Daewoo Doosan ADT DA30 DA40 Operation & Maintenance Manual MX532099-1 - PDF DOWNLOAD

MX532099-1 August 2014

ADT

Operation & Maintenance Manual DA30 / DA40 DA30 - Serial Number 7X0504 and Up DA40 - Serial Number 8X0502 and Up

Operation & Maintenance Manual DA30 / DA40 ADT DA30 - Serial Number 7X0504 and Up DA40 - Serial Number 8X0502 and Up

DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the world.

Copyright 2014 OperationDOOSAN and Maintenance Manual

MX532099-1 August 2014 Copyright Doosan 2011

1. Foreword

DA30 DA40

English

OPERATING & MAINTENANCE MANUAL NORTH AMERICA VERSION

NOTE The English version is the "Original Instruction".

All other languages are translated from the Original Instructions.

Operating & Maintenance Manuals are available in certain other languages. If other languages are required, please contact your local Doosan Dealer for details of availability.

Manufacturer:

Dealer:

Doosan Infracore Norway AS N - 6440 Elnesvågen - NORWAY

Printed in Norway Operating & Maintenance Manual

1-1

Table1.of contents Foreword 1. Foreword............................................................ 1-5

Groeneveld pump test......................................... 3-16

Introduction.......................................................... 1-6

Keypad, buttons and switches............................. 3-18

Safety information................................................ 1-12

Cab ventilation..................................................... 3-21

Federal emission control systems....................... 1-14

Controls............................................................... 3-24

California emission control warranty statement... 1-20

Other cab equipment........................................... 3-30

4. Running-in period............................................. 4-1

2. Safety Instructions............................................ 2-1

1. Running-in operation...................................... 4-3

2. Running-in services........................................ 4-4

1. Dump truck knowledge................................... 2-3

2. General precautions. ..................................... 2-3

5. Operating Instructions...................................... 5-1

3. Precautions before starting the engine.......... 2-8

Precautions on work sites................................... 5-3

4. When starting the engine............................... 2-10

5. Do not go close to high-voltage cables.......... 2-10

Some simple rules to be observed prior to operation.............................................................. 5-6

6. Battery hazard prevention............................... 2-11

1. Starting the engine.......................................... 5-7

7. Air conditioning system hazard prevention..... 2-12

2. Operating the dump truck............................... 5-9

8. Rules to follow when filling fuel or oil.............. 2-13

3. Parking the dump truck.................................. 5-22

9. Expansion tank coolant level.......................... 2-13

4. Stopping the engine....................................... 5-22

10. Machine turning............................................ 2-13

5. Checks after stopping the engine................... 5-23

11. Emergency steering....................................... 2-14

6. Loading and tipping........................................ 5-23

12. Travelling on slopes....................................... 2-14

7. Tyre handling.................................................. 5-25

13. Operation of brakes....................................... 2-14

8. Cold weather.................................................. 5-27

14. Engine over speed (Emergency retarder)...... 2-15

9. Long term storage.......................................... 5-28

15. Wading.......................................................... 2-15

10. Battery power assistance............................... 5-29

16. Dangerous loads........................................... 2-16

11. Towing the dump truck.................................... 5-30

17. Welding on the dump truck............................ 2-17

12. Manual release of parking brake.................... 5-30

18. Top tailgate.................................................... 2-18

13. Manual release of the ball valve on tilting circuit.......................................................... 5-31

19. Engine bonnet............................................... 2-19

14. Troubleshooting.............................................. 5-32

20. Tiltable cab.................................................... 2-19

21. Body support................................................. 2-21

22. Service position............................................. 2-22

23. Wheel chocks................................................ 2-22

6. Lubricants.......................................................... 6-1

Lubrication schedule DA30 T2/T4/Stage 3B........ 6-3

24. Articulation lock............................................. 2-23

Overview of oil and lubrication points (DA30 T2/T4/Stage 3B................................................... 6-4

25. Lifting / hoisting............................................. 2-23

Oil specification sheet (DA30 T2/T4/Stage 3B.... 6-5

26. Dump truck transportation............................. 2-24

Filling capacities (DA30 T2/T4/Stage 3B............. 6-6

27. High pressure................................................ 2-24

Lubrication schedule (DA40 T2/T4/Stage 3B...... 6-7

28. Safety labels.................................................. 2-25

Overview of oil and lubrication points (DA40 T2/T4/Stage 3B................................................... 6-8

Oil specification sheet (DA40 T2/T4/Stage 3B.... 6-9

Filling capacities (DA40 T2/T4/Stage 3B............. 6-10

Transmission oil list.............................................. 6-11 Axles oil list.......................................................... 6-14

3. Operating Controls............................................ 3-1

Overview of the instrument panels and controls. 3-3

Instruments.......................................................... 3-5

Monitor warning / indicator symbols and lights.... 3-9

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Operating & Maintenance Manual

Table of contents

1. Foreword

Maintenance............................................................ 7-1

Maintenance precautions.................................... 7-3

Maintenance table............................................... 7-5

Initial 100 Hours Service .................................... 7-8

Initial 500 Hours Service..................................... 7-12

8 Hours / Daily Service........................................ 7-17

40 Hours / Weekly Service.................................. 7-25

500 Hours Service............................................... 7-28

1000 Hours Service............................................. 7-43

2000 Hours Service............................................. 7-57

4000 Hours Service............................................. 7-65

Yearly recommended maintenance..................... 7-69

8. Technical Data................................................... 8-1

Measurements..................................................... 8-3

Engine................................................................. 8-4

Transmission....................................................... 8-4

Hydraulic system................................................. 8-5

Tyre pressures..................................................... 8-5

Electrical system................................................. 8-6

Bulbs ................................................................. 8-7

Metering conversion table................................... 8-7

Tool kit content (standard)................................... 8-7

Tool kit content (optional).................................... 8-7

Rimpull Performance .......................................... 8-8

Graph of altitude power reduction DA30 T2/T4/Stage 3B.......................................... 8-10

Graph of altitude power reduction .

DA40 T2/T4/Stage 3B.......................................... 8-11

Engine and retarder brake capacity chart........... 8-12

Torque limits for bolts........................................... 8-13

Reference information......................................... 8-13

Consumeable parts............................................. 8-13

Product signs....................................................... 8-14

Periodic service................................................... 8-16

Operating & Maintenance Manual

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1. Foreword

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Operating & Maintenance Manual

1. Foreword

Foreword This manual provides rules and guidelines which will help you use this dump truck safely and effectively.

This manual describes procedures for operating, handling, lubricating, maintenance, checking and adjustment.

It will help the operator to achieve peak performance through effective, economical and safe dump truck operation and maintenance.

• Keep this manual in the dump truck at all times and ensure that all personnel read it carefully before operating the dump truck.

• Continue studying the manual until proper operating procedures are completely adopted as personal habit.

• This manual describes the basic techniques. The operator's skill will increase with correct knowledge of dump truck operation.

• Operation, inspection and maintenance should be carefully carried out, and safety must be given first priority.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual from your local Doosan dealer.

If you sell the dump truck, be sure to give this manual to the new owners.

Doosan Infracore Norway AS cannot be held responsible for damage or injury caused through use of improper spare parts not specified by Doosan Infracore Norway AS, improper handling, operation and utilisation of the dump truck in other ways than those described in this manual. Not can Doosan Infracore Norway AS be held responsible for unauthorised modifications or the non-adherence to local, national government or international regulations.

This Operating & Maintenance Manual may contain standard extra equipment and optional accessories that are not available in your area. Please consult your local Doosan Dealer for those items you may require.

Doosan Infracore Norway AS aim to continuously improve the dump trucks and therefore retain the right to make design changes and improvements whenever we feel it will improve the efficiency of the dump truck.

Doosan Infracore Norway AS also reserve the right to change data and equipment without prior notice, as well as amending instructions for maintenance and other service measures.

WARNING • This dump truck complies with EC directives 2006/42/EC (Machinery Directive) with amendments,

2000/14/EC (Noise Emission Directive) with amendments, 2004/108/EC (Electronic Compatibility)

with amendments and 2004/26/EC (Exhaust Gas Emission) with amendments.

Dump trucks complying with the directives display the CE mark.

The dump truck must not be modified in such a way that it no longer complies with the EC - directive.

• Improper operation and maintenance of this dump truck can be hazardous and could result in seri

ous injury or death.

• Operators and maintenance personnel should read this manual thoroughly before operation or maintenance.

• Some actions involved in operation and maintenance of the dump truck can cause serious acci

dents, if they are not carried out in a manner described in this manual.

• The procedures and precautions given in this manual apply only to intended uses of the dump

truck. If you use your dump truck for any unintended uses that are not specifically prohibited, you

must be sure that it is safe for you and others. In no event should you or others engage in the pro

hibited uses or actions which are described in this manual.

