doosan da30-5 articulated dump truck service repair manual

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  • Shop Manual

    - 5

    ENGLISH

    Norway

    PART NO: MX533347 PRINT DATE:

  • GENERAL INSTRUCTIONS

    SHOP MANUAL

    Ch 0 page 1

    Manufacturer: Dealer:

    Printed in Norway

    Doosan Infracore Norway AS N - 6440 Elnesvågen - NORWAY

    Shop Manual DA30-5

    Serial Number 721001 - up; 741001 - up; 720402; 740401.

    Engilsh

  • SHOP MANUAL

    GENERAL INSTRUCTIONSCh 0 page 2

    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

  • GENERAL INSTRUCTIONS

    SHOP MANUAL

    Ch 0 page 3

    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 ............................................................................................. 12 Injurious noise ................................................................................... 13 Organic solvent ................................................................................. 14 Fueling ................................................................................................ 15 Fire and Explosion Prevention ......................................................... 15 Fire and explosion risks ................................................................... 17 In case of Fire .................................................................................... 18 Coolant ............................................................................................... 19 Refrigerant ......................................................................................... 20 Air pollution ....................................................................................... 21 Operation in extreme conditions ..................................................... 22 Liquid or gas under high pressure .................................................. 26 Asbestos ............................................................................................ 27 Lead .................................................................................................... 27 Battery hazard prevention ................................................................ 28 Disposal of hazardous materials ..................................................... 30 Jacked up vehicle or bodywork ....................................................... 31 Crushing and Cutting Danger .......................................................... 31 Heavy units ........................................................................................ 32 More than one person working with the same object .................... 33 Involuntary start of electric motors etc. .......................................... 33 Rotating parts .................................................................................... 34 Splinters, flying object When using certain tools ........................... 35 Springs under load ............................................................................ 36 Precautions for disassembly and assembly ................................... 37

  • SHOP MANUAL

    GENERAL INSTRUCTIONSCh 0 page 4

    The Shop Manual is prepared as an aid to performing quality repairs by giving the service personnel an under- standing of the dump truck, and showing the correct way perform repairs and make judgements.

    Make sure that you understand the manual and use it at every available opportunity. The manual will also serve as a useful guide to office personnel and other persons who are involved with the dump truck in one way or another.

    Foreword

    How to use the SHOP MANUAL:

    The main index give an view of the chapters index page no.

    The manual is divided into the following chapters:

    In the chapters index you will find the page no. for the description of each part.

    Each part will describe: Structure and function: This section explains how the components are built and how they work.

    Testing and adjusting: This section explains checks to be made before and after performing repairs, as well as adjustments to be done at the completion of the checks and repairs.

    Disassemly and assembly: This section describes how to remove, install, disassemble, repair and assemble components, and the work order. Special tools are listed at the end of each chapter. The special tools are an excellent aid in the work shop. By using special tools, the job will be easier to perform and in some cases a special tool is required to carry out the work. List of all special tools for the complete truck are listed in the “Special Tool Guide”.

    Maintenance standard: This section gives the judgement standards when inspecting disassembled parts.

    Troubleshooting: When a fault is detected, this section is used as before the practical fault finding starts. A skilled and trained mechanic together with the Shop Manual is the best combination for troubleshooting when repair instruction is needed.

    At the end of each chapters are the main Troubleshooting

    This manual is valid for the serial nos. listed on the first page.

    Distributing and updating: 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.

    Because of the different variants the parts and images which are contained in this book can be different from the current model of dump truck . For the spare parts please used the parts catalogue for current model.

    Chapter 1: Engine

    Chapter 2: Transmission

    Chapter 3: Drive line

    Chapter 4: Lubrication

    Chapter 5: Hydraulic system

    Chapter 6: Electric system

    Chapter 7: Front frame

    Chapter 8: Rear frame

    Chapter 9: Option

    Chapter 10: Error codes list

    NOTE

  • GENERAL INSTRUCTIONS

    SHOP MANUAL

    Ch 0 page 5

    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.

    Bolt quality marking Strength marking on screws consists of two numerals that may be separated by a point (.). The numerals indi- cate tensile and yield limits of material in N/mm². - Numeral 1 denotes a hundreths of the tensile limit in N/mm². - Numeral 1 x numeral 2 denotes a tenth of the yield limit in N/mm².

    A bolt designated 8.8 thus has tensile limit 800 N/mm² and yield limit 640 N/mm².

    Nut quality marking The designation for nuts consists of one numeral. The numeral denotes that the nut is of equal strength to a bolt with the same first number. A nut of strength class 8 is thus equally strong to a bolt of class 8.8.

    Torque limit table

    :ssalcytilauQ noisnemiD

    8.8 )mN(M

    9.01 )mN(M

    9.21 )mN(M

    8M 01M 21M

    42 74 18

    33 56 411

    04 97 631

    41M 61M 81M

    821 791 572

    181 772 683

    712 333 364

    02M 22M 42M

    583 815 566

    145 827 539

    946 478 0211

    72M 03M 33M 63M

    169 0131 0771 0822

    0531 0481 0842 0123

    0261 0122 0892 0583

    :ssalcytilauQ noisnemiD

    8.8 )mN(M

    9.01 )mN(M

    9.21 )mN(M

    1x8M 52,1x01M

    1x01M

    52 84 94

    53 86 07

    24 18 48

    5,1x21M 52,1x21M

    5,1x41M

    38 58 531

    711 021 091

    041 441 882

    5,1x61M 5,1x81M 5,1x02M

    402 492 804

    782 314 475

    443 694 886

    5,1x22M 2x42M 2x72M

    645 696 0001

    867 979 0141

    129 0711 0961

    2x03M 2x33M 2x63M

    0931 0681 0532

    0591 0162 0133

    0432 0313 0793

    :ssalcytilauQ noisnemiD

    8.8 )mN(M

    9.01 )mN(M

    9.21 )mN(M

    FNU"8/3 FNU"61/7 FNU"2/1

    14 66 99

    95 39 141

    37 511 571

    FNU"61/9 FNU"8/5 FNU"4/3

    241 791 443

    102 972 684

    052 743 606

    FNU"8/7 FNU"1 FNU"8/11

    745 418 0711

    277 0511 0661

    369 0341 0602

    FNU"4/11 FNU"8/31 FNU"2/11

    0261 0712 0482

    0922 0703 0004

    0582 0283 0005

    :ssalcytilauQ noisnemiD

    8.8 )mN(M

    9.01 )mN(M

    9.21 )mN(M

    CNU"8/3 CNU"61/7 CNU"2/1

    83 16 39

    45 78 131

    86 801 361

    CNU"61/9 CNU"8/5 CNU"4/3

    331 381 223

    781 952 554

    432 323 865

    CNU"8/7 CNU"1 CNU"8/11

    615 277 0901

    927 0901 0551

    909 0631 0391

    CNU"4/11 CNU"8/31 CNU"2/11

    0351 0202 0562

    0612 0582 0573

    0962 0553 0864

  • SHOP MANUAL

    GENERAL INSTRUCTIONSCh 0 page 6

    Loctite 242/243: Middle strength (for locking of screws, bolts and nuts).

    Loctite 270/2701: High strength (for locking of screws, bolts

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