play (rotate bearing inner ring several times in both directions). CALCULATION EXAMPLE: Dimension I 331.25 mm Dimension II - 265.00 mm Dimension III - 63.60 mm Difference = shim s = 2.60 mm...
Page 497 DRIVE LINE Ch 3 page Reassembly Heat the tapered roller bearing and insert it until contact is obtained. CAUTION Risk of burn injuries, wear protective gloves! Adjust roller bearing after cooling down! Figure 400 Set the rolling torque of the pinion bearing 1.5 …...
Page 498 DRIVE LINE Ch 3 page Reassembly Insert input flange and fix it by means of disk and slotted nut. Tightening torque MA = 1200 Nm (S) Slotted nut wrench 8325 (S) Fixing device 532227 (S) Locking device 509110 Preliminarily mount slotted nut without Loctite! While tightening rotate input pinion several times in both directions! Figure 404...
Page 499 DRIVE LINE Ch 3 page Reassembly Determination of shims for setting of bearing rolling torque (differential bearing) and backlash (bevel gear set) Required shims must be determined by means of the read value (deviation/test dimension) and the corresponding data in the following table! (KRS –...
Page 500 DRIVE LINE Ch 3 page Reassembly Cover some drive and coast flanks of the crown wheel with marking ink. Then insert the premounted differential into the axle drive housing. (S) Inner extractor 532218 (S) Eye nut 532220 Figure 412 Insert the determined shim (e.g. s = 1.5 mm) into the bearing housing and reset the bearing outer ring until contact is obtained.
Page 501 DRIVE LINE Ch 3 page Reassembly Leakage test of lock Pressurize the lock (p = 1 bar), close shut-off valve and remove air line. No noticeable pressure loss is allowed to occur within 10 sec! Operation is only necessary for version with DHL! Figure 416 By rotating the input flange, roll crown wheel over the input pinion in both directions several times.
Page 502 DRIVE LINE Ch 3 page Reassembly Wet the outer diameter of the shaft seal with spirit directly before installation and fill the space between seal and dust lip with grease! Mount the shaft seal with the seal lip showing to the oil chamber.
Page 503: Contact Pattern Examples Of Gleason Tooth System
DRIVE LINE Ch 3 page CONTACT PATTERN EXAMPLES OF GLEASON TOOTH SYSTEM Field of application: The contact pattern examples are applicable for all bevel gear sets in MT and MS axles which have a ratio between 1.5 < i < 6. Furthermore, the examples are only valid for ground bevel gear sets.
Page 504: Example 1: Dedendum Tooth Position
DRIVE LINE Ch 3 page EXAMPLE 1: Dedendum tooth position The contact pattern on the convex and concave flank is too close to the root, although more than 50% of the flank in h-direction is covered. An adjustment is necessary! Feature: On the convex flank the contact pattern is tan gent to the toe, on the concave flank it...
Page 505: Example 3: „Line"Contact Pattern
DRIVE LINE Ch 3 page EXAMPLE 3: „LINE“CONTACT PATTERN The contact pattern on the convex and concave flank is too close to the top. The contact pattern is too small and is not tangent to the middle of tooth. An adjustment is necessary! Adjustment: Install thicker pinion shaft! Figure 429 The convex contact pattern must be tangent to the...
Page 506 DRIVE LINE Ch 3 page With differential housing in secure position. Reassemble the two rear axle adapters. Apply locking liquid on bolt threads: locktite 245 Figure 433 Tighten bolts M20 Torque: 574 Nm Figure 434 Reassemble articulation bearing to differential house adapter.
Page 507 DRIVE LINE Ch 3 page Move tandem housing in positon and assemble it to the differen- tial adapter. Apply loctite no.? WARNING Be aware of personal injury. Figure 437 Fit wheels and assemble wheel nuts 20 pcs Width across flat: 30 mm Figure 438 Figure 439 Lift the tandem unit and remove safety supports under the axle...
Page 508: Assemble The Tandem Housing Unit To The Rear
DRIVE LINE Ch 3 page Assemble the tandem housing unit to the rear Assemble the tandem housing to the rear frame. Lift the rear wagon with the crane. Move the tandemhousing unit under the rear frame and connect the frame and axle housing. Figure 441 Make sure that the guide pin meet the hole in the frame.
Page 509 Figure 446 Fill oil to the axle housing, Oil: Spirax S3 ALS 80W-90. (For fluid type and specifications, re- fer to the DOOSAN Operating & Maintenance Manual Chapter 6) the machine should be placed on a horizontal ground. Figure 447 Check the oil level on the tandem housing.
Page 510 DRIVE LINE Ch 3 page Note: SHOP MANUAL...
Page 511: Rear Wheel Hub
DRIVE LINE Ch 3 page Rear wheel hub, Outer view and section drawing Pos Description Pos Description Pos Description Brake disc Wheel axle Shim Brake disc O-ring Shim Brake disc Ring Screw Flange Wheel bolt Plug O-ring Seal ring Wheel nut Screw Roller bearing Support...
Page 512 DRIVE LINE Ch 3 page Note Important ! When assembly: Become aware of the direction of the (deflector) Scoop ring (pos 13) Figure 450 SHOP MANUAL...
Page 513: Disassembly The Rear Wheel Hub
DRIVE LINE Ch 3 page Disassembly the rear wheel hub NOTE Before disassembly see the chapter 3 section: Safety precautions Drain the oil (A). Loosen the drain screw plug on the tandem housing. Disconnect the brake hose from hub (C) Disconnect screws (B) 20 x M16x70 ISO4014-10.9 20 x Washer 17x30x3 NS-ISO...
Page 514 DRIVE LINE Ch 3 page Carefully lift the gear wheel (9), scoop ring (13) and the disc carrier (10) from the hub. Note: Heavy objects, use lifting device. Separate the disc carrier (10) from the gear wheel (If the part have to be changed) 16 x Screw M16x50 ISO4017-10.9 Tightening torque 280 Nm.
Page 515 DRIVE LINE Ch 3 page Remove the disc plate (9 pcs) When remove the return mechanism, knock down the slot pin and remove the lock ring. Lift out the return mechanism Remove the piston, use compressed air into the oil line to lift the piston up.
Page 516 DRIVE LINE Ch 3 page Pre-assemble the wheel axle Assembly the wheel bolts. Use hydraulic press or sledgehammer. NOTE Be aware of personal injury Use safety glasses and be aware of flying objects Figure 457 Preassemble the distance ring (3): Insert the O-ring (2) and oil the surface.
Page 517 DRIVE LINE Ch 3 page Clean the wheel axle and apply oil the surface Figure 461 Assemble the preassembled distance ring Figure 462 With plastic mallet knock carefully on the ring Clean the surfaces Assemble the outer bearing. Figure 463 Clean the axle and apply oil before assemble the bearing.
Page 518 DRIVE LINE Ch 3 page Clean the axle and apply oil before assemble the bearing. WARNING Be aware of personal injury Figure 465 500 KG Use tube to press the bearing in position. Hold press on the tube to the bearing temperature is cool down WARNING Be aware of personal injury Figure 466...
Page 519: Assemble The Wdb Rear Hub
DRIVE LINE Ch 3 page Finaly check on the movement, by hand check about the ring can be moving springy, approx 2 mm by hand. Protect bearing and connection surfaces before the next step. Figure 468 Assemble the WDB rear hub Clean surfaces and assemble the outer bearing cup Figure 469 SHOP MANUAL...
Page 520 DRIVE LINE Ch 3 page Assemble the slide ring seal When assembly the slide ring seal it is important to clean the surface of the connection well. Assemble the guide ring between the flange and O-ring. NOTE The rings are make together, dont mix the ring from others ring set.
Page 521 DRIVE LINE Ch 3 page Place the hub in assembly rack after assemble of the bearing cup and the seal ring. Clean the bearing surface and assemble the bearing cup Assemble the guide ring Pos 23-24 Assemble the guide ring Pos. 23 and 24 Turn the hub housing 180 °...
Page 522 DRIVE LINE Ch 3 page Assemble the guide ring (pos Fasten both of the ends, use clue, Loctite 406 Figure 477 Figure 478 Place the hub in assembly rack after assemble of the bearing cup and the seal ring. Lubricate seal area Clean the bearing surface and before inserting the assemble the bearing cup...
Page 523 DRIVE LINE Ch 3 page Assemble the return mechanism (pre-assembled) NOTE For details about pre-assembling of the return mecha- nism, see in this chapter, front WDB hub assembly. Sec- tion: Pre-assembly of the return mechanism. Figure 481 Preassemble the return mechanism- piston legend to the sketch: 1= pin 2= gripping rings...
Page 524 DRIVE LINE Ch 3 page Assemble the lock ring Pos 29, Secure with 6 pcs. slot pin Pos 28 See figure 483. Insert the plug Figure 483 Be careful with the seal ring Clean the bearing surface and Clean the surface and assemble the bearing cup assemble the seal ring Figure 484...
Page 525 DRIVE LINE Ch 3 page Assembly the disc package in Brake disc- rotating (Qty 4) the hub housing. Available 4,7 mm See the calculation example below Brake disc- stationary (Qty 5) Available3,8 mm, 4,0 mm, or 4,2 mm. Figure 487 Calculation example: Measure x........
Page 526 DRIVE LINE Ch 3 page Apply oil to the parts and place the brake discs, one by one. Assemble the guide ring Start assembly with outer disc. Use glue: Loctite no.406 Assemble the guide ring Assemble the piston ring at both ends. Pos 23-24 Pos 21 - 22 1 The outer discs...
Page 527 DRIVE LINE Ch 3 page Place the flange. 20pcs. screw M16x50 ISO4017 - 10.9 Apply locking liquid: TreeBond 1374 Washer: 17x30x3 NS-ISO 7089 300HV Insert the plug Tighetening torque: 280 Nm. Be careful with the seal ring Clean the bearing surface and Clean the surface and assemble the bearing cup assemble the seal ring...
Page 528 DRIVE LINE Ch 3 page While the pressure is on: Remove the “Line up tool”, lubricate the parts and as- semble the carrier. Figure 495 Connect the lifting device. Remove the pressure tool and as- semble plug in the oil line. Assemble the guide ring Clean the surface and Use glue: Loctite no.406...
Page 529 DRIVE LINE Ch 3 page With attention and carefully assemble the hub on the axle. NOTE The seal ring is made of specially material and while assemblying the ring have to be handle very carefully and surfaces have to be cleaning well. WARNING Be aware of personal injury - piston...
Page 530 For more details about assembling Calculation example: DRIVE LINE Ch 3 page Measure A........47,10 of the return mechanism, see Legend to the sketch: Measure B.........- 6,40 1 = Pin description in the Shop Manual, Gives:..........= 40,70 2 = Gripping rings Discs unit........
Page 531 DRIVE LINE Ch 3 page Assemble the gear wheel to contact with the bearing inner ring. NOTE Do not press! With no press, rotate the hub housing 20 times Check the rolling resis- tance. Example, resistance: 8 - 17 Nm. NOTE At this stage, no preload on the bearing.
Page 532 DRIVE LINE Ch 3 page re details about assembling Figure 503 eturn mechanism, see Assemble the inner bearing. Assemble the gear wheel Clean the axle and apply oil Place the end plate and with 2 screws to contact with the bearing ption in the Shop Manual, before assemble the bearing.
Page 533 DRIVE LINE Ch 3 page mble the Return mechanism- piston For more details about assembling (example 2,2 mm) Locate the shims Calculation example: Measure A........47,10 of the return mechanism, see Assemble the inner bearing. Assemble the gear wheel Legend to the sketch: Measure B.........- 6,40 Clean the axle and apply oil...
Page 534 DRIVE LINE Ch 3 page Finally check the rolling resistance. 28 - 37 Nm 28 - 37 Nm Figure 508 Figure 509 Only for machines to the serial number -->8X0510 Assemble the scoop ring. Screw M6x20 ISO4062-8.8 Apply locking liquid: Tree Bond 1374 Tightening torque: 9,5 Nm NOTE...
Page 535 DRIVE LINE Ch 3 page Connect the gear wheel and the car- rier. Washer 17x30x3 NS-ISO 7089 300HV Screw M16x50 ISO4017-10.9 EL Apply locking liquid: Tree Bond 1374 Tightening torque 280 Nm. Figure 512 SHOP MANUAL...
Page 536 DRIVE LINE Ch 3 page The press is stay on ! Figure 513 SHOP MANUAL...
Page 537: Cooling Cirquit Rear Brake
DRIVE LINE Ch 3 page Cooling cirquit rear brake Oil level Figure 514 SHOP MANUAL...
Page 538 DRIVE LINE Ch 3 page Figure 515 SHOP MANUAL...
Page 539: Axle And Tandem Housing Bearing
DRIVE LINE Ch 3 page Axle and Tandem housing Bearing Cross section DRIVELINE-VIEW BOGGI AXLE The tandem housing reduction gear consists of a pinion gear which transfers the rotation power through idle gears, end gears, and wheelshafts to the driven wheels. The tandem (spur) gears are in constant mesh, driving both wheels at the same side.
Page 540: Checking Clearance In The Tandem Bearing
DRIVE LINE Ch 3 page Checking clearance in the Tandem bearing. Check the diametric clearanse. Place the magnetic stand on the outer side of the frame bar. Reset the indicator to zero With crane or hydraulic jack, lift one of the sides until the wheels are clear from the floor.
Page 541: View Of The Tandem Bearing
DRIVE LINE Ch 3 page View of the Tandem bearing Figure 518 Figure 519 Inner ring (C) Outer ring (A) Outer ring (F) Seal ring Thrust ring (B,E) Inner ring (D) SHOP MANUAL...
Page 542 DRIVE LINE Ch 3 page Figure 520 SHOP MANUAL...
Page 543: Calculation Of The Tandem Bearing
DRIVE LINE Ch 3 page Calculation of the Tandem bearing Screw to Diametric the tandem housing Screw to the axle housing Figure 521 New vs, axial clearance example: Insert the measuring out values Measure A: 5,01 Measure F: 50,02 Sum A,F,: 55,03 55,03 Measure B:...
Page 544: Disassemble Tandem Housing Unit
DRIVE LINE Ch 3 page Disassemble Tandem housing unit Safety precautions. CAUTION Connect the articulation lock to front frame. Figure 522 CAUTION Secure the machine with wheel chocks on the front wheel. Figure 523 Drain the oil from axle housing and tandemhousing. NOTE Draining of oil from tandem housing is not neces- sary if removal takes place just for work on the...
Page 545: Disassemble The Tandem Unit From The Rear Frame
DRIVE LINE Ch 3 page Disassemble the tandem unit from the rear frame It is also possible to disassemble the tandem housing without dis- assemble the axle housing. See note on next page. Unfasten the rear propeller shaft from the differential flange M12x60 DIN912-12.9 Secure the rear propeller shaft for damage with a strop Figure 525...
Page 546 DRIVE LINE Ch 3 page NOTE If it is not possible to lift the rear frame off the tandem unit, the tandem unit could be pulled off the rear axle housing by using the arrangement as shown on the figure. Place the arrangement between the wheels.
Page 547: Disassembly The Axle Housing From The Tandemhousing
DRIVE LINE Ch 3 page Disassembly the axle housing from the tandem- housing Lift one side of the tandem unit and place safety supports under the axle housing. Be sure that the tandem unit is safely placed at the safety support. Safeguard the tandem housing with the crane Figure 532 Disassemble the wheel nut...
Page 548: Disassemble The Tandem Bearings
DRIVE LINE Ch 3 page Disassemble the tandem bearings Remove the actual tandem bearing. On top of the bearing, remove the M12 hexagon plug, fasten a lifting device in upper mounting holes and lift to take the weight of the tandem bearing. Unscrew the 30 M20- screw attaching the tandem bearing to the rear axle housing.
Page 549: Assemble The Tandem Housing To The Axle
Fill oil on the axle housing. Oil: Spirax S3 ALS 80W-90. (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Fill up the machine with oil when it is placed on a straight level...
Page 550 DRIVE LINE Ch 3 page Assemble the wheel. 20 pcs Width across flat: 30mm Torque limit: 450 Nm. Assemble the tandem housing to the rear frame. Lift the rear wagon with the crane. Move the tandemhousing unit under the rear frame and connect Figure 543 the frame and axle housing.