• Doosan Infracore Norway AS delivers dump trucks that comply with all applicable regulations and

standards of the country to which it has been shipped. If this dump truck has been purchased in

another country or purchase from someone in another country, it may lack certain safety devices

and specifications that are necessary for use in your country. If there is any question about

whether your product complies with the applicable standards and regulations of your country,

consult your local Doosan Dealer before operating the dump truck.

• Safety descriptions are given in SAFETY INFORMATION on page 12 and in SAFETY INSTRUCTION,

chapter 2.

Operating & Maintenance Manual

1-5

1. Foreword

Introduction Intended use This Doosan articulated dump truck is designed to be used mainly for earth moving at sites, both on and off road conditions.

The basic machine is intended to be used under normal conditions, that is, outdoors, above ground, off road, for earthmoving, and in an ambient temperature between -25°C and +45°C with maintained performance. Condition that deviate from this are also described in this manual. For use on public roads the machine must be adapted according to governing national legislation (only DA30). If it is used for other purposes or in potentially dangerous environments for example explosive atmosphere, areas with dust contain asbestos etc. special safety regulations must be followed and the machine must be equipped for such use and handling.

Contact the Doosan dealer for more information. The machine is designed for a maximum machine weight (includes equipment and attachments) of 51,400 kg for DA30 and 70,300 kg for DA40. If the maximum weight is exceeded, no warranties on the part of the manufacturer will apply. However, always pay attention to national regulations for traveling on public roads.

General description Doosan DA30, DA40 is an articulated, 6-wheel drive dump truck.

The free-swinging rear tandem housing, and the special articulation system, provide excellent performance in soft and difficult terrain.

The special body design ensures that a low centre of gravity is maintained and an even load distribution to front and rear wheels, for stability on uneven ground and for fast easy tipping. The Doosan dump truck is designed and manufactured to work under difficult conditions.

In addition, the wide range of optional equipment allows the dump truck to be used for several different applications.

Environmental requirements Be aware of the environment when operating and during service and maintenance of the machine. Always follow local and national environmental legislation applicable to all handling of the machine Engine DA30 and DA40 has a Scania DC9 (9,3 liter) and DC13 (12,7 liter) engines .

DA30 T4i/Stage3B and DA40 T4i/Stage 3B - These engines have a optimised cylinder block containing wet cylinder liners that can easiliy be exchanged.Individual cylinder heads with 4 valves per cylinder promotes repairability and fuel economy. The engine is equipped with a Scania developed Engine Management System, EMS, in order to ensure the control of all aspects related to engine performance.

The injection system is Scania’s XPI (Extra High Pressure Injection), a common rail system that in combination with SCR (Selective Catalytic Reduction) gives low exhaust emissions with good fuel economy and a high torque.

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Operating & Maintenance Manual

1. Foreword

DA30 T2 and DA40 T2 - These engines have a optimised cylinder block containing wet cylinder liners that can easiliy be exchanged. Individual cylinder heads with 4 valves per cylinder promotes repairability and fuel economy.

The engine is equipped with a Scania developed Engine Management System, EMS, in order to ensure the control of all aspects related to engine performance. The injection system is based on electronically controlled unit injectors that gives low exhaust emissions with good fuel economy and a high torque.

Electrical System The machine has three control units. The Gauge Panel for the instrumentation is integrated with the display unit and also warning lights and instruments and provides the operator with information via there. The VCU( vehicle control unit) for the machine, receives signals from sensors on the machine and these are passed to the main screen . The E-ECU controls the engine.

Transmission The transmissions ZF ErgoPower L II 8 EP 320(DA30) and 8 EP 420(DA40) consist of a multi-speed powershift transmission with integrated transfer case and front-mounted hydrodynamic torque converter. The torque converter is a wear-free starting device which is continuously variable adapting itself to the given situations (necessary input torque). Input by direct mounting via diaphragm to the engine, or by using a joint-shaft with mechanic.

Brakes Service brakes All hydraulic operated wet multiple disc brake on each wheel.

There are two separate circuits. Self adjusting system.

Engine brake Electronically operated, speed dependent brake which, gives high performance engine braking.

Efficient only when lock-up clutch is connected.

Retarder brake The integrated hydrodynamic retarder is installed in the basic transmission between converter and gear box.

Praking brake Spring actuated, hydraulic released single disc brake on the rear prop. shaft. Self-adjusting system.

Operating & Maintenance Manual

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1. Foreword

Steering system The steering movement is created by articulation of the frames in relation to each other. The steering is fully hydraulically controlled . It has steering arc of 45.

The machine is equipped with the ground driven emergency steering pump fitted on the transmission.

Suspension The dump truck is equipped with gas-hydraulic suspension cylinders on the front axle. It is a hydraulic cylinder filled with oil and nitrogen gas.

Cab The cabin has an automatically controlled and ventilation system with defrosting system for the windows. Air conditon is standard. The cab has two emergency exits: the door and the front side window on the left side, which are broken with the hammer in the cab if use of that evacuation route is nacessary.

FOPS and ROPS The cabin is approved as a protective cabin according to FOPS and ROPS standards. FOPS is an abbreviation of Falling Object Protective Structure (roof protection) and ROPS is anabbreviation of Roll Over Protective Structure (roll overprotection). Never carry out any unauthorized alterations to the cabin, e.g.lowering the roof height, drilling, welding on brackets for fire extinguisher, radio aerial or other equipment, without first having discussed the alteration with personnel at the DOOSAN Infracore Norway Engineering Department. This department will decide whether the alteration may cause the approval to become void. It is important that all parties concerned are aware of these regulations.

Hydraulic system DA30 The system have one variable displacement piston pump.

Pump supplies steering, tilting, fan and brakes system, where the steering circuit has priority.

The main hydraulic pump is fitted on the transmission.

DA40 The system have two variable displacement piston pumps.

One pump for the steering, accumulator charging and tilting.

Where the steering circuit has priority.

One pump for the cooling fan and tilting.

The main hydraulic pump is fitted on the transmission, and second hydraulic pump is fitted on the engine.

Equipment The machine can be provided with different types of optional equipment, depending on the requirements of different markets or special needed. Examples of such equipment are automatic greasing, body heating, heated driver seat .

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Operating & Maintenance Manual

1. Foreword

CE Marking (Declaration of Conformity) This machine is CE marked. This means that when delivered themachine meets the applicable " Essential Health and Safety Requirements," which are given in the Machinery Safety Directive, 2006/42/EC. Any person carrying out changes that affect the safety of the machine, is also responsible for the same.

As proof that the requirements are met, the machine is supplied with an EU Declaration of Conformity, issued by Doosan for each separate machine. This EU declaration also covers attachments manufactured by Doosan. The documentation is a valuable document, which must be kept safe and retained for at least ten years. The document should always accompany the machine when it is sold.

If the machine is used for other purposes or with other attachments than described in this manual, safety must at all times and in each separate case be maintained. The person carrying out such action is also responsible for the action which,in some cases, may require a new CE marking and the issue of a new EU Declaration of Conformity.

The European Union EMC-directive The electronic equipment of the machine may in some cases cause interference to other electronic equipment, or suffer from external electromagnetic interference, which may constitute safety risks.

The EU EMC directive on "Electromagnetic Compatibility," 2004/108/EC, provides a general description of what requirements can be made of the machine from a safety perspective, where limit values have been established in international standrds.

A machine or device which meets the requirements must be CE marked. Our machines have been tested particularly for electromagnetic interference. The CE marking of the machine and the declaration of conformity also cover the EMC directive.

If other electronic equipment is fitted to this machine, the equipment must be CE marked and tested on the machine with regard to electromagnetic interference.

NOTE All installation of optional communication equipment must be carried out by trained professionals and in accordance with the Doosan instructions applicable to the machine.

Declaration of Conformity The next page shows a copy of EU declaration of conformity for machine .

Applies to Doosan articulated dump truck.

Operating & Maintenance Manual

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1. Foreword

DECLARATION OF CONFORMITY

DR AF T

I hereby declare that the following machine has been manufactured in conformity with the provisions of the 2006/42/EC (Machinery Directive), 2000/14/EC (Noise Emission Directive), 2004/108/EC (Electromagnetic Compatibility) and 2004/26/EC (Exhaust Gas Emission) and its amendments.

MACHINE IDENTIFICATION: Type of Machine: Articulated dump truck Brand: DOOSAN Model Name: .............................

PIN: .............................

MANUFACTURER: Doosan Infracore Norway AS N - 6440 ELNESVÅGEN NORWAY

MAIN SAFETY COMPONENTS PROVIDED WITH THE MACHINE: ROPS (ISO 3471)/FOPS (ISO 3449) Safety cabin TIER ...........

SOUND POWER LEVEL Lwa is ....dB(A), at 2100 rpm, measured according to ISO 6395.

SPECIFIC DIRECTIVE AND (DRAFT) STANDARDS APPLIED: ISO 12100-1 ISO 6683 ISO 12100-2 ISO 11112 EN 474-1 ISO 6405-1 EN 474-6 ISO 6405-2 ISO 14121-1 ISO 3457 ISO 5010 ISO 2867 ISO 3450 EN 349 I declare on behalf of the manufacturer that the machine comply with the essential health and safety requirements applicable to it.

Date: Signature:

............................ ............................

Name: Position:

........................... ...........................

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Operating & Maintenance Manual

1. Foreword

Poduct plates With the aid of the product plates shown below it is possible to identify the machine and its components . The product identification number (PIN) indicates the model designation engine code and serial number of the machine . the compenent identification number CIN indicates the serial number of the component .

When ordering spare parts and in all telephone enquiries or correspondense the PiN and CIN must awlays be quoted.

6 7 1 8 5 7 5

4 3 2

1. Product plae with Product Identification Number, PIN and model/type number for complete machine, as well as the manufacturer's mane and address. The plate is located on the right side of dumper of the front of rear frame.

2. The engine type designation , part and serial number. The plate is located on the left side on fron of engine.

3. The transmission type designation and serial number. The plate is located on the top of transmission.

4. The part and serial numbers ,name of supplier and date of manufacture.The plate is locates on the top of front hub.

5. The part and serial numbers ,name of supplier and date of manufacture.The plate is locates on the top of rear hub.

6. The part and serial numbers ,name of supplier and date of manufacture.The plate is locates on the rear differetial.

7. The part and serial numbers ,name of supplier and date of manufacture.The plate is locates on the bogie.

8. Cab type, and serial number, ROPS/FOPS number are located on the front siad of cab.

Operating & Maintenance Manual

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1. Foreword

Safety information Most accidents are caused by the failure to follow safety rules for the operation and maintenance of the dump truck. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the dump truck before operation and performing maintenance.

Signal words The signal words "DANGER", "WARNING", "CAUTION" are used throughout safety messages and safety decals in this manual or on the machine. They indicate an existence of and the relative seriousness of, a hazard. All there indicate that a safety risk is involved. Observe is present, no matter which signal word appears nest to it.

NOTE

CAUTION

- This word is used for precautions that must be taken to avoid actions which could shorten the life of the dump truck.

- This word denotes safety messages for hazards which could result in minor or moderate injury if the hazard is not avoided.

This word might also be used for hazards where the only result could be damage to the dump truck.

WARNING

- This word denotes safety messages where there is a potentially dangerous situation which could result in serious injury or death if the hazard is not avoided. These safety messages usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the dump truck.

DANGER

- This word denotes safety messages where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may result in serious damage to the dump truck.

To identify labels on the dump truck, the following colours are used.

YELLOW & BLACK

GREEN & WHITE

- These colours are used on safety labels where there is high/ potential/moderate probability of death/injury if the hazard is not avoided.

- These colours are used on information labels.

Know the capacity and limits of your dump truck!

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Operating & Maintenance Manual

1. Foreword

AEM Safety manual ( North America only) The AEM Safety manual delivered with machine gives general safety information.

The AEM Safety Manual be read and understood before beginning operation or maintenance and is not intended to replace the Operation & Maintenance Manual delivered with the machine.

Operating & Maintenance Manual

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1. Foreword

FEDERAL EMISSION CONTROL SYSTEMS Emission Control System Warranty Statement General Warranty Provisions The emission control systems of your new Scania Engines "Scania" industrial diesel engine were designed, built and tested using genuine parts, and were certified as being in conformity with federal emission control regulations. Scania warrants to the original owner, and to each subsequent owner, of a new Scania industrial diesel engine "You" that engine: 1. Was designed, built and equipped so as to conform at the time of sale with all applicable regulations under Section 213 of the Clean Air Act, 42 U.S.C. °Þ 7547, for their full useful life and designed, built and equipped so as to conform with all applicable regulations adopted by the California Air Resources Board pursuant to its authority under Chapters 1 and 2, Part 5, Division 26 of the California Health and Safety Code, and: 2. Is free from defects in material and workmanship which would cause such engine to fail to conform to applicable regulations for its warranty period or otherwise cause the failure of a warranted part to be identical in all material respects to the part as described in the engine manufacturer's application for certification.

Where a warrantable condition exists, Scania will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts, and labor.

Warranty Period This warranty shall apply for one of the following periods, whichever occurs first: • 3,000 hours of operation as determined by a device to measure hours of use, or • Five years Each engine is equipped with a device to measure hours of use.

If that device fails to account for hours of use because of defects in materials or workmanship, the engine shall be warranted for a period of five years. The warranty period shall begin on the date the engine is delivered to the first ultimate purchaser who, in good faith, purchases the engine for purposes other than imminent resale.

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Operating & Maintenance Manual

1. Foreword

The Warranty on Emission-related Parts Shall be Interpreted as Follows: 1. Any warranted part which is not scheduled for replacement as required maintenance in Scania's written instructions for maintenance and use of the engine by owner shall be warranted for the warranty period defined above. If any such part fails during the period of warranty coverage, it shall be repaired or replaced by the engine manufacturer according to Subsection (4) below. Any such part repaired or replaced under the warranty shall be warranted for the remaining warranty period.

2. Any warranted part which is scheduled only for regular inspection in Scania's written instructions for maintenance and use of the engine by owner shall be warranted for the warranty period defined above. A statement in such written instructions to the effect of "repair or replace as necessary" shall not reduce the period of warranty coverage. Any such part repaired or replaced under warranty shall be warranted for the remaining warranty period.

3. Any warranted part which is scheduled for replacement as required maintenance in Scania's written instructions for maintenance and use of the engine by owner shall be warranted for the period of time before the first scheduled replacement point for that part. If the part fails before the first scheduled replacement, the part shall be repaired or replaced by the engine manufacturer according to Subsection below.

Any such part repaired or replaced under warranty shall be warranted for the remainder of the period before the first scheduled replacement point for the part.

4. Repair or replacement of any warranted part under the warranty provisions of this article shall be performed at no charge to the owner at a warranty station.

5. Notwithstanding the provisions of Subsection (4) above, warranty services or repairs shall be provided at all manufacturer distribution centers that are franchised to serve the subject engines.

6. The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective provided that such diagnostic work is performed at a warranty station.

7. The engine manufacturer shall be liable for damages to other engine components proximately caused by a failure under warranty of any warranted part.

8. Throughout the engine's warranty period defined above, the engine manufacturer shall maintain a supply of warranted parts sufficient to meet the expected demand for such parts.

9. Any replacement part, as defined in Section 1900 (b), Title 13 of the California Code of Regulations, may be used in the performance of any maintenance or repairs and must be provided without charge to the owner. It is not necessary for replacement parts to be the same brand or by the same manufacturer as the original part sold with the engine. Such use shall not reduce the warranty obligations of the engine manufacturer.

Operating & Maintenance Manual

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1. Foreword

10. Add-on or modified parts, as defined in Section 1900 (b), Title 13 of the California Code of Regulations, that are not exempted by the California Air Resources Board may not be used. The use of any non-exempted add-on or modified parts shall be grounds for disallowing a warranty claim made according to this article. The engine manufacturer shall not be liable under this article to warrant failures of warranted parts caused by the use of a non-exempted add-on or modified part 11. The Executive Officer of the California Air Resources Board may request, and in such case, the engine manufacturer shall provide, any documents which describe that manufacturer's warranty procedures or policies.

Parts Covered by the Warranty The the following is a list of parts considered to be part of the Emission Control Systems covered by the Emission Warranty for Scania industrial engines which were built to conform to federal and California emission control regulations: 1. Fuel injection system 2. Air Induction System: C. Intake manifold D. Turbocharger system E. Charge air cooling system 3. Exhaust manifold system 4. Smoke puff limiter (included in ECU) 5. Oil fill cap 6. Complet SCR System A. DEF tank B. DEF tank level sensor C. DEF tank pump D. DEF tank temperature sensor E. DEF hose F. DEF injector G. DEF injector pressure sensor H. DEF injector temperature sensor I.

Catalyst temperature sensor

J. SCR control unit (EEC3) K. SCR Catalyst L. NOX sensor

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Operating & Maintenance Manual

1. Foreword

7. Miscellaneous items used in the above systems: A. Electronic control unit (ECU), sensors, wiring harnesses B. Hoses, belts, connectors, assemblies, clamps, fittings tubing, sealing gaskets or devices and mounting hardware C. Pulleys, belts and idlers D. Emission control information labe

IMPORTANT This list does not include all expendable maintenance parts.

• Expendable emission related parts requiring

scheduled maintenance are warranted until their

first scheduled replacement point.