Page 551 DRIVE LINE Ch 3 page Note: SHOP MANUAL...
Page 552: Disassemble The Tandem Housing's Inside Parts
DRIVE LINE Ch 3 page Disassemble the tandem housing’s inside parts See the section: Safety precautions. WARNING Be aware of personal injury. Use the same precaution when changing the tandem housing and disassembling the hub. Drain oil from the tandem housing and the axle housing Figure 547 Disassemble the brake hoses.
Page 553 DRIVE LINE Ch 3 page NOTE Pos.no. refers to the exploded drawing on previous side. Disasseble the bolt (pos33) Take away the pos. 29-32 33-34 Figure 550 Disassemble screw from bolt on the other side (pos 24) M10x20 ISO4017-8.8 fzb Disassemble screws from the same bolt on opposite side of tandem unit Figure 551...
Page 554 DRIVE LINE Ch 3 page Place the tandem housing with the inside down. Disassemble 20 pcs screw M16x60 ISO4014-10.9 Loosen the hub from the tandem housing by putting 2 screws M12 or M16 into the tierce hole. (See arrow) Figure 553 By using crane, lift the hub up from the tandem housing.
Page 555 DRIVE LINE Ch 3 page Move the idle gear to the side and by lifting the device, take it out Figure 557 5 0 1 5 5 5 Disassemble the conical roller bearing Control the idle gear for damage. Clean before assemblage. Figure 558 Lift out the piniong drive.
Page 556 DRIVE LINE Ch 3 page Disassemble the snap ring Take out the thrust washer Figure 561 Disassemble the bearings Figure 562 Take out the snap ring and thrust washer with the O-ring. Disassemble the O-ring. Figure 563 Take out the oil seal Clean the tandem housing inside before assemblage.
Page 557 DRIVE LINE Ch 3 page Assemble the idle gears in the tandem house Pre-assemble the idle gear. 20 pcs, M16x45 DIN912-12.9 Apply locking liquid: Tree Bond 1374 5 0 1 5 5 5 Torque limit: 333 Nm Assemble the bearing cup to the pinion drive. (Cool down to -20°C before assembly) Use plastic hammer to install the bearing cup.
Page 558 DRIVE LINE Ch 3 page Screws Line up the part and assemble the bolt (It is advantageous to cool down the bolt to -20°C Bolt before assembly) O-ring Shims Washer Screw Figure 569 Use plastic hammer to knock the bolt in. Figure 570 Fasten the bolt Screw M10x25 ISO4017-10.9...
Page 559 DRIVE LINE Ch 3 page Measuring equipment: Micrometer 0 - 25 mm Ring D 85 - d 70 x h10,00 Place the ring in the mashining groove, with the micrometer measure distance from top of the ring an to the bolt. Calculation example: Measure to the bolt end.......
Page 560 DRIVE LINE Ch 3 page Check the pre-tensioning: 10 Nm Assemble the hub to the tandem housing See section: Assemble the hub to the tandemhousing. Figure 574 NOTE When both idle gears are assembled, assemble the pinion gear. SHOP MANUAL...
Page 561: Assembly Piniong In The Tandem House
DRIVE LINE Ch 3 page Assembly piniong in the tandem house Assemble new oil seal Figure 575 Figure 576 Assemble the pinion drive 2 Distance ring 2 pcs. ball-bearing 1 pcs. thrust washer 1 pcs. O-ring 1 pcs. snap ring Assemble the distance ring.
Page 562 DRIVE LINE Ch 3 page Grease the sealing ring Figure 578 Assemble the pinion drive. Figure 579 Figure 580 Use plastic hammer to assemble the pinion drive into the tandem housing. Figure 581 Assemble the cover. Apply sealing compound Loctite 574 to the flange Use plastic hammer to knock the cover gradually down.
Page 563: Tyres
DRIVE LINE Ch 3 page Tyres A tyre consists of four primary components; casing plies, beads, belts and tread. All four components are primarily responsible for the fundamentar characteristics of the tyre. Figure 584 BELTS. Extra layers of rubber-coated cord are placed between the outer plies and the tread, in order to protect the plies, preventing cuts from reaching the ply cords and absorbing shock.
Page 564 DRIVE LINE Ch 3 page Note SHOP MANUAL...
Page 565 Ch 4 LUBRICATION SYSTEM Page Chapter 4 Lubrication System T w i n SHOP MANUAL...
Page 566 Ch 4 Page LUBRICATION SYSTEM SHOP MANUAL...
Page 567 Ch 4 LUBRICATION SYSTEM Page Chapter 4 Lubrication System Index Lubrication system parts ......................5 Greasing cycles ........................... 7 Lubrication Points on DA series ....................9 Grease pressure switch ......................10 The 5/2 way valve ........................11 The relief valve ........................... 11 The minimum level switch ......................
Page 568 Ch 4 Page LUBRICATION SYSTEM SHOP MANUAL...
Page 569 Ch 4 LUBRICATION SYSTEM Page Lubrication system parts External and intenal parts A Groeneveld Twin automatic greasing sytems comprises the following parts: External components 1. An electric grease pump (plunger pump work- ing with CANBus) with integrated grease reservoir and a digital control unit with data storage facility; 2.
Page 570 Ch 4 Page LUBRICATION SYSTEM Groeneveld Twin internal wiring The electronic control unit steers and controls the Control unit course of the greasing cycles. All system and pro- gram parameters are stored in it. The control unit processes mal-function reports, gives possible alarms reports and automatically records a log.
Page 571 Ch 4 LUBRICATION SYSTEM Page Greasing cycles Every greasing cycle consists of four phases. The greasing cycles as carried out alternately by the grease lines A and B. The 5/2 way valve, which is inte- grated in the pump housing, determines which primary grease line is connected to the pump and which is con- nected to the grease reservoir.
Page 572 Ch 4 Page LUBRICATION SYSTEM Grease is pumped into the metering unit (pumping phase A) through primary grease line A. Because of the grease pressure, internal plunger (3) is pushed to right, passed channel (1). The grease fills cham- bers (2) through the channels and press the exter- nal plunger (4) to the right.
Page 573 Ch 4 LUBRICATION SYSTEM Page Lubrication Points on DA series Figure 9 SHOP MANUAL...
Page 574 Ch 4 Page LUBRICATION SYSTEM Grease pressure switch The grease pressure switch notifies the control unit that sufficient pressure has been built up during the pump- ing phase stops the pump. When the required pressure is not reached, the pumping phase is only ended after reaching the set maximum pumping time and an alarm will follow.
Page 575 Ch 4 LUBRICATION SYSTEM Page The 5/2 way valve When the 5/2 way valve is at stationary (not ener- gized), greasing will take place through primary grease line A and the pressure in primary grease line B will decrease and the grease will be lead back to the reservoir through return line R When the the 5/2 way valve is energized by the control unit, the grease supply channel P will be con-...
Page 576 Ch 4 Page LUBRICATION SYSTEM The minimum level switch A minimum level switch monitors the grease level in the reservoir. When the grease reaches the minimum level, the minimum level switch will notify the control unit. After “X” cycles, the pump stops to avoid it to work empty.
Page 577 Ch 4 LUBRICATION SYSTEM Page The continuous-test cycle With a continuous-test cycle extra grease can quickly be added to the greasing points or the grease system can be bled. Proceed as follows to carry out a continuous-test cycle: 1. Turn on the contact switch. 2.
Page 578 Ch 4 Page LUBRICATION SYSTEM Solid additivites in the grease (e.g. Teflon (PFTE) and graphite) can cause blockages in the greasing system in the long run. Therefore Groeneveld advises against the use of these kinds of grease in the greasing system. Grease with molybdenum disulphide (MoS ) may only be used when the grease is of top quality and contains no more than 5% MoS...
Page 579 Ch 4 LUBRICATION SYSTEM Page NOTE Please install a 1 meter hose in between the pump outlet and the manometer to give the test circuit some extra contents in away that small pressure fluctuations can be faded and make sure that this manometer assembly it can handle minimal 250 bar.
Page 580 Ch 4 Page LUBRICATION SYSTEM Dimensions of the Twin Pump Figure 20 SHOP MANUAL...
Page 581 Chapter 5 Hydraulic system (One Pump Solution)
Page 582 HYDRAULIC Ch 5 page SHOP MANUAL...
Page 583 Components, capacities and oil types ..........5 Hydraulic system main function......................6 Hydraulic System Description ......................7 Hydraulic System Components ......................7 Hydraulic parts view DA30 / DA40 ....................8 Main Valve Circuit ...........................9 Main Valve - List Of Components ....................10 Hydraulic System pressure ......................10 Main Valve - Orifices ........................11...
Page 584 HYDRAULIC Ch 5 page Service brakes overview .......................59 Parking brake, description ......................60 Parking brake circuit veiw ......................61 Accumulators ..................62 Description of the Accumulators ....................62 Filling table of Correction Factors ....................65 Accumulator charging: ........................66 SHOP MANUAL...
Page 585 BIO oil cannot be mixed with hydraulic oil and system need to be flushed • Type of BIO oil to be accepted by Doosan (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Hydraulic tank DA30: •...
Page 586 HYDRAULIC Ch 5 page Hydraulic system main function. The hydraulic system has two pumps. The steering system, accumulators, tilting functions and the cooling fan functions are fed by hydraulic pump 1 (145ccm/rev.), driven by the engine. The emergency sterring system is fed by the emergency steering pump (3) (maximum 50 l/min) which is driven by the truck’s motion, either forwards or backwards.
Page 587 The 2,15 Litre parking brake accumulator is placed on the left side of the cab front wall along with the 3,3 Litres front service brake accumulator. The two 3,3 Litre rear service brake accumulators are placed on the right side of the cab front wall. The accumulators are from Doosan Infracore Norway factory loaded with Nitrogen (N Return Filter The hydraulic return filter has as function filter all hydraulic oil that returns to the tank.
Page 588 Fan Drive Motor The Fan Drive Motor is located at the front end of the engine, just behind the cooler package. Access is ob- tained by removing the bonnet. Hydraulic parts view DA30 / DA40 Figure 3 SHOP MANUAL...
Page 589 HYDRAULIC Ch 5 page Main Valve Circuit Figure 4 SHOP MANUAL...
Page 590 HYDRAULIC Ch 5 page Main Valve - List Of Components Pos. Description Function Solenoid valve Parking brake release valve 1, 11, 21, 30, Coil: 24 V, 14 W Prssure relief valve Pump pressure spike clipper valve 4, 5, 6, 7 Check valve Brake accumulator charge and isolated function...
Page 591 HYDRAULIC Ch 5 page Main Valve - Orifices There are 7 orifices on the main valve. Below, positioning of them on the hydraulic diagram and in the main valve and, also, their function on the hy- draulic system. Figure 5 SHOP MANUAL...
Page 592 HYDRAULIC Ch 5 page Figure 6 Position 9: Orifice M6 - Ø 0,8mm Damping the activation of brake charging. Position 10: Orifice M6 - Ø 0,8mm Limit the charge rate of the parking brake accumulator (ACC 3). Position 12: Orifice M6 - Ø 1,5mm Limiting flow to brake charge circuit, pilot supply and diff lock function.
Page 593 HYDRAULIC Ch 5 page Main Valve - Spare Parts & Torques Position Description Part no. Head/socket Torque Relief valve Cartridge: 7/8” (22,2mm) 45Nm Set screw: 3/16” (4,8mm) Lock nut: 11/16”(17,5mm) Seal Kit Position Description Part no. Head/socket Torque Relief valve Cartridge: 13mm 10Nm Set screw: 3mm...
Page 594 HYDRAULIC Ch 5 page Position Description Part no. Head/socket Torque Check valve 8mm! * 10Nm * Make sure 8mm socket facing outside of port! Position Description Part no. Head/socket Torque Relief valve 10mm 60Nm Seal Kit Position Description Part no. Head/socket Torque Check valve...
Page 595 HYDRAULIC Ch 5 page Position Description Part no. Head/socket Torque 30Nm Flow Control Valve , Spring, Plug) (Poppet Position Description Part no. Head/socket Torque Solenoid valve 7/8” (22,2mm) 30Nm Coil 3/4” (19,0mm) 3,5Nm! Seal Kit Position Description Part no. Head/socket Torque 10Nm +Locking fluid...
Page 596 HYDRAULIC Ch 5 page Tilt valve - Exploded Find information about each part in the parts catalog Figure 7 SHOP MANUAL...
Page 597 HYDRAULIC Ch 5 page Description Pos nr. / Items Spool Complete spool/outlet section Flange kit 37(40Nm), 38, 39 Cap kit 3 [1(10Nm), 2, 31], 4, 5(10Nm), 32 Seal kit4,31 Spring kit 6, 7, 8, 9 PLC-Cartridge 22, 35 Relief valve 21 [22,34(80Nm)] Relief valve 23 [22,34(80Nm)]...
Page 598 HYDRAULIC Ch 5 page SHOP MANUAL...
Page 599 HYDRAULIC Ch 5 page Hydraulic circuit DA30 Up to mod. no. 7X0545 3,0 bar 0,2 bar 0,2 bar 3,5 bar...
Page 601 Hydraulic circuit DA40 Up to mod. no. 8X0567 3,0 bar 0,2 bar 0,2 bar 3,5 bar...
Page 602 Ch 5 HYDRAULIC page...
Page 603 HYDRAULIC Ch 5 page NOTE SHOP MANUAL...
Page 604 HYDRAULIC Ch 5 page Pump description • Variable axial piston pump • LS – operated • Mounted at rear of transmission • Driven by the engine • Ratio • Maximum volume 145 ccm • Stand – by pressure 25 ±2.0bar (idle) •...
Page 605 HYDRAULIC Ch 5 page Test block The Test Block is the place where is possible to check all the main pressures from the hydraulic system. Through the test ports, it is possible to diagnose the maximum and minimum values of the hydraulic pressures of each part of the system.
Page 606 HYDRAULIC Ch 5 page Main pump pressure adjusting Low Pressure Adjustment: Connect the manometer at the test port P1M (140) on the Test Block. Engine idle, pressure 20 bar. Adjust the pump to the correct value 20 bar: • Loosening the nut and turning the screw clockwise you will increase pressure •...
Page 607 HYDRAULIC Ch 5 page Main pump pressure adjusting High Pressure Adjustment: Connect the manometer at the test port P1M on the Test Block. Test the high pressure 280 bar with to run the engine 1000 rpm and raise the tilt cylinder to end stop. Adjust the pump to the correct value 280 bar: •...
Page 608 HYDRAULIC Ch 5 page Main pump circuit Drain S (In) TANK P (Out) LSP1 Figure 14 SHOP MANUAL...
Page 609 HYDRAULIC Ch 5 page Main pump parts list Item Description Item Description SHOP MANUAL...
Page 610 HYDRAULIC Ch 5 page SHOP MANUAL...
Page 611 HYDRAULIC Ch 5 page Main pump exploded view Hose connection Figure 15...
Page 613 Main pump section drawing Section B - B Section A - A Figure 16...
Page 614 Ch 5 HYDRAULIC page...
Page 615 HYDRAULIC Ch 5 page Pump, disassemble - assemble the shaft Disassembly of the pump in the warranty period is not allowed. In this instance the period of guarantee is not valid. Take the dimension A – top of max. volume stop screw to servo cover.
Page 616 This oil flow is amplified in the flow amplifier and the total oil flow is directed to the steering cylinders. The orbitrol has a displacement of 160cm3/rev(DA30) and 250cm3/rev(DA40) and the amplification factor is 8. This means that total displacement is 160 cm3 x 8 = 1280 cm3(DA30) and 250 cm3 x 8 = 2000(DA40) per steering wheel revolution.
Page 617 Orbitrol: • Displacement: DA30 - 160 cm³ (9.76 in³ / rev) DA40 - 250 cm³ (15.25 in³ / rev) • Rated oil flow: 25 L/min (6.60 U.S. gal / min) The Steering Master Valve is located on the cab front wall (firewall).
Page 618 HYDRAULIC Ch 5 page Figure 20 SHOP MANUAL...
Page 619 HYDRAULIC Ch 5 page Figure 21 SHOP MANUAL...