• Emission related parts scheduled for inspection and

replacement only as necessary are not considered

expendable and if repaired or replaced under

warranty shall be warranted for the remaining

warranty period.

See Specific Warranty Exclusions below.

General Warranty Limitations To retain the dependability of the exhaust emission control originally built into your Scania industrial diesel engine, it is essential that engine is installed according to Scania installation instructions and emission certificates. Your engine is designed to operate on diesel fuel only. Use of any other fuel can result in your engine no longer operating in compliance with state or federal emissions requirements. The use of alternative fuels shall not void the warranties on any engine certified to use such fuel.

In addition, as the engine owner, You are responsible for the performance of all scheduled maintenance listed in your owner's manual, and all necessary repairs, on your new Scania industrial diesel engine. Scania may deny a warranty claim if the engine or part has failed because of abuse, neglect, improper maintenance or unapproved modifications.

Receipts covering the performance of regular maintenance should be retained in the event questions arise concerning maintenance.

The receipts should be transferred to each subsequent owner of the engine with the emission warranted engine. Scania cannot, however, deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

The Warranty covers the cost of diagnosis, repair and replacement parts and services of warranted components and systems performed by an authorized Scania distributor or dealer using genuine Scania parts. You may elect to have maintenance, replacement or repair of these components and systems performed by any repair establishment or individual without invalidating the Warranty.

Operating & Maintenance Manual

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1. Foreword

The use of other than Scania replacement parts also does not invalidate the warranty on other components unless such parts cause damage to warranted parts. However, the cost of such services or parts will not be covered by the Warranty.

You are responsible for initiating the warranty process. The California Air Resources Board suggests that You present your heavyduty off-road engine to an authorized Scania dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.

WARNING AVOID DEATH OR SERIOUS INJURY

Use of replacement parts which are not of equivalent quality may impair the effectiveness of emission control systems.

Accordingly, it is recommended that only Scania repair or replacement parts be used for maintenance, repair or replacement of emission control systems.

If other than Scania parts are used for maintenance, repair or replacement, the owner should obtain assurance that such parts are warranted by their manufacturer to be equivalent to genuine Scania parts.

Specific Warranty Exclusions This warranty does not cover: 1. Malfunctions in any part caused by any of the following: misuse, abuse, improper adjustments, modifications, alteration, tampering, disconnection, improper or inadequate maintenance, or use of fuels not recommended for the engine as described in the Operator's Manual.

2. Engine installation, including cooling system, intake system and exhaust system installation, that is not completed according to the Scania installation instructions and emissions certificate for this engine type.

3. Damage resulting from accidents, acts of nature or other events beyond the control of Scania 4. The replacement of expendable maintenance items such as filters, hoses, belts, oil, thermostat, exhaust system and coolant made in connection with scheduled maintenance services once these parts have been replaced.

5. Replacement items which are not genuine Scania parts or not authorized by Scania.

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Operating & Maintenance Manual

1. Foreword

6. Inconvenience, loss of use of the engine or commercial loss.

7. Any engine on which the actual use cannot be accurately determined because of a failure of the device to track hours of use unrelated to defects in materials or workmanship.

8. Any engine operating outside the United States.

Customer Support If the you do not receive the warranty service to which you believe you are entitled under the Warranty, or if you need additional support or information concerning the Warranty,

contact: Scania USA. Inc. Address: 121 Interpark Blvd, suite 1002, 78216, San AAntonio, Texas Mailing address: 121 Interpark Blvd, suite 1002, 78216, San Antonio, Texas Telephone: +1 210 403 0007 Fax: +1 210 403 0211 E-mail: contact@scaniausainc.com California customers shall also be furnished a copy of the California Emission Control Warranty Statement applicable to each new Scania engine purchased.

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1. Foreword

California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board is pleased to explain the emission control system warranty on your 2011 engine. In California, new heavy-duty off-road engines must be designed, built, and equipped to meet the State's stringent anti-smog standards.

Scania CV AB must warrant the emission control system on your engine for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fuel-injection system and the air induction system. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Scania CV AB will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts and labor.

Manufacturer's Warranty Coverage The 2011 and later heavy-duty off-road engines are warranted for a period of five years or 3,000 hours of operation, whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or replaced by Scania CV AB. Owner's Warranty Responsibilities • As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner's manual. Scania CV AB recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but Scania CV AB cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

• As the heavy-duty off-road engine owner, you should however be aware that Scania CV AB may deny you warranty coverage if your heavy-duty off-road engine or a part has failed because of abuse, neglect, improper maintenance or unapproved modifications.

• Your engine is designed to operate on Diesel fuel only. Use of any other fuel can result in your engine no longer operating in compliance with California's emissions requirements.

• You are responsible for initiating the warranty process. The ARB suggests that you present your heavy-duty off-road engine to a Scania CV AB dealer as soon as a problem exists.

The warranty repairs should be completed by the dealer as expeditiously as possible.

• If you have any questions regarding your warranty rights and responsibilities, you should contact Scania USA, Inc at 1-210403-0007.

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Catalytic Converter

WARNING AVOID DEATH OR SERIOUS INJURY

The SCR catalytic converter contains vanadium pentoxide, a chemical known to the State of California to cause cancer.

The SCR converter is fitted in the silencer and does not constitute a health hazard during normal use and handling.

When performing work on the SCR catalytic converter which can result in exposure to dust, safety precautions must be taken. Such work includes, for example, opening the silencer machining and scrapping the catalytic converter.

Safety precautions when working on the SCR-system.

• Inhalation: If dust is inhaled, the person should be provided with fresh air immediately. Seek medical attention • Eye contact: Rinse eyes with water immediately. If irritation persists, seek immediate medical attention.

• Skin contact: Wash with water and soap. Remove contaminated clothes.

• Ingestion: If large amounts have been ingested, drink plenty of water and induce vomiting. Seek medical attention Environmental hazards • Vanadium pentoxide is toxic to water organisms and can cause detrimental long term effects to water environment.

Environmental protection measures • The SCR catalytic converter is a manufactured article that contains vanadium pentoxide, a hazardous substance. Before disposing of, or scrapping, a spent SCR catalytic converter, it should be tested for any hazardous characteristics (ignitability, corrosivity, reactivity, acute hazardousness, and toxicity), as those categories are described in 22 CCR 66261.30. If the spent SCR catalytic converter exhibits hazardous characteristics and is being disposed of, it will be considered by the State of California to be a hazardous waste subject to Title 22, California Code of Regulations. Before disposing of hazardous waste, review and follow all pertinent federal and California requirements.

• Vanadium pentoxide is a listed commercial chemical product - P120 - pursuant to 22 CCR 66261.33 (e). According to the State of California, commercial chemical products that are discarded or intended to be discarded are hazardous wastes and are subject to all provisions of Title 22, California Code of Regulations. Before disposing of vanadium pentoxide, review and follow all pertinent federal and California requirements.

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1. Foreword

• If the SCR catalytic converter is opened for maintenance, any dust spillages from the catalyst should be collected and tested for the presence of vanadium pentoxide before proper disposal. Dust spillages should also be tested for any hazardous characteristics (ignitability, corrosivity, reactivity, acute hazardousness, and toxicity), as those categories are described in 22 CCR 66261.30, before proper disposal. If the dust contains either vanadium pentoxide or exhibits hazardous characteristics and is being disposed of, it will be considered by the State of California to be a hazardous waste subject to Title 22, California Code of Regulations. Before disposing of hazardous waste, review and follow all pertinent federal and California requirements.

• Do not dispose of the spent SCR catalytic converter or its constituent parts into any waterways, storm drains or sanitary sewers.

WARNING AVOID DEATH OR SERIOUS INJURY

The SCR catalytic converter contains vanadium pentoxide, a chemical known to the State of California to cause cancer.

Additional considerations when working on the SCR-system • Perform work on the SCR catalytic converter in all well ventilated area. Use protective goggles and gloves if there is any risk of splashing or spraying of reductant or coolant.

• When engine is running, the exhaust system parts can reach such high temperatures there is a risk of personal injury. Make sure that exhaust system temperature has decreased to a suitable level before starting to work.

• The SCR system is heated by water from the engine cooling system. The cooling system runs at overpressure and when the engine is hot the coolant is hot. Do not open any hoses without first stopping the coolant flow in the hose.

• A P3 type respirator/filter mask or a type FFP3 fine dust musk, protective goggles and gloves should be used for any work where there is a risk of exposure to dust from the SCR catalytic converter.

• Use a disposable overall and dispose of it properly after machining.

• Eating, drinking or smoking while working is not permitted.

• Any dust from the SCR catalytic converter should be removed using a vacuum cleaner with microfilter to minimize exposure.

• Make sure that work surface is cleaned after completed work; Vacuum first then swab.