Page 620 HYDRAULIC Ch 5 page Steering Pressure Adjustment Steering Pressure Adjustment NOTE Only on model 7X0544 - 8X0566 Loosen steering master valve (Orbitrol) Remove hose supports to pull valve down to access adjusting port. Remove plug next to master valve mounting flange 8mm Allen /Unbrako key.
Page 621 HYDRAULIC Ch 5 page Steering valve • OSQA / OLSQ • Amplification value 8 The Steering Valve is located on the front front wagon, left-rear. Removal Figure 24 Thoroughly clean the steering valve and the area around for any accumulated dirt. Place a container below the valve to catch any hydraulic fluid spilt during removal.
Page 622 HYDRAULIC Ch 5 page Steering circuit DA30 / DA40 Orbitrol Figure 25 Steering valve Figure 26 Figure 27 SHOP MANUAL...
Page 623 Connect lubrication lines if fitted. Fill cylinder with hydraulic oil, and install hydraulic hoses. (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Control Check that all connections are located in the same positions as before removal, and that all hoses are correctly routed.
Page 624 HYDRAULIC Ch 5 page 380 Nm To/from Steering Valve 380 Nm Rear pivot bolt Steering Cylinder (left side shown) 380 Nm Front pivot bolt 380 Nm Figure 29 SHOP MANUAL...
Page 625 HYDRAULIC Ch 5 page Steering cylinder, sectional drawing. Torque Limit Pos. 3: 1370 Nm Pos. 7: 5 Nm Pos. 13: 450 Nm Figure 30 Steering cylinder ass’y Pos Qt’y Description Screw Bushing Piston Steering Piston seal O-ring Locking screw Casing O-ring Backup ring Steering...
Page 626 HYDRAULIC Ch 5 page Emergency steering pump • Variable radial piston pump • Mounted on rear of transmission • Driven by output shaft (Ground driven) • Maximum volume: 32 ccm • Maximum delivery: 50 l/min The dump truck is equipped with a ground driven radial piston pump fitted at the transmission.
Page 627 HYDRAULIC Ch 5 page Figure 32 SHOP MANUAL...
Page 628 HYDRAULIC Ch 5 page Figure 33 SHOP MANUAL...
Page 629 HYDRAULIC Ch 5 page Tilting system Tilt Lever The Tilt Lever is located in the cab in console on drivers right hand side. It is joystick designed for controlling hydraulic functions, using 0,5 - 4,5 Vdc outputs. This joystick has two (2) contactless hall effect sensors that provide mirrored voltage outputs for controlling proportional valve drivers.
Page 630 HYDRAULIC Ch 5 page View of the tilting system Figure 37 SHOP MANUAL...
Page 631 HYDRAULIC Ch 5 page Tilt cylinders: • Double acting • • Cylinder diameter DA30: 115mm DA40: 125mm • Piston diameter DA30: 70mm DA40: 85mm • Stroke DA30: 2290mm DA40: 2614 mm Figure 38 SHOP MANUAL...
Page 632 HYDRAULIC Ch 5 page The Tilt Cylinders are located on the rear wagon on each side of the dumper body. To remove the cylinders, rise the dumper body, and place body on safety stand. Removal Thoroughly clean the tilt cylinder and the area around for any accumulated dirt.
Page 633 HYDRAULIC Ch 5 page Tilt cylinder, sectional drawing. 13 14 15 16 Figure 40 Tilting cylinder ass'y Pos Qt’y Description DA30 DA40 Internal circlip Ø105mm Ø105 mm Spherical insert Cylinder end forged Ø115mm Ø125 mm Hexagonal socket screw M8x20 M8x20 Piston head Ø115mm...
Page 634 HYDRAULIC Ch 5 page Fan system To FDM port From FDM port From FD port TANK To T2 port Oil cooler Figure 41 SHOP MANUAL...
Page 635 HYDRAULIC Ch 5 page Fan Drive Motor The Fan Drive Motor is located at the front end of the engine, just behind the cooler package Access is obtained by removing the bonnet. Removal: Drain the cooling system. Remove the upper coolant and charge air hoses from cooler package.
Page 636 HYDRAULIC Ch 5 page Disassemble the fan and fan motor Drain the cooling system; Remove the pipeline between the en- gine and the air cooler (1); Remove clamping band for the hose and wiring; Disassemble the inlet cooling hoses from the thermostat housing (2); Disassemble the hydraulic hoses from the fan motor (3);...
Page 637 HYDRAULIC Ch 5 page Brakes Brake circuit view...
Page 638 Ch 5 HYDRAULIC page...
Page 639 HYDRAULIC Ch 5 page Service brakes overview Figure 45 SHOP MANUAL...
Page 640 HYDRAULIC Ch 5 page Parking brake, description The parking brake is spring actuated, hydraulic released, self adjusting, single disc brake mounted at the fixed propeller shaft in rear chassis. Operation When the parking brake switch, is switched to the “on” - position, the parking brake accumulator, charged by the hydraulic pump is closed by the solenoid valve and park brake oil is returned to tank.
Page 641 HYDRAULIC Ch 5 page Parking brake circuit veiw Solenoide Valve All the pressures on the brake system are adjusted by software. Figure 47 SHOP MANUAL...
Page 642 If the pressure of the gas contained in the nitrogen bottle is greater than the maximum permissible operating pressure of the accumulator, a pressure regulator must be fitted to the nitrogen bottle. Doosan recommends that the precharge should be checked during the first week following commissioning of the system.
Page 643 HYDRAULIC Ch 5 page Gas Bottle Fittings and Part Numbers To meet the requirements of different markets, Parker’s UCA Charging and Gauging Kits are supplied with an adapter to suit the appropriate gas bottle fitting. Controls A Inflation valve B Bleed valve 1 UCA 3 Adapter (short) 4 Adapter (insert) with fibre washer...
Page 644 HYDRAULIC Ch 5 page Operating Instructions Only fluids in Group 2 as defined by the Pressure Equipment Directive 97/23/EC are permitted for use in A and AP Series accumulators – see Piston Accumulator Operating Instructions, bulletin 1240-T1. Before installation, refer to the pressure and temperature limits shown on the nameplate. For cyclic loading, consult Parker regarding the fatigue-free working pressure range or limiting of the number of cycles for finite life applications.
Page 645 HYDRAULIC Ch 5 page Filling table of Correction Factors Table of Correction Factors Precharge Temperature t °C Example The satisfactory operation of a hydraulic system requires a precharge pressure of 100 bar. The operating temperature t 50°C and the temperature at precharging t0 is 20°C. From the table, a correction factor of 0.91 should be applied, giving a precharge pressure at 20°C of 91 bar.
Page 646 HYDRAULIC Ch 5 page Accumulator charging: • Minimum charging (start) 170 - 190 bar (ACC3) • Maximum charging (pressure relief) 205 bar Figure 50 SHOP MANUAL...
Page 647 HYDRAULIC Ch 5 page SHOP MANUAL...
Page 648 Chapter 5 Hydraulic system (Two Pumps Solution) 8X0502 - 8X0549...
Page 650 Hydraulic system main function......................7 System pressure ..........................8 Hydraulic parts view DA 40 (Two Pumps) ..................8 Main Valve - Spare Parts & Torques ....................9 Hydraulic circuit DA40 (Two pumps) .....................15 Startup test procedure ..............17 Pumps ....................18 P1 and P2 description ........................18 Test block ............................19...
Page 651 HYDRAULIC SYSTEM Ch 5 page Accumulators ..................58 Description of the Accumulators ....................58 Filling table of Correction Factors ....................61 Accumulator charging ........................62 SHOP MANUAL...
Page 652 HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL...
Page 653 BIO oil cannot be mixed with hydraulic oil and system need to be flushed • Type of BIO oil to be accepted by Doosan Infracore Norway (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Hydraulic tank DA40: •...
Page 654 HYDRAULIC SYSTEM Ch 5 page Hydraulic system main function. The hydraulic system has three pumps. The steering system, accumulators and tilting functions are fed by hydraulic pump 1 (145ccm/rev.). Cooling fan system and the tilting functions are fed by hydraulic pump 2 (60ccm/rev). Both pumps are driven by the engine.
Page 655 HYDRAULIC SYSTEM Ch 5 page System pressure Brake system pressure: • Front brake circuit 59±2 bar • Rear brake circuit 2.4 bar less pressure than front Pressure monitoring sensors: • Main pump Sensor monitors exact value • Emergency steering pump 2.2 / 2.5 bar (vehicle moving) •...
Page 656 HYDRAULIC SYSTEM Ch 5 page Main Valve - Spare Parts & Torques Position Description Part no. Head/socket Torque Check valve 8mm! * 10Nm * Make sure 8mm socket facing outside of port! Position Description Part no. Head/socket Torque Relief valve 531087 Cartridge: 7/8"...
Page 657 HYDRAULIC SYSTEM Ch 5 page Position Description Part no. Head/socket Torque Check valve BC1-0,6 8mm! * 10Nm * Make sure 8mm socket facing outside of port! Position Description Part no. Head/socket Torque 2, 3 Relief valve PLC053-300 10mm 60Nm Seal Kit 532023 Position Description Part no.
Page 658 HYDRAULIC SYSTEM Ch 5 page Position Description Part no. Head/socket Torque Solenoid valve 524484 7/8" (22,2mm) 30Nm Coil 530049 3/4" (19,0mm) 3,5Nm! Seal Kit 532011 Position Description Part no. Head/socket Torque Shuttle valve 10Nm + Locking Fluid Seal Kit 532025 Position Description Part no.
Page 659 HYDRAULIC SYSTEM Ch 5 page Figure 4 Position 9: Orifice M6 - Ø 0,8mm Damping the activation of brake charging. Position 10: Orifice M6 - Ø 0,8mm Limit the charge rate of the parking brake accumulator (ACC 3). Position 12: Orifice M6 - Ø 1,5mm Limiting flow to brake charge circuit, pilot supply and diff lock function.
Page 660 HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL...
Page 661 HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL...
Page 662 HYDRAULIC SYSTEM Ch 5 page Hydraulic circuit DA40 (Two pumps) Figure 5 SHOP MANUAL...
Page 663 Ch 5 HYDRAULIC SYSTEM page SHOP MANUAL...
Page 664 HYDRAULIC SYSTEM Ch 5 page NOTE SHOP MANUAL...
Page 665 HYDRAULIC SYSTEM Ch 5 page Pumps P1 and P2 description • Variable axial piston pump • LS – operated • Mounted at rear of transmission • Driven by the engine • Ratio • Maximum volume Pump 1 145 ccm Pump 2 60 ccm •...
Page 666 HYDRAULIC SYSTEM Ch 5 page Test block The Test Block is the place where is possible to check all the main pressures from the hydraulic system. Through the test ports, it is possible to diagnose the maximum and minimum values of the hydraulic pressures of each part of the system.
Page 667 HYDRAULIC SYSTEM Ch 5 page Pump P1 pressure adjusting Low Pressure Adjustment: Connect the manometer at the test port P1M (140) on the Test Block. Engine idle, pressure 20 bar. Adjust the pump to the correct value 20 bar: • Loosening the nut and turning the screw clockwise you will increase pressure •...
Page 668 HYDRAULIC SYSTEM Ch 5 page High Pressure Adjustment: Connect the manometer at the test port P1M on the Test Block. Test the high pressure 280 bar with to run the engine 1000 rpm and raise the tilt cylinder to end stop. Adjust the pump to the correct value 280 bar: •...
Page 669 HYDRAULIC SYSTEM Ch 5 page Pump P2 pressure adjusting Low Pressure Adjustment: Connect the manometer at the test port P1M (140) on the Test Block. Engine idle, pressure 25 bar. Adjust the pump to the correct value 20 bar: • Loosening the nut and turning the screw clockwise you will increase pressure •...
Page 670 HYDRAULIC SYSTEM Ch 5 page High Pressure Adjustment: Connect the manometer at the test port P1M on the Test Block. Test the high pressure 280 bar with to run the engine 1000 rpm and raise the tilt cylinder to end stop. Adjust the pump to the correct value 280 bar: •...
Page 671 HYDRAULIC SYSTEM Ch 5 page Pumps circuit Figure 16 SHOP MANUAL...
Page 672 HYDRAULIC SYSTEM Ch 5 page Pumps parts list Item Description Item Description SHOP MANUAL...
Page 673 HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL...
Page 674 HYDRAULIC SYSTEM Ch 5 page Pump exploded view Hose connection Figure 17 SHOP MANUAL...
Page 675 Ch 5 HYDRAULIC SYSTEM page SHOP MANUAL...
Page 676 HYDRAULIC SYSTEM Ch 5 page Section A - A Section B - B Figure 18 SHOP MANUAL...
Page 677 Ch 5 HYDRAULIC SYSTEM page SHOP MANUAL...
Page 678 HYDRAULIC SYSTEM Ch 5 page Pumps, disassemble - assemble the shaft Disassembly of the pump in the warranty period is not allowed. In this instance the period of guarantee is not valid. 1.Take the dimension A – top of max. volume stop screw to servo cover.
Page 679 HYDRAULIC SYSTEM Ch 5 page Steering system Description: The steering system is built up of an orbitrol steering unit, a steering valve dinamic flow amplifier and two steer- ing cylinders. When the orbitrol is activated, a controlled oil flow is directed to the flow amplifier. This oil flow is amplified in the flow amplifier and the total oil flow is directed to the steering cylinders.
Page 680 HYDRAULIC SYSTEM Ch 5 page Steering Master Valve (Orbitrol) Orbitrol: • Displacement: 250 cm³ (15.25 in³ / rev) • Rated oil flow: 25 L/min (6.60 U.S. gal / min) The Steering Master Valve is located on the cab front wall (firewall). Access is obtained by tilting the cab. (Ref.
Page 681 HYDRAULIC SYSTEM Ch 5 page Figure 22 SHOP MANUAL...
Page 682 HYDRAULIC SYSTEM Ch 5 page Figure 23 SHOP MANUAL...
Page 683 HYDRAULIC SYSTEM Ch 5 page Steering Pressure Adjustment Steering Pressure Adjustment Loosen steering master valve (Orbitrol) Remove hose supports to pull valve down to access adjusting port. Remove plug next to master valve mounting flange 8mm Allen /Unbrako key. Insert allen key 6mm into the adjusting screw. Adjust pressure by turning key, turn key clock- wise to increase pressure, or anticlockwise to reduce pressure.
Page 684 HYDRAULIC SYSTEM Ch 5 page Steering valve • OSQA / OLSQ • Amplification value 8 The Steering Valve is located on the front front wagon, left-rear. Removal Thoroughly clean the steering valve and the area around for any accumulated dirt. Figure 26 Place a container below the valve to catch any hydraulic fluid spilt during removal.
Page 685 HYDRAULIC SYSTEM Ch 5 page Steering circuit DA30 / DA40 Orbitrol Figure 27 Steering valve Figure 28 Figure 29 SHOP MANUAL...
Page 686 Connect lubrication lines if fitted. Fill cylinder with hydraulic oil, and install hydraulic hoses. (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Control Check that all connections are located in the same positions as before removal, and that all hoses are correctly routed.
Page 687 HYDRAULIC SYSTEM Ch 5 page 380 Nm To/from Steering Valve 380 Nm Rear pivot bolt Steering Cylinder (left side shown) 380 Nm Front pivot bolt 380 Nm Figure 31 SHOP MANUAL...
Page 688 HYDRAULIC SYSTEM Ch 5 page Steering cylinder, sectional drawing. Torque Limit Pos. 3: 1370 Nm Pos. 7: 5 Nm Pos. 13: 450 Nm Figure 32 Steering cylinder ass’y Pos Qt’y Description Screw Bushing Piston Steering Piston seal O-ring Locking screw Casing O-ring Backup ring...
Page 689 HYDRAULIC SYSTEM Ch 5 page Emergency steering pump • Variable radial piston pump • Mounted on rear of transmission • Driven by output shaft (Ground driven) • Maximum volume: 32 ccm • Maximum delivery: 50 l/min The dump truck is equipped with a ground driven radial piston pump fitted at the transmission.
Page 690 HYDRAULIC SYSTEM Ch 5 page Figure 34 SHOP MANUAL...
Page 691 HYDRAULIC SYSTEM Ch 5 page Figure 35 SHOP MANUAL...
Page 692 HYDRAULIC SYSTEM Ch 5 page Tilting system Tilt Lever The Tilt Lever is located in the cab in console on drivers right hand side. It is joystick designed for controlling hydraulic functions, using 0,5 - 4,5 Vdc outputs. This joystick has two (2) contactless hall effect sensors that provide mirrored voltage outputs for controlling proportional valve drivers.
Page 693 HYDRAULIC SYSTEM Ch 5 page View of the tilting system Figure 39 SHOP MANUAL...
Page 694 HYDRAULIC SYSTEM Ch 5 page Tilt cylinders • Double acting • • Cylinder diameter 125mm • Piston diameter 85mm • Stroke 2614 mm Figure 40 SHOP MANUAL...
Page 695 HYDRAULIC SYSTEM Ch 5 page The Tilt Cylinders are located on the rear wagon on each side of the dumper body. To remove the cylinders, rise the dumper body, and place body on safety stand. Removal Thoroughly clean the tilt cylinder and the area around for any accumulated dirt.
Page 696 HYDRAULIC SYSTEM Ch 5 page Tilt cylinder, sectional drawing. 13 14 15 16 Figure 42 Tilting cylinder ass'y Pos Qt’y Description Internal circlip Ø105 mm Spherical insert Cylinder end forged Ø125 mm Hexagonal socket screw M8x20 Piston head Ø125 mm Seal Bearing strip O-ring...
Page 697 HYDRAULIC SYSTEM Ch 5 page Fan system To FDM port From FDM port From FD port TANK To T2 port Figure 43 SHOP MANUAL...
Page 698 HYDRAULIC SYSTEM Ch 5 page Fan Drive Motor The Fan Drive Motor is located at the front end of the engine, just behind the cooler package Access is obtained by removing the bonnet. Removal: Drain the cooling system. Remove the upper coolant and charge air hoses from cooler package.
Page 699 HYDRAULIC SYSTEM Ch 5 page Disassemble the fan and fan motor Drain the cooling system; Remove the pipeline between the en- gine and the air cooler (1); Remove clamping band for the hose and wiring; Disassemble the inlet cooling hoses from the thermostat housing (2);...
Page 700 HYDRAULIC SYSTEM Ch 5 page Brakes Brakes circuit view Figure 47 SHOP MANUAL...
Page 701 Ch 5 HYDRAULIC SYSTEM page SHOP MANUAL...
Page 702 HYDRAULIC SYSTEM Ch 5 page Service brakes overview Figure 48 SHOP MANUAL...
Page 703 HYDRAULIC SYSTEM Ch 5 page Parking brake, description The parking brake is spring actuated, hydraulic released, self adjusting, single disc brake mounted at the fixed propeller shaft in rear chassis. Operation When the parking brake switch, is switched to the “on” - position, the parking brake accumulator, charged by the hydraulic pump is closed by the solenoid valve and park brake oil is returned to tank.
Page 704 HYDRAULIC SYSTEM Ch 5 page Parking brake circuit veiw Figure 50 Solenoide Valve Figure 51 All the pressures on the brake system are adjusted by software. SHOP MANUAL...
Page 705 If the pressure of the gas contained in the nitrogen bottle is greater than the maximum permissible operating pressure of the accumulator, a pressure regulator must be fitted to the nitrogen bottle. Doosan recommends that the precharge should be checked during the first week following commissioning of the system.
Page 706 HYDRAULIC SYSTEM Ch 5 page Gas Bottle Fittings and Part Numbers To meet the requirements of different markets, Parker’s UCA Charging and Gauging Kits are supplied with an adapter to suit the appropriate gas bottle fitting. Controls A Inflation valve B Bleed valve 1 UCA 3 Adapter (short)
Page 707 HYDRAULIC SYSTEM Ch 5 page Operating Instructions Only fluids in Group 2 as defined by the Pressure Equipment Directive 97/23/EC are permitted for use in A and AP Series accumulators – see Piston Accumulator Operating Instructions, bulletin 1240-T1. Before installation, refer to the pressure and temperature limits shown on the nameplate. For cyclic loading, consult Parker regarding the fatigue-free working pressure range or limiting of the number of cycles for finite life applications.
Page 708 HYDRAULIC SYSTEM Ch 5 page Filling table of Correction Factors Table of Correction Factors Precharge Temperature t °C Figure 55 Example The satisfactory operation of a hydraulic system requires a precharge pressure of 100 bar. The operating temperature t 50°C and the temperature at precharging t0 is 20°C. From the table, a correction factor of 0.91 should be applied, giving a precharge pressure at 20°C of 91 bar.
Page 709 HYDRAULIC SYSTEM Ch 5 page Accumulator charging • Minimum charging (start) 195 bar • Maximum charging (relief) 205 bar Figure 56 SHOP MANUAL...
Page 710 HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL...
Page 711 ELECTRICAL SYSTEM Ch 6 page Chapter 6 Electrical system SHOP MANUAL...
Page 712 Central lubrication main unit, (overview) ..................37 Rear frame ...........................39 DA series functions and parameters ..........40 Brake/brake charge system (Accumulators) (7) .................40 WDB Cooling (only on DA40) (7) ....................40 Emergency Steering system (9) ....................41 Park brake (6) ..........................42 Low engine oil pressure (2) ......................42 Low coolant level (3) ........................42...
Page 713 ELECTRICAL SYSTEM Ch 6 page Quick warmup function .........................46 Cooldown function ........................46 Alternative engine speed ......................47 Interior light ...........................47 Retarder and Engine brake (24 - 25) ....................47 Emergency Stop ...........................47 Fuel Heater ...........................48 A/C compressor control ........................48 To be implented ................. 49 Engine electrical components.
Page 714 ELECTRICAL SYSTEM Ch 6 page SHOP MANUAL...
Page 715 ELECTRICAL SYSTEM Ch 6 page How to use the electrical documentation The electrical documentation consists of three different types of documents: map, circuit drawings and a cross reference list. Each document includes a different quantity of component numbers. Component numbers (abbreviation: Comp.no.) Each electrical component got its own private component number (Pos) The component number is the same for the Shop Manual as for the Parts Catalogue.
Page 716 DA series functions and parameters ..........Open the Index list to find the page Brake/brake charge system (Accumulators) ................WDB Cooling (only on DA40) ..................... Emergency Steering system ....................... TO BE IMPLENTED: ........................hvere the component is described. Park brake ..........................
Page 717 ELECTRICAL SYSTEM Ch 6 page Description of the VCU2 functionality Doosan Moxy VCU 2 Figure 1 The VCU2 is place inside cabin on rear wall right side, covered by interior plate NOTE IF ANY INTERNAL FAILURE OCCUR, THE VCU2 SHOULD BE REPLACED FOR A NEW ONE.
Page 718 ELECTRICAL SYSTEM Ch 6 page Find wiring contact on VCU2 Figure 2 On the VCU2 there is contact point for different wiring connections. These are all markt with an X and a number (X1 X2 etc.) These number you can find on the Electrican Circuit drawing.
Page 719 ELECTRICAL SYSTEM Ch 6 page Figure 4 To find the fuse locatrion on Circuit Figure 5 SHOP MANUAL...
Page 720 ELECTRICAL SYSTEM Ch 6 page LCD Instrumentation Unit Warning Lights Display 10 11 12 13 14 15 16 Figure 6 18. Working lights and extra high beam 1. Engine failure warning 19. Rotating beacon light 2. Low engine oil pressure warning 20.
Page 721 ELECTRICAL SYSTEM Ch 6 page LCD screen main menu Figure 7 LCD use description There are 6 point to choise on the screen To find, use the up and down and select buttons to choise • User setting Trip counter A and B reset •...
Page 722 ELECTRICAL SYSTEM Ch 6 page Pos reference list Pos. No Circuit and Map No. Description VCU2 text (circuit diagram) place ref. 1- G4 Steering column switch 1- I 5 OPBTN2 Operating buttons 1- M5 Tip joystick 1- K4 Foot brake pedal 1- F11 LCD unit 1- E15...
Page 723 ELECTRICAL SYSTEM Ch 6 page Pos. No Circuit and Map No. Description VCU2 text (circuit diagram) place ref. 2- A4 Accumulator2 Rear brake 2- B4 Accumulator3 Park brake 2- B4 A (body lift) 2- B4 Park brake 2- B4 Emergency steering 2- C4 Ambient 2- C4...
Page 724 ELECTRICAL SYSTEM Ch 6 page Pos. No Circuit and Map No. Description VCU2 text (circuit diagram) place ref. 2- B9 RH front direction light 2- C9 RH high/low beam 2- D10 LH mirror arm low beam 2- D10 LH mirror work light 2- D10 LH upper mirror 2- D10...
Page 725 ELECTRICAL SYSTEM Ch 6 page Pos. No Circuit and Map No. Description VCU2 text (circuit diagram) place ref. 1- J9 Diagnostics 1- G8 LCD USB connector 2- B15 Main fuse 100a 2- B15 Secondary Fuse 15A 2- D15 Secondary Fuse 20A 2- E14 Engine heater relay Cab split- Deutch HDP20...
Page 726 ELECTRICAL SYSTEM Ch 6 page Description of the main electrical system. General description Voltage The truck has a 24V system. The batteri ÷ is used as ground connection. Supply Two batteries, each 12V/230Ah, are connected together in serial connection to provide the system with 24V. The batteries are located in the right hand side fender.
Page 727 ELECTRICAL SYSTEM Ch 6 page NOTE ·Never shut off main switch when engine are running ·Keep the batteries in good condition. ·Batteri power assistance: see Operating and Maintenance manual ·When exchanging electrical components: allways turn off the bat- tery main switch. ·Remember that a open circuit symptom in a warning light circuit might be a broken bulb.
Page 728 ELECTRICAL SYSTEM Ch 6 page SHOP MANUAL...
Page 729 ELECTRICAL SYSTEM Ch 6 page Component position Electrical parts view NOTE Principal components Go to the Pos reference list to find place on the circuit drawings parts be- long to. X-BS VCU2 El.central 130 Main switch 131 Battery 140 Hydraulic testpoint 171 Engine emergency switch off 172 Exp tank level 173 Air filter sensor...
Page 730 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL...
Page 731 ELECTRICAL SYSTEM Ch 6 page El.system, outside front and rear NOTE Go to the Pos reference list to find place on the circuit drawings parts be- long to. Figure 13 1003246 SHOP MANUAL...
Page 732 ELECTRICAL SYSTEM Ch 6 page Electrical equipment inside cab El.system, Cab inside NOTE Go to the Pos reference list to find place on the circuit drawings parts be- long to. 41 Operation switch panel 42 Tip joystick 43 Foot brake pedal 44 LCD unit 46 Accelerator pedal 47 Park brake switch...
Page 733 ELECTRICAL SYSTEM Ch 6 page Switch panel Figure 16 SHOP MANUAL...
Page 734 ELECTRICAL SYSTEM Ch 6 page Heater unit exploded Fan speed regulator To this figure see component list next page Figure 17 To get access to service work for the heater and AC unit, following this description: Remove the chair from cabine Remove plastic panels covering the unit To get inside of unit, remove the front steel plate.
Page 735 ELECTRICAL SYSTEM Ch 6 page Heater unit parts list Cabine upper front window. Pos. Description GROMMET INSULATION FRESH AIR DOOR INSILATION SIDE SPACER M4x25 RED CAP D50mm INSULATION REAR HOSE NOZZLE COOLING/HEATCOIL LEVER SEAL DRAIN VALVE SEAL FRESH AIR FRESH AIR DOOR EXPANSION VALVE INSULATION INSULATION...
Page 736 ELECTRICAL SYSTEM Ch 6 page Air conditioning system componenets Figure 19 The refrigeration cycle of vehicle air conditioning consists of the compressor, the condenser, the receiver-dryer, the expansion valve and the evaporator. When the refrigerant is circulated in the A/C system, the heat of the passenger compartment is drawn away by the evaporator and released outside the vehicle by the condenser.
Page 737 ELECTRICAL SYSTEM Ch 6 page Product final inspection The following controls are performed on each unit before leaving SNDC. 1)HEATER CONTROL • Tightness test • Water valve operation (opening/closing) 2)AIR CONDITIONING CONTROL • Tightness test • Thermostat connection 3)ELECTRICAL FUNCTIONS •...
Page 738 ELECTRICAL SYSTEM Ch 6 page Refrigerant charging WARNING The air conditioning system uses only R134a refrigerant and SP20 PAG oil WARNING The air conditioning system works only if the vehicle is running. While using the air conditioning system, keep all doors and windows closed. EVACUATION When the air conditioning system is opened to the atmosphere, moisture contained in the air will remain in the system.
Page 739 ELECTRICAL SYSTEM Ch 6 page Regulation controll Prior to the inspection: • Check that the air inlets are not blocked by any residues. • Check that the cab air louvers are opened to avoid evaporator freeze. • With the automatic slack adjuster, check the compressor drive belt movement and ten- sion: A too high tension: early wearing of the compressor bearings A too low tension: early wearing of the belt...
Page 740 ELECTRICAL SYSTEM Ch 6 page Repair If a repair is performed on an R134a compressor or system, evacu- ate the system for at least 30 minutes before recharging to ensure the removal of moisture which may have been absorbed by the PAG oil in the compressor and system.
Page 741 ELECTRICAL SYSTEM Ch 6 page Preassure reading and troubleshooting HP to high (level 1) After 3 minutes Compressor The condenser is Clean con- LP 2,5bar partially clogged denser HP 21bar HP to high (level 2) 1. recovery and recycle After 3 minutes compressor Circuit excessive refrigerant...
Page 742 ELECTRICAL SYSTEM Ch 6 page Safety measures Personal protective equipment Skin protection: Impervious gloves. Eye protection: Safety glasses. Storage recommendations Store in a cool, well-ventilated area of low fire risk and out of direct sunlight. Protect cylinder and its fittings from physical damage. Storage in subsurface locations should be avoided.
Page 743 ELECTRICAL SYSTEM Ch 6 page Place the thermometer in one of the air louvers, and check the cool air outlet temperature. Outside Temperature at Time needed to temperature louver exit reach temperature +20°C +4°C 2 min +25°C +4°C 3,5 min +30°C +4°C 5 min...
Page 744 ELECTRICAL SYSTEM Ch 6 page Use of the A.T.C The screen displays the cab temperature setting, the desired tem- perature in the cab. Pressing “1” will increase the displayed value. Each touch on “1” increases the value on the display by 1°C. The maximum value to be set is 28°C.
Page 745 ELECTRICAL SYSTEM Ch 6 page AIR CONDITIONING MODE Pushing A/C engages / disengages the compressor clutch. When the A/C symbol appears on the display, then the cooling sys- tem will be in operation. Conversely when the ECON symbol is lit, the compressor is turned off.
Page 746 ELECTRICAL SYSTEM Ch 6 page Press the A/C button and then AUTO and set the temperature 5°C above the desired temperature. Air Conditioning and heating will be simultaneously on and the blower goes to maximum flow in order to defog the windscreen. Figure 19 FAILURE CODES In case of sensor failure used to automatic adjustment, the display...
Page 747 ELECTRICAL SYSTEM Ch 6 page Central lubrication main unit, (overview) NOTE For this lubrication unit these Pos number not are on the Pos reference list Figure 19 SHOP MANUAL...
Page 748 ELECTRICAL SYSTEM Ch 6 page Figure 20 SHOP MANUAL...
Page 749 ELECTRICAL SYSTEM Ch 6 page Rear frame NOTE Go to the Pos reference list to find place on the circuit drawings parts belong to. The bracket Body down sensor breaking sensor beam is adjustable and must be adjusted cor- rectly in order for sensor to Gap between plate work.
Page 750 Rear tandem temperature alarm: 86/90°C Oil level alarm filter time: 3 sec Alarmbits2: .space 2 ; ** WDB Cooling (only on DA40) ** CAN signal from rear frame Front WDB oil level too low Sensor error on FRONT HUBS Alarm (red,...
Page 751 ELECTRICAL SYSTEM Ch 6 page Emergency Steering system (9) Reads output shaft speed from transmission. Alarm trigger: 2.2/2.5bar + >200rpm for 3 seconds Alarm (red, Sensor error on EMST loud alarm) Pressure too low while vehicle moving Warning (amber, Sensor error Transmission output shaft short beep) SHOP MANUAL...