• Make sure you clean your hands after working with SCR catalytic converter to avoid ingestion.

• Work done on the SCR catalytic converter may generate waste considered by the State of California to be a hazardous waste subject to Title 22, California Code of Regulations.

Before disposing of hazardous waste, review and follow all pertinent federal and California requirements.

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Safety Instructions

WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death.

This safety section also contains precautions for standard extra equipment and optional accessories.

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Safety Instructions...................................................................................................................... 2-1 1. Dump truck knowledge......................................................................................................... 2-3 2. General precautions. ........................................................................................................... 2-3 3. Precautions before starting the engine................................................................................. 2-8 4. When starting the engine................................................................................................... 2-10 5. Do not go close to high-voltage cables............................................................................... 2-10 6. Battery hazard prevention.................................................................................................. 2-11 7. Air conditioning system hazard prevention......................................................................... 2-12 8. Rules to follow when filling fuel or oil.................................................................................. 2-13 9. Expansion tank coolant level.............................................................................................. 2-13 10. Machine turning.................................................................................................................. 2-13 11. Emergency steering........................................................................................................... 2-14 12. Travelling on slopes............................................................................................................ 2-14 13. Operation of brakes............................................................................................................ 2-14 14. Engine over speed (Emergency retarder).......................................................................... 2-15 15. Wading............................................................................................................................... 2-15 16. Dangerous loads................................................................................................................ 2-16 17. Welding on the dump truck................................................................................................. 2-17 18. Top tailgate......................................................................................................................... 2-18 19. Engine bonnet.................................................................................................................... 2-19 20. Tiltable cab......................................................................................................................... 2-19 21. Body support...................................................................................................................... 2-21 22. Service position.................................................................................................................. 2-22 23. Wheel chocks..................................................................................................................... 2-22 24. Articulation lock.................................................................................................................. 2-23 25. Lifting / hoisting.................................................................................................................. 2-23 26. Dump truck transportation.................................................................................................. 2-24 27. High pressure..................................................................................................................... 2-24 28. Safety labels....................................................................................................................... 2-25

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1. Dump truck knowledge Learn how to use the control devices, instruments and warning devices. Be sure you understand the meaning of the WARNING signs and other cautionary messages. Always know the dimension and performance limits of your dump truck.

Remember the check points and checking method of fluid levels.

2. G eneral precautions.

(See also precautions for Maintenance and Operating instructions).

2.1. Safety rules • ONLY trained and qualified personnel can operate and maintain the dump truck.

• Follow all safety rules, precautions and instructions when operating or performing maintenance on the dump truck.

• ALWAYS USE SEAT BELT DURING DRIVING! If there is instructor or passenger in the cab, be sure that they are seated on the instructor seat and are using their seat belt!

• Never operate the dump truck if you are under the influence of alcohol, medicines or other drugs.

• When working with other operators or persons on work site traffic duty, be sure all personnel understand all hand signals that are to be used.

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2.2. Clothing and personal protection items Avoid loose clothing, jewellery and loose long hair which may catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothing because it is hazardous to your health and is flammable.

2.3. Unauthorised modification • Any modification made without authorisation from Doosan Infracore Norway AS can create hazards.

• Before making a modification, consult your local Doosan dealer. Doosan Infracore Norway AS will not be responsible for any injury or damage caused by unauthorised modification.

2.4. Getting on and off the dump truck • Always use handles and steps when entering and getting off the dump truck.

• Ensure safety, maintaining at least three-point contact of hands and feet with handles and steps.

• NEVER jump on or off the dump truck. NEVER get on or off a moving dump truck.

• Always clean off grease, oil, ice, snow and dirt to avoid slippery truck surfaces.

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2.5. Fire prevention for fuel and oil Fuel, oil and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. • Keep flames away from flammable fluids.

• Stop the engine and do not smoke when refuelling.

• Tighten all fuel and oil caps securely.

• Refuelling and oiling should be carried out in well ventilated areas.

• Spilt fuel and oil must always be cleaned up immediately.

• Keep oil and fuel in a secure place and do not allow unauthorised persons to enter.

2.6. Precautions when handling at high temperatures Immediately after operations are stopped, the engine coolant, engine oil and hydraulic oil are at high temperatures, and are still under pressure. Attempting to remove the cap, drain the oil or coolant, or replace the filters may lead to serious burns. Always wait for the temperature to fall, and follow the specified procedure when carrying out these operations.

• To prevent hot coolant from spurting out: 1. Turn engine off 2. Allow coolant to cool down.

3. Slowly loosen cap to relieve pressure before removing.

• To prevent hot oil from spurting out: 1. Turn engine off 2. Allow oil to cool down.

3. Slowly loosen cap to relieve pressure before removing.

2.7. F ire extinguisher, first aid kit an warning triangle (option) • If the first aid kit is present in the cab, keep it in its storage place.

Location: Left hand side in the cab, below the rear side window.

If missing contact your local Doosan dealer.

• Know how to use the fire extinguisher (Distributor/ Dealer fitted).

If the fire extinguisher is missing, contact your local Doosan dealer.

Location: Left hand side in the cab.

• If the warning triangle is present, keep it in its storage place.

Location: Toolbox in the right hand side fender.

• See also Safety equipment in chapter 3.

• Know what to do in case of fire.

• Be sure you know the phone numbers of persons you should contact in case of an emergency.

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2.8. Precautions for optional accessories • When installing and using optional accessories, read the information related to the equipment in this manual.

• Do not use equipment or parts that are not authorised

by Doosan Infracore Norway AS. Use of unauthorised equipment or parts could create a safety problem and adversely affect the proper operation and useful life of the dump truck.

• Any injury, accidents, product failure resulting from the use of unauthorised attachments will not be the responsibility of Doosan Infacore Norway AS.

2.9. P rotection against falling objects and roll-over protection The cab on this dump truck is tested and approved to current ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) standards.

ISO 3471 ROPS ISO 3449 FOPS • This cab meets the requirements for objects falling onto the cab roof, and will protect the operator while he is remaining in the cab.

• This cab meets the requirements for roll-over protection.

A precondition for protection is that the operator USES THE SEAT BELT and remains in the cab. Therefore, hold onto the steering wheel if the dump truck should roll over. DO NOT ATTEMPT TO JUMP CLEAR! • The approval sign for ROPS/FOPS is located on the fire wall underneath the bonnet.

• Structural damage, an overturn, modification, alteration or not permitted repair can affect the cab strength and there by void the certification.

• Consult Doosan Infacore Norway AS or your Doosan Dealer to determine this structure’s limitations without voiding its certification.

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2.10. Emergency exit A

• This dump truck is fitted with two emergency exits.

• Left door and front side window on right hand side.

• If door is blocked, you can get out through the front side window.

• Remove hammer (A) from storage location and break front side window.

2.11. Precautions for urea Reductant contains 32.5% urea and freezes at -11°C. It is easy to handle and non-toxic at this mixture. However, reductant is a highly corrosive fluid which must not come into contact with materials which are sensitive to corrosion.

It is therefore important to bear the following in mind: • Rinse off reductant spillages with plenty of water.

• If reductant seeps into electrical connections or electrical cables, these must be renewed.

WARNING unning the engine without reductant violates R emissions legislation and will damage the SCR system

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3. Precautions before starting the engine 3.1. Safety at the work site • Before starting the engine, make sure that the bonnet is closed and thoroughly check the area for any unusual conditions that could be potentially dangerous.

• Before starting the engine, examine the terrain and soil conditions of work site. Determine the best and safest method of operation.

3.2. Fire prevention • Thoroughly remove wood chips, leaves, paper and other flammable material accumulated in the engine compartment, or other places on the dump truck.

THEY COULD CAUSE FIRE!.

• Marsh land, when dry, is highly flammable. Marsh land can self ignite even in low temperatures.

Always keep the engine and engine compartment clean!

• Check fuel, lubrication and hydraulic system for leaks. Have any leaks repaired. Clean up any excess oil, fuel or other flammable fluids. (Check points see daily maintenance “Walk around check”) • Be sure that the fire extinguisher is present and working. The fire extinguisher shall be located on left hand side in the cab.

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3.3. In driver’s cab • Do not leave tools or spare parts laying around in the operator’s cab. They may damage or break the control levers or switches.

They could also hit the operator and cause serious injury.

Always keep the tools in the tool box (in right hand side fender).

• Keep the cab floor, controls, steps and handrails free of oil, grease, ice, snow and dirt.

3.4. Ventilation for enclosed areas If it is necessary to start the engine within an enclosed area, provide adequate ventilation. Exhaust fumes from the engine can KILL.

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3.5. Precautions for mirrors, windows and lights • Remove all dirt from the surface of the windows and lights to ensure that you can see well.