Page 752 ELECTRICAL SYSTEM Ch 6 page Park brake (6) Engage automatically if ignition is switched off. If switch is in released position when turning on ignition, the driver will need to flip the switch on-off to release park brake. Lamp will turn on/off: 10/50bar If pressure sensor (PBOUT) fails, the lamp will reflect switch position.
Page 753 ELECTRICAL SYSTEM Ch 6 page Charge lamp (12) Lamp state is controlled from Scania canbus message. Scania ECU is monitoring the alternator. Body tip system (13) Green float: Body down (proxy switch contact) and A pressure( body lift) < 7.5bar and engine running. The float solenoid valve is open to tank in this state.
Page 754 The rear differential lock will automatically disengage if vehicle speed >12km/h or if center differential lock is released. The front differential is a limited slip locking type. On the DA40 the rear differential is a limited slip locking type. SHOP MANUAL...
Page 755 Retarder temperature (measured on transmission via canbus): >10°C = 0% 10-94°C = 1% 95-112°C = 1-100% >112°C = 100% Front WDB oil temperature (DA40 only, measured via VCU2): >10°C = 0% 10-74°C = 1% 75-115°C = 1-100% >115°C = 100% Charge air compensated temperature (measured on engine via canbus and in front of cooling pack): The fan is controlled to maintain a maximum 25°C rise in charge air temperature in respect to the ambient tem-...
Page 756 ELECTRICAL SYSTEM Ch 6 page Quick warmup function The quick warmup function is using the ZF retarder to add heat into transmission oil and engine coolant water. NOTE The ZF software may need an upgrade to accept this feature. The quick warmup is automatically activated when the following conditions are met: Engine speed = 400..900rpm Engine coolant temperature <...
Page 757 ELECTRICAL SYSTEM Ch 6 page Alternative engine speed The F1 button on the panel is used to control the engine rated speed. F1 inactive = 2100rpm F1 active = 1950rpm Changing mode is only possible when the transmission is in NEUTRAL. When the 1950rpm rated speed is selected the VCU2 will control the engine droop via the canbus.
Page 758 ELECTRICAL SYSTEM Ch 6 page Fuel Heater The fuel heater is enabled with a button on the switch panel. The fuel heater is located inside the diesel filter on the engine. The heater also has an integrated thermostat that will switch off at ap- prox.
Page 759 ELECTRICAL SYSTEM Ch 6 page To be implented Alarmbits 4: .space 2 ; ** General hydraulic 1 ** Sensor error on A(TIP) TIP-UP proportional solenoid abnormal value TIP-UP proportional solenoid open circuit TIP-DOWN proportional solenoid abnormal value Alarm (red, TIP-DOWN proportional solenoid open circuit loud alarm) FLOAT solenoid short circuit FLOAT solenoid open circuit...
Page 760 ELECTRICAL SYSTEM Ch 6 page Alarmbits 8: .space 2 ; ** Sensor 2 ** Accelerator/tip joystick 5V error Alarm (red, Accelerator pedal signal error loud alarm) Tip joystick signal error Gear selector signal error Alarmbits 9: .space 2 ; ** Engine/TM external ** EP400 oil level sensor error Alarm (red, Coolant level low...
Page 761 ELECTRICAL SYSTEM Ch 6 page Engine electrical components. Alternator Specifications Alternator 28V 35 - 100A Output at 6000 rpm. 2500 W Gear ratio 3,5:1 Number of poles Resistance in rotor approx. 11.2 ohm +/- 5% Resistance in stator, Phase-Phase 0.085 ohms +/- 0.001 Brushes, min, length >2.5 mm Slip rings, min.
Page 762 ELECTRICAL SYSTEM Ch 6 page Charge testing The alternator must not be run without the battery connected. The rectifiers can otherwise overload and be damaged. Output test Connect a calibrated test instrument with load resistor as illustrated. Start the engine and let it run for a few minutes before carrying out the test.
Page 763 ELECTRICAL SYSTEM Ch 6 page 150 Starter Voltage: 24 V Max power consumption: 6,7 kW (9,1 hp) Bosch JE: Assembly Specifications Power 6.7 kW Direction of rotation (viewed towards flywheel housing) Anti-clockwise Min. diameter of commutator 42.5 mm Min. length of carbon brushes 17.5 mm Spring pressure of carbon brushes 47-53 N...
Page 764 ELECTRICAL SYSTEM Ch 6 page Integral parts 1 Solenoid switch 2 Coupling lever 3 Field windings with pole shoes 4 Rotor with commutator 5 Starter pinion 6 Brush holder with four carbon brushes Figure 33 Exploded view drawing 1 Excitation winding 2 Bolt 3 Compression spring 4 Bearing...
Page 765 ELECTRICAL SYSTEM Ch 6 page Renewal Carbon brushes Equipment required Four spring locks are required to renew the carbon brushes and springs simply and safely. These can be easily made from thin sheet steel which is cut into four pieces approximately 20 x 40 mm. Work description Before renewal, the starter motor should be removed.
Page 766 ELECTRICAL SYSTEM Ch 6 page Engine EMS S6 / S8 Control unit S6 / S8 Tier2 and Tier4 Power supply: Nominal 24 V DC . The Control unit is transient and reverse voltage protected by a series diode. Function The engine control unit collects information that it later converts to signals for controlling the fuel system, alternator, starter motor, radiator fan and air conditioning.
Page 767 ELECTRICAL SYSTEM Ch 6 page The sensor group includes: Coolant temperature sensor, T33 Charge air pressure sensor, T47 Charge air temperature sensor, T47 Figure 41 You can make an aid from steel wire, see illustration, to make it easier to remove the connectors from the control unit.
Page 768 ELECTRICAL SYSTEM Ch 6 page Electrical cable routing Important! Electrical cables must be correctly routed and clamped in order to prevent chafing and cable faults Example Figure 45 SHOP MANUAL...
Page 769 ELECTRICAL SYSTEM Ch 6 page EMS connection chart Figure 46 SHOP MANUAL...
Page 770 ELECTRICAL SYSTEM Ch 6 page Figure 47 SHOP MANUAL...
Page 771 ELECTRICAL SYSTEM Ch 6 page EMS pin list A1/1 Control of injector, cylinder 4 +24V XPI injector, (V144) A1/2 Control of injector, cylinder 5 +24V XPI injector, (V145) A1/3 Control of injector, cylinder 6 +24V XPI injector, (V146) A1/4 Not used A1/5 Not used A1/6...
Page 772 ELECTRICAL SYSTEM Ch 6 page A6/3 Heating of intake air temperature and flow sensor +24V Intake air temperature and flow sensor (T126) A6/4 Grounding, position sensor for throttle Ground Position sensor for throttle, (T162) A6/5 Voltage supply, position sensor for throttle +5V Position sensor for throttle, (T162) A6/6 Not used A6/7...
Page 773 ELECTRICAL SYSTEM Ch 6 page B4/7 CAN exhaust gas aftertreatment CAN HIGH EEC3 B4/8 CAN exhaust gas aftertreatment CAN LOW EEC3 B4/9 Not used B4/10 Not used B5/1 Control of starter motor Digital output signal Starter motor (relay) M1 A1 B5/2 Not used B5/3...
Page 774 ELECTRICAL SYSTEM Ch 6 page SHOP MANUAL...
Page 775 ELECTRICAL SYSTEM Ch 6 page Engine Management System S8 T21, charge air temperature sensor T122, charge air pressure sensor T33, coolant temperature sensor T5, oil pressure sensor T74, T75, engine speed sensors T111, fuel pressure sensor V141-V148, XPI injectors V120, fuel inlet metering valve T125, exhaust back pressure sensor M1, starter motor...
Page 776 ELECTRICAL SYSTEM Ch 6 page Introduction The S8 has been developed to control the Scania XPI fuel system. More components than before are controlled by the engine control unit and the control of some components has been extended. The communication and control of the following components operates as in the S7: Engine speed sensors Coolant temperature sensor Charge air pressure sensor...
Page 777 ELECTRICAL SYSTEM Ch 6 page Adaptation Fuel injection is optimised through adaptation. In this case the engine control unit adapts to each individual injector at regular intervals in order to provide the best possible performance and fuel economy. During adaptation, the engine idles hard with the exhaust brake active. Alternator The engine control unit determines when the alternator is to charge.
Page 778 ELECTRICAL SYSTEM Ch 6 page Request for torque The control units for the gearbox management system, TCU, and VCU, can, if necessary, request torque via the engine control unit, e.g. when changing gear and for traction control. The system concerned may request maximum torque for a short period, then the torque is limited to approximately 70% for a further period.
Page 779 ELECTRICAL SYSTEM Ch 6 page Engine speed and camsghaft sensors Engine speed sensors There are two engine speed sensors in the EMS system, en- 1 Engine speed sensor 1, T74 gine speed sensor 1 and engine speed sensor 2. The sensors 2 Engine speed sensor 2, T75 are inductive.
Page 780 ELECTRICAL SYSTEM Ch 6 page Sensor engine coolant temperature T33, Coolant temperature sensor Function: Coolant temperature sensor, XPI fuel system Applies to engines with cylinder block generation 2. The engine control unit uses the value from the coolant temperature sensor to adjust the fuel quantity and injection timing when starting the engine and when the engine is cold.
Page 781 ELECTRICAL SYSTEM Ch 6 page Sensor coolant level monitor Detach the connector, grasp the sensor firmly and pull it out from its position under the coolant reservoir. The sensor is not in direct contact with the coolant so it is not necessary to drain the coolant. Figure 53 Sensor engine boost temperature T121, Charge air temperature sensor...
Page 782 ELECTRICAL SYSTEM Ch 6 page Engine charge air pressure T122, Charge air pressure sensor Function: The charge air pressure sensor detects the absolute pressure in the intake manifold, i.e. the atmospheric pressure plus the positive pressure provided by the turbocharger. The signal from the sensor is directly proportional to the charge air pressure.
Page 783 ELECTRICAL SYSTEM Ch 6 page Control unit EMS S8 The engine control unit controls the engine functions. Figure 59 Fuel pressure sensor The fuel pressure sensor informs the engine control unit of the current fuel pressure in the accumulator. Function: The fuel pressure sensor registers and informs the engine control unit of the current fuel pressure in the accumulator.
Page 784 ELECTRICAL SYSTEM Ch 6 page Fuel inlet metering valve Resistance values Temperature °C Resistance ± 0.5 ohms Figure 61 The fuel inlet metering valve controls how much fuel is brought into the high pressure pump. The fuel inlet metering valve is located on the high pressure pump. The fuel metering valve controls the fuel flow to the high pressure pump and is controlled by a PWM signal from the engine control unit.
Page 785 ELECTRICAL SYSTEM Ch 6 page Transmission spesification of electrical components Transmission speed sensors Figure 63 Transmission sensors for speed pick-up. Hall-Sensor of the Output Working range: 2 Hz to 5 Khz Supply voltage: 24 V Distance between sensor and gear ring: 1,0 mm + 0,5 mm Figure 64 SHOP MANUAL...
Page 786 ELECTRICAL SYSTEM Ch 6 page Transmission temperature sensors The temperature sensor oil out from transmission is placed inside converter housing. Remove plug vith 24 mm Allen screw key Figure 66 Figure 65 Clutch pressure controller ZF position (Solenoid valve) number Resistance at 20°C 11 Temperature sensor oil in from cooler...
Page 787 ELECTRICAL SYSTEM Ch 6 page Transmission solenoid valves Shifting block I Shifting block II Propotional valve Resistance at 20°C 11 Ω Shifting block I Pressure regulator valve Pressure regulator valve Pressure regulator valve Pressure regulator valve Pressure regulator valve Pressure regulator valve Presure reduce valve 9bar Wiring harness ErgoControl II...
Page 788 ELECTRICAL SYSTEM Ch 6 page Transmission pressure switch Figure 71 Figure 70 Transmission electric switch Sensor, sump temperature Restance: 1 kΩ to 1,5 kΩ Measure point: Connector pos 156 between 8 and 9 SHOP MANUAL...
Page 789 ELECTRICAL SYSTEM Ch 6 page Sensors hydraulic system Figure 72 143 – Rear Brake 145 – Tilt Cylinder Pressure Pressure 144 – Park Brake 142 – Front Brake 140 – Pump 1 Pressure Pressure Pressure Figure 73 SHOP MANUAL...
Page 790 ELECTRICAL SYSTEM Ch 6 page Steering valve, el. connection 147 - Emergency Steering Figure 74 SHOP MANUAL...
Page 791 ELECTRICAL SYSTEM Ch 6 page Main valve el. connection Figure 75 SHOP MANUAL...
Page 792 ELECTRICAL SYSTEM Ch 6 page Parking brake sensor 191 – Parking Brake Figure 76 SHOP MANUAL...
Page 793 ELECTRICAL SYSTEM Ch 6 page Body float sensor 192 – Body Float Figure 77 SHOP MANUAL...
Page 794 ELECTRICAL SYSTEM Ch 6 page Body tilting sensor The body tilting sensor is assembled on rear frame. For safety reasons this registers if body is up or down. Adjusting the plate breaking sensor beam Raise the body approximately 400mm from frame 400mm Figure 78 Lower the plate until it breaks sensor beam.
Page 795 ELECTRICAL SYSTEM Ch 6 page Electrical chart and circuit Cab roof cable set Figure 80 SHOP MANUAL...
Page 796 ELECTRICAL SYSTEM Ch 6 page Cab floor cable set Figure 81 SHOP MANUAL...
Page 797 ELECTRICAL SYSTEM Ch 6 page Cab inside rear wall cable set Back wall inside cab X1-23 S1-6 Sensor interface unit Figure 82 SHOP MANUAL...
Page 798 ELECTRICAL SYSTEM Ch 6 page SHOP MANUAL...
Page 799 ELECTRICAL SYSTEM Ch 6 page Wiring (cable set) S1 - S6 Wiring S1 - S6 Figure 83 SHOP MANUAL...
Page 800 Ch 6 ELECTRICAL SYSTEM page Cirquit chart cabine (No1) Figure 84 SHOP MANUAL...
Page 801 ELECTRICAL SYSTEM Ch 6 page Junction box battery compartment Figure 85 Figure 86 Figure 87 SHOP MANUAL...
Page 802 ELECTRICAL SYSTEM Ch 6 page SHOP MANUAL...
Page 803 ELECTRICAL SYSTEM Ch 6 page Cirquit chart front and rear frame (No2) SHOP MANUAL...
Page 804 Ch 6 ELECTRICAL SYSTEM page Exhaust Emmission Control Wiring diagram for the exhaust emission control Figure 88 SHOP MANUAL...
Page 805 ELECTRICAL SYSTEM Ch 6 page System overview for electrics 1 Control unit EEC3 2 NOx sensor 3 Temperature sensor 4 Level and temperature sensor 5 Reductant pump 6 Reductant doser 7 Coolant valve 8 Electrically heated reductant hoses Figure 90 1 Reductant tank 2 Control unit EEC3 3 Reductant pump...
Page 806 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL...
Page 807 FRONT WAGON Ch 7 Page Chapter 7 Front Wagon Index 7.1 Introduction ......................2 7.2 Front Axle Suspension ..................3 7.2.1 Hydraulic gas cylinder disassembly ..................4 7.2.2 Repairing the Hydraulic gas cylinder .................. 6 7.2.3 Hydraulic gas cylinder reassembly ..................8 7.2.4 Panhard Bar ........................
Page 808 Ch 7 FRONT WAGON Page 7.1 Introduction The Front Wagon is built up around the front frame, which is the base for the engine and the trans- mission. The frame is resting on the front suspension, and connected to the rear wagon in the articulation bearing.
Page 809 FRONT WAGON Ch 7 Page 7.2 Front Axle Suspension The Front Axle Suspension consists of two independent suspension arms connected to each other via the cross tube. Rubber cushions are acting as springs, and take the weight resting on the suspension which also are equipped with dual sets of shock absorbers.
Page 810 Ch 7 FRONT WAGON Page 7.2.1 Hydraulic gas cylinder disassembly NOTE The Hydraulic gas cylinder reduce the motion in the wheel suspension when driving on rough road condition. Figure 3 Attach chain with hooks onto lifting eyes on each side of the engine. Raise the dump truck.
Page 811 FRONT WAGON Ch 7 Page DANGER Place hydraulic stand beneath suspension arm to prevent it from falling down on removal. Figure 7 Thoroughly clean the front suspension. Cover Plate Unscrew and remove the suspension cover plate Figure 8 Remove locking bolt. Remove lubrication attachment.
Page 812 Ch 7 FRONT WAGON Page 7.2.2 Repairing the Hydraulic gas cylinder 1: Oil check valve (fill oil) 2: Bleed valve 3: Gas valve 4: Test point M28 x 1.5 Checking cylinder pressure tool kit: 531794 Adapter (Use adapter 531854 to check and fill nitrogen.) Attach tool on cylinder test point to perform pressure test.
Page 813 3.8 liters of oil to the cylinder either by pouring which will be slow, or by low pressure pumping of the measured amount of oil 68. (For fluid type and specifications, refer to the DOOSAN Oper- Figure 15 ating & Maintenance Manual Chapter 6) Close the rod to 640 mm to eject all air and excess of oil.
Page 814 Ch 7 FRONT WAGON Page 7.2.3 Hydraulic gas cylinder reassembly Position the hydraulic cylinder in the upper bracket, and replace the bolt. Figure 18 Adjust the length of the damper, or use the floor jack to line up the holes for the lower fastening bolt. Replace lower bolt and washer and secure with cotter pin.
Page 815 FRONT WAGON Ch 7 Page Lubricate the bolts, assemble the wheel and tighten bolts WARNING Serious injury or death may occur if handled improperly. WARNING Figure 22 Be aware of the risk of injury to people and equipment when handling heavy objects! Perform a test drive to see that the front suspension is functioning properly.
Page 816 Ch 7 FRONT WAGON Page 7.2.4 Panhard Bar The Panhard Bar restrict the sideways motion and stabilises in the front suspension. Removal Thoroughly clean the front suspension. Remove the two bolts securing the bar to the front frame. Save the shims. Remove the two bolts securing the panhard bar to the left suspension arm.
Page 817 FRONT WAGON Ch 7 Page 7.2.5 Suspension Bearing The Suspension Bearings are the pivot points for the front wheel suspension arms. Removal Thoroughly clean the front suspension. Remove actual wheel. Front frame must be supported on safety stands, not the suspension. Remove the hydraulic cylinder suspension from the suspension arm.
Page 818 Ch 7 FRONT WAGON Page Suspension Bearing Bearing Cover Figure 24 Chain Hoist Chain Hoist Figure 25 SHOP MANUAL...
Page 819 FRONT WAGON Ch 7 Page 7.2.6 Cross Tube Bushings The Cross Tube connects the left and right front suspension arms. The suspension arms rotate relative to the cross tube on the cross tube bushings. Removal Thoroughly clean the front suspension. Remove front wheels.
Page 820 Ch 7 FRONT WAGON Page 7.3 Articulation Hinge System The Articulation Hinge System consists of the Articulation Hinge, and the Articulation Bearing. The articulation hinge is the turning point of the steering motion, and the articulation bearing permits the front wagon and the rear wagon to roll relative to each other during driving.
Page 821 FRONT WAGON Ch 7 Page 7.3.1 Articulation Bearing To measure the wear on the articulation bearing, place the truck on level ground, with front and rear frame in line. If assembled, Disassemble body heating for better access. For axial measurement place a dial indicator on the articula- tion bearing as shown in figure 28.
Page 822 Ch 7 FRONT WAGON Page Removal Thoroughly clean the articulation bearing and the area around for accumulated dirt. Disconnect the intermediate drive shaft in the articulation hinge. (Ref. 3.5.3) Support the drive shaft, as it rotates when rear wagon is moved. Release the hose support to gain more movement on hoses and cables.
Page 823 FRONT WAGON Ch 7 Page 7.3.2 Articulation bearing ass’y Clean parts with a solvent. Locktite 7063 Figure 30 Use high pressure air to clean parts, removing particles that may have occurred in the machining process. Figure 31 Figure 32 Assemble inner ring. Use plastic hammer to carefully fit the inner ring.
Page 824 Ch 7 FRONT WAGON Page Assemble thrust ring to inner and outer ring. Figure 34 Apply locktite 2701 to threaded holes. Figure 35 Assemble and tighten bolts: 30Nm Figure 36 SHOP MANUAL...
Page 825 FRONT WAGON Ch 7 Page Measure outer rings and inner ring. Figure 37 NOTE Measuring details on page 20 - 21 Figure 38 Figure 39 Insert seal rings to outer rings and lubericate them with grease. The seal rings must be assembled correctly for maximum and proper lubrication flow.
Page 826 Ch 7 FRONT WAGON Page Figure 41 SHOP MANUAL...
Page 827 FRONT WAGON Ch 7 Page 7.3.3 Calculation of the Tandem bearing Screw to Diametric the tandem housing Screw to the axle housing Figure 42 New vs, axial clearance example: Insert the measuring out values Measure A: 5,01 Measure F: 50,02 Sum A,F,: 55,03 55,03...
Page 828 Ch 7 FRONT WAGON Page Make sure all surfaces are clean. Apply molokote to all copper. Apply grease to inner ring contact surfaces and Sealrings Figure 43 Figure 44 Figure 45 Fit inner ring and outer ring Figure 46 Assembly of outer rings Carefully fit the outer rings Figure 47 SHOP MANUAL...
Page 829 FRONT WAGON Ch 7 Page Complete Articulation bearing ready for assembly. Figure 48 Inner ring Outer ring Outer ring Seal ring Thrust ring Inner ring Figure 49 SHOP MANUAL...
Page 830 Ch 7 FRONT WAGON Page Installation Position articulation bearing on articulation hinge flange Tighten the 26 bolts. Move the rear wagon into position to enter the bolts fastening the bearing to the front frame. Tighten the 26 bolts. Connect the lubrication line. Manually engage the parking brake.
Page 831 FRONT WAGON Ch 7 Page 7.3.4 Articulation Hinge To measure the wear on the articulation hinge, place the truck on level ground, with front and rear frame in line. Place a hydraulic jack under centre of lower articulation hinge bolt according to Fig 27. Lift with a force of 1800 kp, and read the dial indicator.
Page 832 Ch 7 FRONT WAGON Page Disassemble the screws from the upper and lower articulation hinge bolt. Save the shims for re-use. Figure 52 Tap the upper and lower bolt using a soft mallet. if necessary, use a hydraulic cylinder, press out the upper and lower bolt.
Page 833 FRONT WAGON Ch 7 Page Remove the four bearings and the distance ring from the hinge. Check the condition of the seal rings for possible re-use. Installation Install new seal rings if necessary. Install the four bearings and the distance ring in the hinge. Position the articulation hinge on rear frame, and install the hinge bolts.
Page 834 Ch 7 FRONT WAGON Page Assemble the bearing in the upper part of the articu- lation hinge. See figure1 on previous page. Cool down the bearing cup (−20°C) (See figure 2 for correct position of the bearing cup and V-ring) Insert the bearing cup Pos.3 Insert the distance ring Pos.2 Insert the bearing cup Pos.3...
Page 835 FRONT WAGON Ch 7 Page Cool down the bearing cups (approx -20°C) 4 pcs. Insert the outer bearing cup. Figure 58 Press the bearing cup into articulation hinge. With the plate, press the bearing cup approx 1 mm under the outer surface.
Page 836 Ch 7 FRONT WAGON Page Clean the groove. Cleaning licuid: Loctite 7063 Figure 62 Assemble the V-rings 4pcs. Apply glue in the groove. Glue: Loctite 406 Figure 63 Figure 64 Press well around the V-ring in bottom of the groove. Figure 65 SHOP MANUAL...
Page 837 FRONT WAGON Ch 7 Page Pre-assemble the articulation hinge bolt Assemble the bearing cone on the bolt. Cool down the bolt (Approx − 20°C). Assemble the bearing. Figure 66 Tool for assemble the bearing: Pipe Ø 110 x ø101 x 130 mm. At the top, a plate Ø110 x 20 mm.
Page 838 Ch 7 FRONT WAGON Page Apply grease in the bearing cup. Grease type: See the Operating and Maintenance Manual lubrication list. Figure 70 Assemble the upper bearing cone at both ears. Figure 71 By crane, lift the articulation hinge and carefully connect the articulation hinge to the rear frame.
Page 839 FRONT WAGON Ch 7 Page Center the hinge for proper fitting of the upper bolt Figure 74 With a thin (1 mm) rounded tool, check that the V-ring is in it’s position. Figure 74 Line up the bore and assemble the upper bolt with the bearing cone.
Page 840 Ch 7 FRONT WAGON Page Procedure for the pre-tensioning the articulation bearing bolt. See figure 70 CAUTION The articulation hinge bolt is heavy, use caution when assem- bling 1 Assemble the plate, Pos 1. (ref.fig.57) Figure 77 2 Assemble 2 pcs washers and 2 pcs screws. Pos 2 and 3.
Page 841 FRONT WAGON Ch 7 Page 7.4 Fenders, Mudguards and Bonnet Fenders, Mudguards and Bonnet are together with the hydraulic tank, diesel fuel tank and cab, the bodywork of the dumper. Fenders and mudguards are exposed parts which are likely to be beaten up under heavy use, and should be replaced if damaged, as misalignment will reduce the protection for the internal parts, and reduce service life.
Page 842 Ch 7 FRONT WAGON Page 7.4.1 Fender RH The right hand Fender contains an air supply tank and the safety support for the cab, accessible by a hatch. The hatch is also the base for the right hand head lamp, as well as serving as working platform for engine main- tenance.
Page 843 FRONT WAGON Ch 7 Page 7.4.2 Fender LH The left hand Fender contains the battery main switch and the batteries, accessible by a hatch. The hatch is also used as a working platform for engine maintenance. WARNING Never turn off battery main switch when engine is running Never turn off battery mainSwitch when ignition is on Leave battery main switch on for atleast 5 minutes after engine has completely stopped.
Page 844 Ch 7 FRONT WAGON Page 7.4.3 Mudguard The Mudguards cover the front halves of the front wheels, and also act as a bridge from the fender working platform towards the diesel fuel tank on the right side, and to the cab door and hydraulic tank/central lubrication on the left side.
Page 845 The bonnet can also be locked with the key to keep unauthorized personnel from opening. For maintenance on the bonnet lock and release mechanism, the bonnet must be opened. If the bonnet can not be opened do to a malfunction in the mechanism, contact Doosan Infracore Norway for information on how to proceed.
Page 846 Ch 7 FRONT WAGON Page Bonnet Lock Lock Bracket Adjusting Nuts Adjustable Bonnet Lock Receptacle Release Wire Release Mechanism Release Handle Figure 89 Bonnet Lock Assembly SHOP MANUAL...
Page 847 FRONT WAGON Ch 7 Page 7.4.6 Bonnet Removal Thoroughly clean the bonnet and the area around for accumulated dirt. Open the bonnet, and secure with the catcher. (Ref. Operation and Maintenance Manual 2.19) Replace two nut with lifting eyes. (See Fig 80) Attach lifting device in the two lifting eyes, and use a crane to lift to take up the weight of the bonnet.
Page 848 Ch 7 FRONT WAGON Page 7.4.7 Bonnet adjustment and control Adjust bonnet forward/backward to a suitably seal towards coolingpack (all around). Figure 91 Bonnet should not extend beyond bonnet beam. Tighten the two foremost screws. Figure 92 Check the sides, bonnet should extend the same amount on both sides Figure 93 SHOP MANUAL...
Page 849 FRONT WAGON Ch 7 Page Measure gap between cab and bonnet, should be about 15mm. (both sides) Figure 94 Adjust height with shim (aligned with cab). Check if sealing inside bonnet against airfilter beam touches about the same time. Close the bonnet and check that the lock is functioning properly. Adjust if necessary, by re-positioning/re-shimming the bonnet lock receptacle.
Page 850 Ch 7 FRONT WAGON Page Assemble locking system to bonnet, bolt torque 68Nm. Lubricate the locking mechanism and check if lock mecha- nism is engaging properly before attaching wire to lock handle. Disassemble lock holder to test locking mechanism. If latch does not lock properly recheck the tension by adjusting wire on socket.
Page 851 FRONT WAGON Ch 7 Page 7.5 Cab The cab is tilted to gain access for maintenance, but if the cab has to be removed from the dumper for some reason, proceed as follows. 7.5.1 Cab Removal Discharge all accumulators. Thoroughly clean the cab and the area around for accumulated dirt. Check that the battery main switch is turned off.
Page 852 Replace the electrical connections on the left hand side of the electrical central. Replace ground connections. Refill AC system.(Authorized personnel only) Refill engine coolant. (For fluid type and specifications, refer to the DOOSAN Operating & Maintenance Manual Chapter 6) Lifting...
Page 853 FRONT WAGON Ch 7 Page 7.5.2 Cab Ventilation Control Panel The Cab Ventilation Control Panel is located in the driver’s front , upper in the roof, right side. WARNING Never turn off battery main switch when engine is running Never turn off battery mainSwitch when ignition is on Leave battery main switch on for atleast 5 minutes after engine has completely stopped.
Page 854 Ch 7 FRONT WAGON Page 7.5.3 Cab Ventilation Unit The Ventilation Unit provides temperature regulated air to all outlets in the cab ventilation system. Heat is provided from the engine cooling system, circulating through the heater unit, and cooling is provided from the air conditioning evaporizer.
Page 855 FRONT WAGON Ch 7 Page To access the valves to fill the system with freon gas or water to the heat system, remove the rear cover on the right side. Then is possible to reach the connectors. The air conditioning filter can be accesed from this way The air heating filter can be accessed from outside the cab, right side.
Page 856 Ch 7 FRONT WAGON Page 7.5.4 Cab Door The Cab Door is the only access to the cab, and should close properly to ensure driver safety and comfort. If door for some reason has to be removed, proceed as follows. Open door fully and pry rear bottom corner of door panel out to disengage some of the velcro securing panel, to get access to the four bolts fastening the door check arm to the door.
Page 857 FRONT WAGON Ch 7 Page 7.5.5 Door Damper Cylinder The Door Damper Cylinder keeps the door in open position when opened, and dampens the door movement. Removal Remove floor mat and rear kick panel. From outside, pull out the expansion lining from the sliding window channel, starting from the end at bottom center.
Page 858 Ch 7 FRONT WAGON Page 7.5.6 Steering Column The adjustable steering column comprises the steering wheel and the control handle for lights, turn signals, horn and windscreen wiper/washer. Removal Check that the steering is in neutral position, and ensure that the articulation lock is engaged. Make sure the battery main switch is turned off.
Page 859 FRONT WAGON Ch 7 Page SHOP MANUAL...
Page 860 REAR WAGON Ch 8 Page Chapter 8 Rear Wagon Index 8.1 Introduction ......................2 8.2 Dumper Body ......................3 8.2.1 Dumper Body ........................3 8.2.2 Tilt Bearing .......................... 4 SHOP MANUAL...
Page 861 Ch 8 REAR WAGON Page 8.1 Introduction The main component of the rear wagon is the rear frame, which is the base for the dumper body and the sup- port for the rear axles. The rear wagon is connected to the front wagon in the articulation bearing. The tiltable dumper body is attached to the rear frame in the tilt bearing.
Page 862 REAR WAGON Ch 8 Page 8.2 Dumper Body 8.2.1 Dumper Body Thoroughly clean the dumper body and tilt bearings for accumulated dirt. To remove Dumber Body, remove the hydraulic tilt cylinders. Hook the crane to the dumper body front lifting point, and lift the body to release the safety stand, and lower the body until resting on the rear frame.
Page 863 Ch 8 REAR WAGON Page 8.2.2 Tilt Bearing If tilt bearings only are going to be replaced it is not necessary to disconnect the tilt cylinders, tail gate operating chains, and remove the body. Remove the six bolts securing each tilt bearing bolt to the dumper body.. Disconnect lubrication lines if equipped.
Page 864 OPTION Ch 9 Page Chapter 9 Option Index 9 Optional Equipment ....................2 9.1 Automatic Tail Gate ........................ 2 9.2 Exhaust Heating For Dumping Body ..................5 9.2.1 View of the Exhaust Body Heating System ................. 5 9.2.2 Assembly of The Exhaust Body Heating System ..............6 9.3 View of the Engine heater ......................