• Adjust the rear view mirrors so that you can see clearly from the operator’s seat, and always keep the surface of the mirrors clean. If any glass is broken, replace it with a new part.

• Check that the head lights, working lights and all other lights are installed to match the operating conditions.

Check also that they light up properly.

4. When starting the engine • Walk around the dump truck just before you enter it. Check area A for people and objects that might be in the way.

• When starting the engine, sound the horn as alert.

• Fasten the seat belt and remain seated while in motion.

Standing up is dangerous! Concentrate on and evaluate surroundings. Stop the dump truck if you are uncertain of how to operate safely.

• Slow driving is required to ensure hazard-free operation, especially on curves, narrow roads, hills/cliffs, bumpy or slippery ground. If the visibility is restricted and/or obstructed, designate a person to check and direct the work site traffic.

• Ensure that you keep a safe distance from other vehicles and nearby people.

Be sure that no persons or objects are situated in the articulation area or the overturn area (left and right hand side of the dump truck) before turning or driving.

Also make sure that no persons or objects are situated behind the dump truck before reversing or when tipping the load.

5. Do not go close to high-voltage cables • Going close to high-voltage cables can cause electric shock.

Do not raise the body near high-voltage cables.

The following actions are effective in preventing accidents: • Wear shoes with rubber or leather soles.

• Use a signalman to give warning if the dump truck approaches too close to the electric cable.

• If the body should touch the electric cable, the operator should not leave the operator’s cab. The operator should remain in the cab until it has been confirmed that the electricity has been shut off.

• When carrying out operation near high-voltage cables, do not let anyone come close to the dump truck.

• Check with the electricity company about the safety zone and voltage of the cables before starting operations.

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6. Battery hazard prevention • Battery electrolyte contains sulphuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself, immediately flush the area with water.

• Battery acid could cause blindness if splashed into the eyes.

If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once.

• If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or hospital immediately.

• When working with batteries ALWAYS wear safety glasses or goggles.

• Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark or flame.

• Before working with batteries, turn the starter switch to the OFF position, and the battery main switch must be turned OFF. • Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals.

• When removing or installing, check which is the positive (+) and negative (-) terminal.

Removing the batteries (see figure): 1. Disconnect (-) terminal connected to the earth point.

2. Disconnect the battery cable between the batteries.

3. Disconnect (+) terminal connected to the starter.

When installing the batteries, carry out the procedure in the opposite order, 3 - 2 - 1.

• Tighten the battery caps securely.

• When removing any battery cap, wear rubber gloves to prevent electrolyte contact with the skin.

Emergency STOP (PUSH)

Battery main switch (OFF)

1

• Tighten the battery terminals securely, check that the terminals are not loose by trying to move the battery cables by hand. Loosened terminals can generate sparks and lead to an explosion.

• Emergency STOP button - use only in emergency situations, health and life hazards.

3 2

WARNING Never turn the battery main switch to the off position when engine is running, this can lead to damage to the electronic system of the machine.

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7. Air conditioning system hazard prevention • The air conditioning system is filled with refrigerant (R134a).

• Always use safety glasses or goggles, gloves, boiler suit and protective footwear when inspecting, servicing and repairing the air conditioning system.

• Refrigerant R134a has a property that can cause frostbite if it comes into contact with bare skin or eyes.

• Always work on the air conditioning system in well ventilated places.

• High concentration of the refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst un consciousness. Very high concentration of the gas can even cause cardiac insufficiency.

Do not smoke when servicing the air conditioning system!

Worker protection rules, refrigerant The following worker protection actions must be taken if there is any contact with escaping refrigerant: • Refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst unconsciousness. Very high concentration of the gas can even cause cardiac insufficiency. In all cases, get into fresh air and move the affected person from the risk zone. Contact a doctor.

• If larger quantities of fluid refrigerant come into contact with skin (frostbite), the injured area should be carefully warmed with luke warm running water and covered with a sterile compress. Contact a doctor.

• If fluid refrigerant comes into contact with a person’s eyes (frostbite), rinse the eyes with lukewarm running water, min.

10 min. Contact a doctor.

• If fluid refrigerant is accidentally swallowed, there can be serious frostbite in the mouth and gullet. Rinse the mouth with water.

DO NOT INDUCE VOMITING. Contact a doctor.

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8. Rules to follow when filling fuel or oil • Spilt fuel and oil may cause you to slip, so always clean up immediately.

• Slowly loosen the caps to relieve pressure before removing the caps.

• Always check fuel/oil specifications (chapter 6, lubricants) before refilling.

• Always refill fuel and oil in a well-ventilated place.

• Always tighten the cap of fuel and oil fillers securely.

• Never use fuel for washing any parts.

9. Expansion tank coolant level 1. If it is necessary to refill coolant to the expansion tank, stop the engine and allow the engine and the expansion tank to cool down before refilling coolant.

2. Slowly loosen the caps to relieve pressure before removing the caps.

3. Always refill using pre-mixed coolant.

(See chapter 7, maintenance)

10. Machine turning This articulated dump truck has two frames and the design allows unrestricted turning between front and rear chassis.

Overturn of one frame while the other remains level is possible.

It is possible that the operator will not receive warning signs of an overturn, therefore: • Avoid high speed turning and hard braking in curves.

• Reduce speed, avoid sudden turning if travelling across slopes.

• The rear chassis stability decreases when tipping. Be alert when body is raised.

Do not under any circumstances drive with raised body!

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11. Emergency steering The emergency steering pump will be activated if the engine stops. It is possible to steer the dump truck when it is in motion, but the steering speed will be slower. If this happens: • Stop as soon as possible and park in a safe place!

Continued driving may result in uncontrollable steering.

• Correct the fault before operating the dump truck again.

If necessary, contact your Doosan Dealer.

12. Travelling on slopes • Travelling on hills, banks or slopes that are steep, can result in the dump truck starting to slide/slip or roll over.

• Always check ground conditions before travelling on slopes.

• Always travel straight up or down on slopes.

• Do not turn on slopes or travel across slopes. Always go down to a flat place to perform these operations.

• Keep travel speed very low.

WARNING Ground conditions, gradients, friction, available traction and type of load is of vital importance for safe operation and stability on slopes.

13. Operation of brakes The service brakes must never be applied for long periods due to danger of fading (loss of braking effect due to overheating).

To avoid fading, depress the pedal firmly and release it after the speed is reduced.

Select a gear and adjust the speed in a downhill slope so that the speed can be controlled with the engine brake or engine and retarder brake, without the use of the service brake to hold the speed. Never use the service brake for long periods. Avoid racing the engine. See also Operating Instructions.

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14. Engine over speed (Emergency retarder) When the operator releases there foot off the accelerator, the exhaust brake (if installed) is automatically engaged. Driving downhill with the accelerator pedal released, the engine rpm’s will increase, when the engine rpm’s reach 2450 the transmission retarder and exhaust brake are activated (100%), this will disengage when rpm’s drop to 2150, the exhaust brake will continue to operate.

It’s called emergency retarder because the cooling capacity is not designed for continuous operation.

If the truck is on a downhill slope and the operator does not release there foot off the accelerator pedal, the exhaust brake and transmission retarder are activated at 2,450 rpm’s to override the operator error.

15. Wading Never drive into water (river beds, ponds, flooded pits, ditches etc.) without knowing the ground surface and depth. The bottom can be slippery, obstacles such as rocks/holes and other dangerous areas can be difficult to determine, and the force of a river current can be substantial. If it is found to be safe, drive slowly to avoid splashing. Do not stop unless absolutely necessary.

The brake linings must be checked/replaced more often when driving in wet and swampy areas, because wear of the linings will increase (see 500 hours service for procedure).

The maximum wading depth is: DA30 - 780mm, i.e. up to the front fenders DA40 - 1250mm, i.e. up to the front fenders

NOTE Under no circumstances let water flow through the grill!

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16. Dangerous loads If the body is exhaust heated, dangerous loads such as explosives or inflammable materials like petrol’s, oils etc.

MUST NOT BE TRANSPORTED. In some countries there may be special national regulations for transportation of dangerous loads.

To shut off the exhaust heating, do as follows: • Always allow the dump truck to cool down before changing exhaust direction.

1. Remove the clamps on both the vertical exhaust pipe and the pipe which goes to the body.

2. Remove the plate which gives heating to the body (in the vertical exhaust pipe).

3. Remove the ring from the pipe which goes to the body and install it into the vertical exhaust pipe.

4. Install the plate which will block the exhaust to the body (in the pipe which goes to the body).

5. Refit the clamps.

For further information, refer to the DOOSAN Shop Manual Chapter 9.

WARNING Closing top exhaust outlet could cause serious damage to the truck

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17. Welding on the dump truck The transmission and the engine are equipped with electronic control units. Before welding on the dump truck: 1. Disconnect batteries.