Page 865 Ch 9 OPTION Page 9 Optional Equipment 9.1 Automatic Tail Gate The optional automatic tail gateis closed when dumper body is down in trnsport position, and opens as the body is tilted. The tail gate consists of the gate itself, and two arms pivoting in the tail gate bearings Removal Thoroughly clean the tail gate and area around for any accumulated dirt Dumper body must be in the down position for removal of the tail gate.
Page 866 OPTION Ch 9 Page WARNING Be aware of the risk of injury to people and equipment when handling heavy objects! When both arms are removed, attach the crane to the tail gate lifting eyes, loosen clamps, and lift off the tail gate.
Page 867 Ch 9 OPTION Page Lift the tail gate and place on dumper body. Secure tail gate temporary with large clamps. Lift each arm in position and secure arm bearing. to the bracket by tightening four bolts. Attach the lubrication line if equipped. Enter the bolts securing the arms to the tail gate, and use the number of shims required to obtain a satisfactory closing of the tail gate.
Page 868 OPTION Ch 9 Page 9.2 Exhaust Heating For Dumping Body 9.2.1 View of the Exhaust Body Heating System Figure 4 SHOP MANUAL...
Page 869 Ch 9 OPTION Page 9.2.2 Assembly of The Exhaust Body Heating System Install the rubber to the rear frame brackets. Connect the body adap- tor to the frame. Use shim between rubber and bracket and the adapter to adjust the contact surface between the body and adapter.
Page 870 OPTION Ch 9 Page Fix the vertical pipe on the silencer and, on the top, ﬁx the elbow with a V-clamp on the glove from the short exhaust pipe. Restrictors on body heating part, assembled as shown on drawing. Restrictor Assemble the flexible pipe between the lower elbow to the exhaust block.
Page 871 Ch 9 OPTION Page 9.3 View of the Engine heater Figure 11 model available SHOP MANUAL...
Page 872 OPTION Ch 9 Page 9.3.1 Engine heater assembly On the right side of engine next to the engine brake, assemble heater element and gasket with bracket. Figure 12 Figure 13 Use strips to attach the cable properly. And make sure connectors are secured with clamps. running the cable where it is most beneﬁcial.
Page 873 Ch 9 OPTION Page Coil cable if necessary and secure it with strips, connect grounding and connector. Figure 15 Use connection point on left side close to cabin steps. The engine heater comes with 115V or 230V output. Figure 16 Connect cable to heater element on engine.
Page 874 OPTION Ch 9 Page Location of the heater element on engine. The element is placed in the engine block behind the oil ﬁlter. Figure 18 SHOP MANUAL...
Page 875 Ch 9 OPTION Page 9.5 Webasto 9.5.1 Webasto View of the Webasto Figure 19 The Webasto is attached to fender with DOOSAN bracket Brackets used: Contact your nearest DOOSAN dealer for bracket components: Set includes: Cable set with safety switch...
Page 876 OPTION Ch 9 Page 9.5.2 Assembly Preparation The Webasto is located inside the left hand side fender. Drill holes for exhaust input and cooling fluid input. Grind sharp edges. Exhaust outlet hole should be located at the bottom. Figure 20 NOTE Clear some distance from weld seam.
Page 877 Ch 9 OPTION Page 9.5.3 Final assembly Pipe from exhaust to bottom (1) approximately 370mm long. Insert pipe from bottom and up, use clamp to lock it into possition on the inside. Pipe from exhaust to webasto (2) approximately 490mm long Figure 24 Assemble cooling hoses(1), power cable(2), fuel hose(3)
Page 878 OPTION Ch 9 Page SHOP MANUAL...
Page 879 ERROR CODES LIST Ch 10 Page Chapter 10 Error codes list Index English ........................2 Engine ............................2 Lubrication ........................... 6 Display internal ..........................7 VCU2 ............................7 Transmission ..........................10 Polish ........................14 Silnik ............................14 Układ smarowania ........................20 ś...
Page 880 Ch 10 ERROR CODES LIST Page English Engine FMI English Throttle Position - Above normal operational range Throttle Position - Below normal operational range Throttle Position - Erratic, intermittent or incorrect Throttle Position - Voltage above normal or shorted high Throttle Position - Voltage below normal or shorted low Throttle Position - Current below normal or open circuit Fuel Delivery Pressure - Above normal operational range...
Page 881 ERROR CODES LIST Ch 10 Page Injector Rail Pressure - Below normal operational range Injector Rail Pressure - Erratic, intermittent or incorrect Injector Rail Pressure - Voltage above normal or shorted high Injector Rail Pressure - Voltage below normal or shorted low Charging System - Erratic, intermittent or incorrect Charging System - Current below normal or open circuit Charging System - Current above normal or grounded circuit...
Page 882 Ch 10 ERROR CODES LIST Page Injector Cyl. #8 - Current below normal or open circuit Injector Cyl. #8 - Current above normal or grounded circuit Injector Cyl. #8 - Mechanical system not responding properly Starter Motor Relay - Above normal operational range Starter Motor Relay - Erratic, intermittent or incorrect Starter Motor Relay - Voltage above normal or shorted high Starter Motor Relay - Voltage below normal or shorted low...
Page 883 ERROR CODES LIST Ch 10 Page 2797 Engine Injector Group 1 - Voltage below normal or shorted low 2798 Engine Injector Group 2 - Erratic, intermittent or incorrect 2798 Engine Injector Group 2 - Voltage above normal or shorted high 2798 Engine Injector Group 2 - Voltage below normal or shorted low 3031...
Page 884 Ch 10 ERROR CODES LIST Page 4341 SCR Reagent Line Heater - Voltage above normal or shorted high 4341 SCR Reagent Line Heater - Current below normal or open circuit 4341 SCR Reagent Line Heater - Current above normal or grounded circuit 4374 SCR Pump Motor Speed - Above normal operational range...
Page 885 ERROR CODES LIST Ch 10 Page Display internal English 520200 19 No contact with ECU (Engine) on CAN1 520201 19 No contact with TCU (Transmission) on CAN1 520202 19 No contact with VCU (Vehicle controller) on CAN1 520203 19 No contact with VCU (Vehicle controller) on CAN2 520204 31 Gear shift is restricted VCU2...
Page 886 Ch 10 ERROR CODES LIST Page 521145 Pressure sensor A (tip up) short circuit 521146 High pressure on PBOUT (park brake) 521146 Low pressure on PBOUT (park brake) 521146 Pressure sensor PBOUT (park brake) open loop 521146 Pressure sensor PBOUT (park brake) short circuit 521147 Emergency steering pressure low 521147...
Page 887 ERROR CODES LIST Ch 10 Page 521202 1 Transmission oil level low 521202 2 Transmission oil level sensor signal error 521222 2 Transmission output speed sensor error/missing 521230 18 Lubrication system low grease level 521230 19 No CAN signal from lubrication system (7km/h speed limit) 521230 31 Lubrication system error (7km/h speed limit) 521310 5...
Page 888 Ch 10 ERROR CODES LIST Page Transmission FMI English 523000 1 Battery low undervoltage 523000 3 Battery overvoltage 523000 4 Battery undervoltage 523010 3 TCU internal 5V power supply overvoltage 523010 4 TCU internal 5V power supply undervoltage 523011 4 TCU internal 7V power supply undervoltage 523020 3 Supply for speed sensors overvoltage...
Page 889 ERROR CODES LIST Ch 10 Page 523110 6 Int. speed sensor 2 input open or short to ground 523110 7 Int. speed 2 does not match with other speeds 523110 8 Int. speed 2 direction of rotation unknown 523110 9 Int.
Page 890 Ch 10 ERROR CODES LIST Page 523210 3 Propvalve for Clutch C short to battery 523210 5 Propvalve for Clutch C open circuit 523210 6 Propvalve for Clutch C short to ground 523210 8 Propvalve for Clutch C short circuit to another valve 523215 0 Clutch D slipping unintentionally 523215 2...
Page 891 ERROR CODES LIST Ch 10 Page 523250 2 Current output 11 unknown electrical component 523250 3 Propvalve for Diff Lock short to battery 523250 5 Propvalve for Diff Lock open circuit 523250 6 Propvalve for Diff Lock short to ground 523250 8 Propvalve for Diff Lock short circuit to another valve 523300 0...
Page 892 Ch 10 ERROR CODES LIST Page Polish Silnik Polish Położenie przepustnicy - powyżej normalnego zakresu pracy Położenie przepustnicy - poniżej normalnego zakresu pracy Położenie przepustnicy - błędne, przerywane lub nieprawidłowe Położenie przepustnicy - napięcie powyżej normalnego lub zwarcie do układu wysokiego napięcia Położenie przepustnicy - napięcie poniżej normalnego lub zwarcie do układu niskiego napięcia...
Page 893 ERROR CODES LIST Ch 10 Page Temperatura cieczy chłodzącej silnik - napięcie powyżej normalnego lub zwarcie do układu wysokiego napięcia Temperatura cieczy chłodzącej silnik - napięcie poniżej normalnego lub zwarcie do układu niskiego napięcia Poziom płynu chłodzącego silnika - poniżej normalnego zakresu roboczego Poziom cieczy chłodzącej silnik - napięcie powyżej normalnego lub zwarcie do układu wysokiego napięcia Poziom cieczy chłodzącej silnik - napięcie poniżej normalnego lub zwarcie do...
Page 894 Ch 10 ERROR CODES LIST Page Wtryskiwacz cyl. #3 - natężenie prądu powyżej normy lub zwarcie obwodu do masy Wtryskiwacz cyl. #3 - Układ mechaniczny nie reaguje prawidłowo Wtryskiwacz cyl. #4 - natężenie prądu poniżej normy lub otwarty obwód Wtryskiwacz cyl. #4 - natężenie prądu powyżej normy lub zwarcie obwodu do masy Wtryskiwacz cyl.
Page 895 ERROR CODES LIST Ch 10 Page Przerwy zapłonu na wielu cylindrach 1322 Przerwa zapłonu cylindra #1 1323 Przerwa zapłonu cylindra #2 1324 Przerwa zapłonu cylindra #3 1325 Przerwa zapłonu cylindra #4 1326 Przerwa zapłonu cylindra #5 1327 Przerwa zapłonu cylindra #6 1328 Przerwa zapłonu cylindra #7 1329...
Page 896 Ch 10 ERROR CODES LIST Page Wyjście NOx - natężenie prądu powyżej normy lub zwarcie obwodu do masy 3226 Temperatura gazów spalinowych - błędna, przerywana lub nieprawidłowa 3241 Temperatura gazów spalinowych - napięcie powyżej normalnego lub zwarcie do 3241 układu wysokiego napięcia Temperatura gazów spalinowych - natężenie prądu poniżej normy lub otwarty 3241 obwód...
Page 897 ERROR CODES LIST Ch 10 Page Podgrzewacz linii reagentu SCR - natężenie prądu poniżej normalnego lub 4341 otwarty obwód Podgrzewacz linii reagentu SCR - natężenie prądu powyżej normalnego lub 4341 zwarcie obwodu do masy Prędkość silnika pompy SCR - powyżej normalnego zakresu pracy 4374 Prędkość...
Page 898 Ch 10 ERROR CODES LIST Page Układ smarowania Pamięć programu - błąd sumy kontrolnej parametrów ostrzeżenia Sterownik - błąd zegara Nieprawidłowe podłączenie lub wyładowany akumulator 3597 Pusty zasobnik smaru 5519 Błąd – awaria układu smarowania 5521 Brak ciśnienia na wyjściu A 5522 Brak ciśnienia na wyjściu B 5523...
Page 899 ERROR CODES LIST Ch 10 Page VCU2 FMI Polish VCU2 Błąd sygnału joysticka wywrotu 521042 2 Błąd sygnału pedału przyspieszania 521046 2 Błąd sygnału wybieraka biegów 521048 2 Otwarta pętla czujnika ciśnienia BR_F (przedni obwód hamulców) 521071 5 Zwarcie czujnika ciśnienia BR_F (przedni obwód hamulców) 521071 6 Otwarta pętla czujnika ciśnienia BR_R (tylny obwód hamulców) 521072 5...
Page 900 Ch 10 ERROR CODES LIST Page Zwarcie czujnika temperatury oleju hydraulicznego 521162 6 Poziom oleju przedniego WDB zbyt niski 521170 1 Uaktywniony wyłącznik AWARYJNY 521171 31 Niski poziom cieczy chłodzącej 521172 1 Zatkany filtr powietrza silnika 521173 0 Nienormalna wartość przesuwu zaworu przechyłu w górę 521180 2 Otwarta pętla zaworu przechyłu w górę...
Page 901 ERROR CODES LIST Ch 10 Page Otwarty obwód sprzęgła klimatyzacji 521350 5 Zwarcie sprzęgła klimatyzacji 521350 6 Otwarta pętla czujnika wysokiego ciśnienia HP (A/C HP) 521351 5 Zwarcie czujnika wysokiego ciśnienia HP (A/C HP) 521351 6 Otwarta pętla czujnika niskiego ciśnienia LP (A/C LP) 521352 5 Zwarcie czujnika niskiego ciśnienia LP (A/C LP) 521352 6...
Page 902 Ch 10 ERROR CODES LIST Page Skrzynia biegów Polish Zbyt niskie napięcie przy rozładowaniu akumulatora 523000 1 Nadmierne napięcie akumulatora 523000 3 Zbyt niskie napięcie akumulatora 523000 4 Nadmierne napięcie wewnętrznego zasilania 5 V sterownika TCU 523010 3 Zbyt niskie napięcie wewnętrznego zasilania 5V sterownika TCU 523010 4 Zbyt niskie napięcie wewnętrznego zasilania 7 V sterownika TCU 523011 4...
Page 903 ERROR CODES LIST Ch 10 Page Wejście czujnika 2 prędkości wewn. otwarte lub zwarte do masy 523110 6 Prędkość wewn. 2 niezgodna z innymi prędkościami 523110 7 Nieznany kierunek obrotów prędkości wewn. 2 523110 8 Prędkość wewn. 2 nieznana 523110 9 Kierunek obrotów wyjściowych niezgodny z innymi 523115 11 Nieznany element elektryczny wejścia czujnika prędkości wyjściowej...
Page 904 Ch 10 ERROR CODES LIST Page Nieznany element elektryczny wyjścia prądowego 3 523210 2 Zawór proporcjonalny dla sprzęgła C zwarty do akumulatora 523210 3 Otwarty obwód zaworu proporcjonalnego dla sprzęgła C 523210 5 Zawór proporcjonalny dla sprzęgła C zwarty do masy 523210 6 Zawór proporcjonalny dla sprzęgła C zwarty z innym zaworem 523210 8...
Page 905 ERROR CODES LIST Ch 10 Page Zawór proporcjonalny dla retardera zwarty z innym zaworem 523245 8 Nieznany element elektryczny wyjścia prądowego 11 523250 2 Zawór proporcjonalny dla blokady dyferencjału zwarty do akumulatora 523250 3 Otwarty obwód zaworu proporcjonalnego dla blokady dyferencjału 523250 5 Zawór proporcjonalny dla blokady dyferencjału zwarty do masy 523250 6...
Page 906 Ch 10 ERROR CODES LIST Page Spanish Motor Spanish Posición del acelerador - superior al margen operacional normal Posición del acelerador - inferior al margen operacional normal Posición del acelerador - errática, intermitente o incorrecta Posición del acelerador - voltaje superior al normal o cortocircuito alto Posición del acelerador - voltaje inferior al normal o cortocircuito bajo Posición del acelerador - corriente inferior a la normal o circuito abierto Presión de liberación de combustible - superior al margen operacional normal...
Page 907 ERROR CODES LIST Ch 10 Page Presión del rail del inyector - inferior al margen operacional normal Presión del rail del inyector - errática, intermitente o incorrecta Presión del rail del inyector - voltaje superior al normal o cortocircuito alto Presión del rail del inyector - voltaje inferior al normal o cortocircuito bajo Sistema de carga - errático, intermitente o incorrecto Sistema de carga - corriente inferior a la normal o circuito abierto...