2. Unplug the connectors on the electronic control units for the engine (S3) and the transmission (S4). The connectors are located on the back under the cabin.

3. Earth point should be less than 1 m from welding point.

4. There should not be sealings and bearings between the welding point and the earth point.

Battery main switch (OFF)

S3 S4

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18. Top tailgate For safe tipping: See Operating Instructions.

If top hinged tailgate is fitted to this dump truck, particular attention should be paid to the material handled in the interest of both safety and efficiency.

The top tailgate is suitable for materials which are both well fragmented and free floating, such as dry earth, gravel, sand, coal, etc. In such instances, discharge should be continuous during the whole cycle of tipping.

However, if the material is poorly fragmented or adhesive, such as clay, bulky boulders etc., it is imperative that a top tailgate is NOT fitted. Such materials do not have an even discharge and problems could arise during the tipping cycle when the material comes in contact with the top tailgate. Cases have been reported where the tailgate restriction has caused the front wheels of the dump truck to leave the ground. Such a situation creates instability of the front of the dump truck, and results in reduction of operator safety.

WARNING Doosan Infacore Norway AS cannot be held responsible for any damage that may occur through improper use of the top hinged tailgate.

DANGER It is hazardous to work/stand underneath the tailgate while the body is raised!

The tailgate must be removed if any work is to be done inside the body while the body is raised.

DA30/DA40 - Removal of the top tailgate: 1. Attach wire or chain to the lifting points. The tailgate shall be disassembled in three parts, tailgate arms (left and right) and the rear tailgate plate.

Be sure that wire or chain are attached to all three tailgate parts before disassembling.

2. Remove all screws (see arrows) on the tailgate (both sides) and lift off the tailgate parts. Approx. weight: DA30 - 790kg DA40 - 810kg

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19. Engine bonnet Do not open the bonnet when the engine is running. The bonnet is fitted with lockable bonnet opener on left hand side. The bonnet must always be closed and secured with the lock when operating the dump truck.

When the bonnet is open, make sure that the bonnet catcher for open position (on left hand side) secures the bonnet from falling down.

• To open the bonnet: 1. Depress the button on the handle grip on left hand side.

2. Lift the bonnet catcher.

3. Push up the bonnet.

4. Check that the bonnet catcher engages.

• To close the bonnet: 1. Push the bonnet forward.

2. Lift the bonnet catcher.

3. Push down the bonnet and see to that the lock engages.

DANGER It is hazardous to work/stand underneath the bonnet without applying the bonnet catcher!

Do not operate the dump truck with a raised and secured bonnet!

20. Tiltable cab Always secure the tilted cab with the support before service/ inspection and other work/stand underneath the cab. The cab must always be closed and secured with the locks when operating the dump truck.

Before tilting the cab, check that there are no loose objects in the cab.

When the cab is tilted, make sure that the support secures the cab from falling down.

•

To tilt the cab: 1. Lift the body and secure it with the body support (see item 21).

2. Stop the engine.

3. Open the bonnet and apply the bonnet catcher (see item 19).

4. Put a plastic bag or similar around the brake fluid reservoirs before the cab is tilted. To prevent brake fluid spillage.

5. The cab has two tilted positions: • Service position - Must be secured with the safety support, see below (item 8) • Top position - T he cover behind the hydraulic tank has to be removed before tilting the cab to top position.

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- If exhaust heating is fitted, this must also be removed.

- The cab must be fastened to a crane or similar when tilted for safety reason.

6. Remove one bolt on each side of the cab.

Spanner: 46 mm 7. Push up the cab by using the hydraulic pump (a) on left hand side. If hydraulic pump is not installed, crane has to be used.

• Make sure that the handle for up-and down pushing (b) is in the up-position (the illustration shows the down position).

8. I n service position: Fasten the safety support (c) to the anchorage point at the cab and front frame, by using the bolts removed in item 6.

The safety support is to be found in the toolbox.

• To lower the cab: 1. Unscrew the safety support (c). Put it back to its storage place in the tool box.

2. Lower the cab by using the hydraulic pump (a) on left hand side. If hydraulic pump is not installed, crane has to be used.

• Make sure that the handle for up-and down pushing (b) is in the down-position (the illustration shows the down position).

3. Refit the bolt on each side of the cab.

4. Remove the plastic bags on the brake fluid reservoirs.

5. Close the bonnet.

6. Lower the body.

7. Refit the cover behind the hydraulic tank and the exhaust heating, if this was removed. a

DANGER It is hazardous to work/stand underneath the cab without applying the safety support!

Do not enter the cab while it is tilted!

Do not operate the dump truck with a tilted and secured cab!

b

c

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Operating & Maintenance Manual

2. Safety Instructions

21. Body support Always secure the raised body with the body support before service/inspection and other work underneath the body. The body support device is intended for empty body only!

• Engagement of the support device: 1. Raise the body.

2. Make sure that the parking brake is on (locked) before leaving the cab.

3. Lift the body support in top position.

4. Slowly lower the body towards the support device until firmly positioned.

5. Return the tip control lever to hold position.

6. Stop the engine and remove the starter switch key.

• Disengagement of the support device: 1. Start the engine.

2. Lift the body slightly.

3. Return the tip control lever to hold position when the body is off the body support.

4. Make sure that the parking brake is on (locked) before leaving the cab.

5. Lower the body support.

6. Lower the body.

DANGER It is hazardous to work/stand underneath the body without applying the body support device!

Do not operate the dump truck with a raised and secured body!

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2. Safety Instructions

22. Service position Prepare the dump truck before service, maintenance and other work on the dump truck. Take every precaution for safe work. If more than one person shall perform work, one person should supervise to maintain the safety.

1. Park on a level ground and apply the parking brake.

OFF

2. Apply the articulation lock (see item 24).

Block the wheels (see item 23).

3. S top the engine and remove starter switch key if not necessary for the work. Disconnect the main switch on the front fender (left hand side).

4. Secure the dump truck from being operated by accident or by persons unauthorised by attaching a warning label to the steering wheel. Do not allow persons to approach the area unnecessarily.

5. Be aware of hot fluids and components.

6. Block up all lifted components to prevent them from falling during work/stand underneath.

Before starting up after work, make sure the dump truck is in good operating condition.

23. Wheel chocks Always place wheel chocks under the wheels to avoid spontaneous rolling: • when parking • during maintenance and other work • during transportation of dump truck.

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2. Safety Instructions

24. Articulation lock The lock prevents the dump truck turning when applied.

• Apply the lock: 1. Take out the spring cotter, lift the pin and swing the linkage forward into the hinge ear.

2. Insert the pin through linkage and ear and refit the spring cotter.

• Release the lock: 1. Take out the spring cotter, and remove the pin through the linkage and ear.

2. Swing the linkage backwards, insert the pin through the link age and ear, and refit the spring cotter.

The lock must always be applied: • During maintenance, greasing and other work.

• When lifting or hoisting the truck, see item 25.

• During dump truck transportation, see item 26.

25. Lifting / hoisting 1. Apply the articulation lock (see item 24).

2. Open and secure (see item 19) the bonnet.

3. Fit suitable lifting wires or chains to the hoisting points at both sides of the body and engine, and use a suitable lifting beam as shown.

Machine net weight: DA30: approx. 23,400 kg

DA40: approx. 30,300 kg

WARNING Never lift or hoist a loaded truck, the points are intended for an empty dump truck only!

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2. Safety Instructions

26. Dump truck transportation 1. Apply the parking brake.

2. Apply the articulation lock.

3. Apply wheel chocks.

Fit suitable wires or chains to the tie down points on the front and rear frame as shown and secure safely.

CAUTION Always transport the truck without load in the body!

27. High pressure Be aware of high pressure in the hydraulic system (with running engine and operated service brakes) and tyres. Do not strike or bend pressure hoses or tubes. Do not use bare hands for checking leaks, use shield as protection to avoid personal injury. Even a pin-hole size leak can penetrate the skin. Always release pressure before maintenance or servicing: Hydraulic: Accumulators contain oil under high pressure!

Always empty the accumulators before working on or opening the hydraulic system.

Procedure: • Stop the engine.

• Operate the brake pedal repeatedly until the accumulators are empty.

• Operate the parking brake switch until the parking brake accumulator is empty.

Accumulators can also be emptied through the accumulator test connectors.

Be aware that the accumulators will be recharged with oil when the engine is re-started.

Tyres: Release the pressure through the rim nipple before attempting to remove any embedded objects or removing tyre/rim assembly from the machine. The pressure inside the tyres is substantial and an explosion can cause damage and serious personal injury. Never heat or weld on rims or surrounding areas when the tyre is inflated. Stand behind the tread when inflating a tyre.

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Operating & Maintenance Manual

2. Safety Instructions

28. Safety labels The following labels are related to safety and should always be present and easy to read. Do not cover labels with paint or similar: Cab certification.