Page 908 Ch 10 ERROR CODES LIST Page Cilindro del inyector 8 - el sistema mecánico no responde correctamente Relé del motor de arranque - superior al margen operacional normal Relé del motor de arranque - errático, intermitente o incorrecto Relé del motor de arranque - voltaje superior al normal o cortocircuito alto Relé...
Page 909 ERROR CODES LIST Ch 10 Page Grupo 2 del inyector del motor - errático, intermitente o incorrecto 2798 2798 Grupo 2 del inyector del motor - voltaje superior al normal o cortocircuito alto 2798 Grupo 2 del inyector del motor - voltaje inferior al normal o cortocircuito bajo Temperatura del tanque de catalizador SCR - superior al margen operacional 3031 normal...
Page 910 Ch 10 ERROR CODES LIST Page Temperatura de la dosificación SCR - errática, intermitente o incorrecta 4337 Temperatura de la dosificación SCR - voltaje superior al normal o cortocircuito 4337 alto Temperatura de la dosificación SCR - corriente superior al normal o circuito a 4337 tierra Calentador de la línea de reactivo SCR - errático, intermitente o incorrecto...
Page 911 ERROR CODES LIST Ch 10 Page Pantalla interna FMI Spanish 520200 19 No existe contacto con la ECU (motor) en CAN1 No existe contacto con la TCU (transmisión) en CAN1 520201 19 520202 19 No existe contacto con la VCU (control del vehículo) en CAN1 520203 19 No existe contacto con la VCU (control del vehículo) en CAN2 El cambio de marcha está...
Page 912 Ch 10 ERROR CODES LIST Page Ciclo abierto del sensor de presión PBOUT (freno de estacionami- 521146 5 ento) Cortocircuito del sensor de presión PBOUT (freno de estacionami- 521146 6 ento) Presión baja de la dirección de emergencia 521147 1 Ciclo abierto de la dirección de emergencia del sensor de presión 521147 5 Cortocircuito de la dirección de emergencia del sensor de presión...
Page 913 ERROR CODES LIST Ch 10 Page Nivel alto del depósito hidráulico 521201 15 Nivel bajo del depósito hidráulico 521201 17 Error de señal del sensor del nivel del depósito hidráulico 521201 2 Nivel de aceite de la transmisión alto 521202 0 Nivel de aceite de la transmisión bajo 521202 1 Error de señal del sensor del nivel de aceite de la transmisión...
Page 914 Ch 10 ERROR CODES LIST Page 521422 6 Cortocircuito del sensor de temperatura del aceite del WDB IZQ trasero 521424 0 Ascenso de caja (límite de velocidad 10 km/h) 521900 2 Error de suministro 5 V de la palanca de mando del acelerador/ volquete Transmisión FMI Spanish...
Page 915 ERROR CODES LIST Ch 10 Page 523100 9 Velocidad de la turbina desconocida La dirección velocidad de entrada 1 no coincide con otras 523105 11 Componente eléctrico desconocido de la entrada 1 del sensor de velocidad de 523105 2 entrada 523105 3 Sobrevoltaje de entrada 1 del sensor de velocidad de entrada 523105 6...
Page 916 Ch 10 ERROR CODES LIST Page Sobrevoltaje del interruptor de restricción del filtro 523155 3 Bajo voltaje del interruptor de restricción del filtro 523155 4 Circuito abierto o cortocircuito a masa del interruptor de restricción del filtro 523155 6 El embrague A se desliza involuntariamente 523200 0 Componente eléctrico desconocido de la salida de corriente 1 523200 2...
Page 917 ERROR CODES LIST Ch 10 Page El embrague E se desliza involuntariamente 523235 0 Componente eléctrico desconocido de la salida de corriente 8 523235 2 Cortocircuito a batería de la válvula prop. del embrague E 523235 3 Circuito abierto de la válvula prop. del embrague E 523235 5 Cortocircuito a masa de la válvula prop.
Page 918 Ch 10 ERROR CODES LIST Page Mensaje JBRC no válido o tiempo excedido 523427 9 Orden no válida del modo operativo 523470 19 Orden no válida de la transmisión 523471 19 Orden no válida del bloqueo del diferencial 523474 19 Orden no válida del bloqueo del convertidor de par 523475 19 Orden inválida del retardador...
Page 919 ERROR CODES LIST Ch 10 Page French Moteur French Position de l’accélérateur - Au-dessus de la plage d’opération normale Position de l’accélérateur - En dessous de la plage d’opération normale Position de l’accélérateur - Erratique, intermittente ou incorrecte Position de l’accélérateur - Tension au-dessus de la normale ou court-circuitée haut Position de l’accélérateur - Tension en-dessous de la normale ou court-circuitée Position de l’accélérateur - Intensité...
Page 920 Ch 10 ERROR CODES LIST Page Température du liquide de refroidissement du moteur - Tension en dessous de la normale ou court-circuitée bas Niveau du liquide de refroidissement moteur - En dessous de la plage d’opération normale Niveau du liquide de refroidissement du moteur - Tension au-dessus de la nor- male ou court-circuitée haut Niveau du liquide de refroidissement du moteur - Tension en dessous de la nor- male ou court-circuitée bas...
Page 921 ERROR CODES LIST Ch 10 Page Cylindre d’injection n° 4 - Intensité au dessus de la normale ou circuit à la masse Cylindre d’injection n° 4 - Le système mécanique ne répond pas correctement Cylindre d’injection n° 5 - Intensité en-dessous de la normale ou circuit ouvert Cylindre d’injection n°...
Page 922 Ch 10 ERROR CODES LIST Page 1442 Position de la soupape de carburant - Erratique, intermittente ou incorrecte 1442 Position de la soupape de carburant- Tension au-dessus de la normale ou court- circuitée haut 1483 Adresse source du disposition de contrôle pour la commande du moteur - Erra- tique 1632 Limite du couple moteur - Erratique...
Page 923 ERROR CODES LIST Ch 10 Page Unité de dosage de catalyse SRC - Erratique, intermittente ou incorrecte 3361 Unité de dosage de catalyse SRC - Tension au-dessus de la normale ou court- 3361 circuitée haut Unité de dosage de catalyse SRC - Tension en dessous de la normale ou court- 3361 circuitée bas Unité...
Page 924 Ch 10 ERROR CODES LIST Page Lubrification FMI French Mémoire de programme - Erreur de somme de contrôle du paramètre d’avertissement Contrôlez - Erreur d’horloge 3597 Mauvais câblage ou batterie faible Réservoir de graisse vide 5519 Erreur système de lubrification 5521 5522 Pas de pression dans la sortie A...
Page 925 ERROR CODES LIST Ch 10 Page VCU2 FMI French VCU2 521042 2 Erreur de signal du bout du joystick Erreur de signal de la pédale d’accélérateur 521046 2 Erreur de signal du sélecteur de vitesses 521048 2 521071 5 Boucle ouverte du capteur de pression BR_F (circuit avant de frein) 521071 6 Court-circuit du capteur de pression BR_F (circuit avant de frein) 521072 5...
Page 926 Ch 10 ERROR CODES LIST Page 521170 1 Niveau d’huile WDB avant trop faible Interrupteur d’arrêt d’urgence activé 521171 31 521172 1 Niveau du liquide de refroidissement bas Filtre à air moteur bouché 521173 0 521180 2 Valeur d’entraînement anormale de la soupape vers le haut 521180 5 Boucle ouverte de la soupape vers le haut 521181 2...
Page 927 ERROR CODES LIST Ch 10 Page 521351 5 Boucle ouverte du capteur de pression HP (HP A/C) 521351 6 Court-circuit du capteur de pression HP (HP A/C) 521352 5 Boucle ouverte du capteur de pression LP (LP A/C) 521352 6 Court-circuit du capteur de pression LP (LP A/C) 521410 5 Boucle ouverte arrière droit des feux de direction...
Page 928 Ch 10 ERROR CODES LIST Page Transmission FMI French 523000 1 Sous-tension de batterie faible 523000 3 Surtension de la batterie 523000 4 Sous-tension de batterie 523010 3 Surtension d’alimentation 5 V interne TCU 523010 4 Sous-tension d’alimentation 5V interne TCU 523011 4 Sous-tension d’alimentation 7 V interne TCU 523020 3...
Page 929 ERROR CODES LIST Ch 10 Page 523110 11 La vitesse int. 2 du sens de rotation ne correspond pas aux autres Composant électrique inconnu entrée 2 du capteur de vitesse int. 523110 2 Surtension d’entrée du capteur de vitesse int. 2 523110 3 Entrée du capteur de vitesse int.
Page 930 Ch 10 ERROR CODES LIST Page 523205 5 Circuit ouvert de soupape proportionnelle pour l’embrayage B Soupape proportionnelle pour l’embrayage B court-circuitée à la masse 523205 6 Soupape proportionnelle pour l’embrayage B court-circuitée sur une autre sou- 523205 8 pape 523210 0 L’embrayage C glisse involontairement Composant électrique inconnu 3 sortie de courant...
Page 931 ERROR CODES LIST Ch 10 Page 523240 0 L’embrayage de blocage glisse involontairement Composant électrique inconnu 9 sortie de courant 523240 2 Soupape proportionnelle pour l’embrayage de blocage court-circuitée à la bat- 523240 3 terie 523240 5 Circuit ouvert de soupape proportionnelle pour l’embrayage de blocage Soupape proportionnelle pour l’embrayage de blocage court-circuitée à...
Page 932 Ch 10 ERROR CODES LIST Page 523471 19 Commande de transmission invalide Commande de blocage différentiel invalide 523474 19 523475 19 Commande de blocage du convertisseur de couple invalide 523476 19 Commande du ralentisseur invalide Surrégime du moteur 523500 0 Erreur de fonction de sécurité...
Page 933 ERROR CODES LIST Ch 10 Page German Motor FMI German Drosselklappenstellung - über Normalbereich Drosselklappenstellung - unter Normalbereich Drosselklappenstellung - ungleichmäßig, mit Aussetzern oder falsch Drosselklappenstellung - Spannung höher als normal oder Kurzschluss an Plus Drosselklappenstellung - Spannung höher als normal oder Kurzschluss an Masse Drosselklappenstellung - Strom niedriger als normal oder unterbrochener Strom- kreis Kraftstoffförderdruck - über Normalbereich...
Page 934 Ch 10 ERROR CODES LIST Page Motorkühlmittelstand - Spannung niedriger als normal oder Kurzschluss an Masse Injektor-Raildruck - über Normalbereich Injektor-Raildruck - unter Normalbereich Injektor-Raildruck - ungleichmäßig, mit Aussetzern oder falsch Injektor-Raildruck - Spannung höher als normal oder Kurzschluss an Plus Injektor-Raildruck - Spannung niedriger als normal oder Kurzschluss an Masse Ladesystem - ungleichmäßig, mit Aussetzern oder falsch Drosselklappenstellung - Strom niedriger als normal oder unterbrochener Strom-...
Page 935 ERROR CODES LIST Ch 10 Page Injektor Zyl. #7 - Mechanik spricht nicht korrekt an Injektor Zyl. Nr. 8 - Strom niedriger als normal oder unterbrochener Stromkreis Injektor Zyl. Nr. 8 - Strom höher als normal oder Erdschluss Injektor Zyl. #8 - Mechanik spricht nicht korrekt an Anlasserrelais - über Normalbereich Anlasserrelais - ungleichmäßig, mit Aussetzern oder falsch Anlasserrelais - Spannung höher als normal oder Kurzschluss an Plus...
Page 936 Ch 10 ERROR CODES LIST Page Injektor Gruppe 1 Motor - Spannung niedriger als normal oder Kurzschluss an 2797 Masse Injektor Gruppe 2 Motor - ungleichmäßig, mit Aussetzern oder falsch 2798 Injektor Gruppe 2 Motor - Spannung höher als normal oder Kurzschluss an Plus 2798 Injektor Gruppe 2 Motor - Spannung niedriger als normal oder Kurzschluss an 2798...
Page 937 ERROR CODES LIST Ch 10 Page SCR-Reagensleitungsheizung - Spannung höher als normal oder Kurzschluss an 4341 Plus SCR-Reagensleitungsheizung - Strom niedriger als normal oder unterbrochener 4341 Stromkreis SCR-Reagensleitungsheizung - Strom höher als normal oder Erdschluss 4341 SCR-Pumpenmotordrehzahl - über Normalbereich 4374 SCR-Pumpenmotordrehzahl - unter Normalbereich 4374...
Page 938 Ch 10 ERROR CODES LIST Page Bildschirm FMI German 520200 19 Kein Kontakt mit ECU (Motor) auf CAN1 520201 19 Kein Kontakt mit TCU (Getriebe) auf CAN1 Kein Kontakt mit VCU (Fahrzeugsteuereinheit) auf CAN1 520202 19 Kein Kontakt mit VCU (Fahrzeugsteuereinheit) auf CAN2 520203 19 520204 31 Gangschaltung ist eingeschränkt...
Page 939 ERROR CODES LIST Ch 10 Page 521146 1 Niedriger Druck an PBOUT (Feststellbremse) 521146 5 Drucksensor PBOUT (Feststellbremse) offener Kreis Drucksensor PBOUT (Feststellbremse) Kurzschluss 521146 6 521147 1 Notlenkung niedriger Druck 521147 5 Drucksensor Notlenkung offener Kreis Kurzschluss Drucksensor Notlenkung 521147 6 521161 0 Öltemperatur WDB vorne sehr hoch...
Page 940 Ch 10 ERROR CODES LIST Page Getriebeabtriebsdrehzahlsensor Fehler/nicht vorhanden 521222 2 521230 18 Schmieranlage niedriger Schmierfettstand Kein CAN-Signal vom Schmiersystem (Geschwindigkeitsgrenzwert 7 km/h) 521230 19 Fehler Schmiersystem (Geschwindigkeitsgrenzwert 7km/h) 521230 31 521310 5 Blinkerleuchte vorne rechts offener Kreis Kurzschluss Blinkerleuchte vorne rechts 521310 6 521311 5 Hauptabblendlicht rechts offener Kreis...
Page 941 ERROR CODES LIST Ch 10 Page Getriebe FMI German 523000 1 Sehr niedrige Batteriespannung 523000 3 Batterieüberspannung 523000 4 Batterie-Unterspannung 523010 3 Überspannung interne 5V-Stromversorgung TCU 523010 4 Unterspannung interne 5V-Stromversorgung TCU 523011 4 Unterspannung interne 7V-Stromversorgung TCU Überspannung Versorgung für Drehzahlsensoren 523020 3 Unterspannung Versorgung für Drehzahlsensoren 523020 4...
Page 942 Ch 10 ERROR CODES LIST Page Interne Drehzahl 2 Drehrichtung stimmt nicht mit anderen Drehrichtungen 523110 11 überein Eingangsdrehzahlsensor 2 - unbekannte elektrische Komponente 523110 2 Überspannung Eingang interner Drehzahlsensor 2 523110 3 Turbinendrehzahlsensor 2 unterbrochen oder Erdschluss 523110 6 Interne Drezahl 2 stimmt nicht mit anderen Drehzahlwerten überein 523110 7 Interne Drehzahl 2 Drehrichtung unbekannt...
Page 943 ERROR CODES LIST Ch 10 Page 523205 5 Unterbrochener Stromkreis Antriebsventil für Kupplung B 523205 6 Antriebsventil für Kupplung B Erdschluss Antriebsventil für Kupplung B Kurzschluss mit anderem Ventil 523205 8 523210 0 Kupplung C rutscht unbeabsichtigt 523210 2 Stromeingang 3 - unbekannte elektrische Komponente Antriebsventil für Kupplung C an Batterie kurzgeschlossen 523210 3 523210 5...
Page 944 Ch 10 ERROR CODES LIST Page 523245 2 Stromausgang 10 - unbekannte elektrische Komponente Antriebsventil für Retarder an Batterie kurzgeschlossen 523245 3 523245 5 Unterbrochener Stromkreis Antriebsventil für Retarder 523245 6 Antriebsventil für Retarder Erdschluss Antriebsventil für Retarder Kurzschluss mit anderem Ventil 523245 8 523250 2 Stromausgang 11 - unbekannte elektrische Komponente...
Page 945 ERROR CODES LIST Ch 10 Page SHOP MANUAL...

Doosan DA40 Shop Manual

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