The cab has been approved to current ROPS/FOPS standards. Structural damage, an overturn, modification, alteration or not permitted repair can affect the cab strength and thereby void the certification. Consult your Doosan Dealer to determine this structure’s limitations without voiding its certification.

Warning - use of top tailgate • Top tailgate is fitted on this dump truck.

Warning - never coast in neutral • Never coast with the gear selector in the neutral position.

• The braking effect and the operator’s safety will be reduced.

• Pay particular attention to the material handled by dump truck with top tailgate.

• Wrong material and improper use of top tailgate can cause a DANGEROUS situation and reduce the operator’s safety.

• Read the operating manual (safety instructions, item 18) before operation.

Operating & Maintenance Manual

Warning - dangerous loads • Explosive or inflammable loads must not be transport if the body is exhaust heated.

• Read the operating manual (safety instructions, item 16) before operation.

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2. Safety Instructions

Emergency exit • The emergency exit can be used by removing the hammer from the storage location and break front side window.

• Read the operating manual (safety instructions, item 2.10) before operation.

Warning - operation, inspection and maintenance • I m p r o p e r o p e ra t i o n a n d maintenance can cause serious injury or death.

• R e a d t h e m a n u a l a n d l a b e l s b e fo r e o p e ra t i o n and maintenance. Follow instructions and warnings in the manual and on labels on the dump truck.

• Always keep the manual in the cab. If this manual is lost, please contact your Doosan Dealer for a replacement.

Caution - engine brake • ALWAYS keep the engine speed below max. allowed rpm.

The engine brake will be automatically engaged.

Warning - parking brake • Ensure the park brake is applied before leaving the machine.

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2. Safety Instructions

Fire extinguisher • The fire extinguisher is located on the left hand side in the cab.

• Read the operating manual (safety instructions, item 2.7)

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2. Safety Instructions

First aid kit • The first aid kit (if fitted) is located on the left hand side in the cab, below the rear side window under instructor seat.

• Read the operating manual (safety instructions, item 2.7).

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2. Safety Instructions

Warning - limited visibility Warning - engine is running • Never open the bonnet with the engine running.

• To prevent serious injury stop the engine before opening the engine bonnet.

• Wait until all engine parts have completely stopped before touching them.

• Keep out of this area when the engine is running, the operator has limited visibility.

• To prevent serious injury or death carry out the following before moving the dump truck: • Be sure no one is on or near the dump truck.

• Sound horn to alert people nearby.

• Do not touch hot surfaces!

Fingers or hands can be burnt.

Warning - welding precaution • Disconnect the batteries and unplug the connectors on the electronic control units before welding.

• Read the operation manual (safety instructions, item 17) before welding.

Warning - pinch danger • Keep clear, pinch danger in the articulation area.

• To prevent serious injury or death carry out the following before moving/turning the dump truck: • Be sure no one is on or near the dump truck.

• Sound horn to alert people nearby.

• Always use the articulation lock when servicing!

• Read the operating manual (safety instructions, item 24).

Operating & Maintenance Manual

Note - sling and/or tie down point • Read the operating manual (safety instruction, item 25 and 26) for correct use of the sling and/or tie down point.

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2. Safety Instructions

Warning - body support • Do not stand underneath the body without applying the body support device.

• Always use the body support when working underneath the body.

• Empty body before body support is used.

• Read also the operating manual (safety instructions, item 21) before operation.

Note - sling and/or tie down point • Read the operating manual (safety instruction, item 25 and 26) for correct use of the sling and/or tie down point.

Warning accumulators contain oil under high pressure • Always empty the accumulators before working on or opening the hydraulic system

Note - sling and/or tie down point

• Read the operating manual (safety instructions, item 27 and chapter 7, maintenance) before servicing.

• Read the operating manual (safety instruction, item 25 and 26) for correct use of the sling and/or tie down point.

ROPS/FOPS approval cab • Read the operating manual (safety instructions, item 2.9).

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2. Safety Instructions

Note - check oil specification • A l w a y s c h e c k o i l specifications before refilling.

• Read the operating manual (chapter 6, lubricants) before refilling.

!

WARNING!

TYPE OF GREASE • Do NOT use grease which contains graphite, teflon or molybdenum.

• For correct type of grease, see Operating & Maintenance Manual.

Note - use correct type of grease • A l w a y s c h e c k g r e a s e specifications before refilling.

• Read the operating manual (chapter 6, lubricants) before refilling.

Warning - air conditioner • Refrigerant R 134a under high pressure.

• Read the operating manual (safety instructions, item 7 and chapter 7, maintenance) before servicing

Warning - hot coolant can spurt out Warning - hot area!

• If it is necessar y to refill coolant to the expansion tank, stop the engine and allow the engine and the expansion tank to cool down.

• The exhaust pipes and nearby area may be hot. Fingers and hands can be burnt!

• Use gloves when checking the transmission oil level or filling oil.

• Slowly loosen the cap to relieve pressure before removing the cap.

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2. Safety Instructions

(Behind the cab)

(Behind the hydr. tank)

Note - fuel tank

Note - transmission

Note - hydraulic tank

• Read the operating manual (safety instructions, item 2.5 and 8) before refilling fuel.

• Read the operating manual (safety instructions, item 2.5 and 8) before refilling oil.

• Read the operating manual (safety instructions, item 2.5 and 8) before refilling oil.

• Always check fuel specification (chapter 6, lubricants) before refilling.

• Always check oil specification (chapter 6, lubricants) before refilling.

• Always check oil specification (chapter 6, lubricants) before refilling.

(Inside battery compartment) Warning - battery acid and gases • Battery electrolyte contains sulphuric acid and can quickly burn the skin and eat holes in clothing. Flush the area with water if you have spilt acid on yourself.

• Batteries generate hydrogen gas. Hydrogen gas is very explosive, and is easily ignited with a small spark or flame.

• Read the operating manual (safety instructions, item 6) before working with batteries.

Note - sling and/or tie down point

Note - urea tank (Only T4) • Read the operating manual (safty instructions, item 2.11) before refilling urea.

• Read the operating manual (safety instruction, item 25 and 26) for correct use of the sling and/ or tie down point.

(Inside battery compartment) Warning - welding precaution • Disconnect the batteries and unplug the connectors on the electronic control units before welding.

• Read the operation manual (safety instructions, item 17) before welding.

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2. Safety Instructions

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3. Operating controls

Operating Controls

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3. Operating Controls

Operating Controls....................................................................................................................3-1 Overview of the instrument panels and controls..........................................................................3-3 Instruments..................................................................................................................................3-5 Monitor warning / indicator symbols and lights............................................................................3-9 Groeneveld pump test...............................................................................................................3-16 Keypad, buttons and switches...................................................................................................3-18 Cab ventilation...........................................................................................................................3-21 Controls.....................................................................................................................................3-24 Other cab equipment.................................................................................................................3-30 Operation of heater....................................................................................................................3-36

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3. Operating controls

Overview of the instrument panels and controls

WARNING Do not drive the dump truck until you are well acquainted with the location and function of instruments and controls. Read the following carefully, together with the chapter about operation.

• Check the instruments now and then, when abnormal values are discovered in time, precautions can be taken to prevent the occurrence of major damage.

• If red symbols/lights illuminate, stop the dump truck as soon as possible at a safe place and take necessary precautions. If you don’t, safety could be compromised and/or the dump truck could be damaged.

• To be able to check the function of instruments and controls, the battery main switch must be connected and the starting switch key must be in position 1.

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3. Operating Controls

Overview of the instrument panels and controls Standard extra equipment and optional accessories are also shown and described.

11

10.

9.

1.

8.

2.

7.

6.

4.

5.

Pos Description 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

3-4

3.

Page

Display screen Tip control lever Gear selector Keypad Throttle pedal (accelerator) Brake pedal Fire extinguisher Steering column Column switch Radio/CD player Cab ventilation panel

3-5 3-28 3-27 3-18 3-26 3-26 3-33 3-26 3-24 3-35 3-21

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Remarks

3. Operating controls

Instruments

Display screen Main display shows all vehicle information and diagostic status of dump truck.

1. Engine revolution counter This counter indicates the engine rpm. Normal revolution: • Low idle: 720 rpm • Max. economic area: 1500 - 1900 rpm • High idle:

2280 rpm ± 20

• Max. allowed rpm:

2400 rpm

1 2. Speedometer This gauge indicates the dump truck travel speed in kilometers per hour (km/h).

2

3. Engine coolant temperature This indicates the temperature of the engine coolant.

This illuminated if temperature is between (97˚C - 103˚C) and it is a attention.

This illuminated if temperature is over (103˚C) and it is a warning.

3

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3. Operating Controls

Instruments 4. Transmission oil temperature This indicates the temperature of the oil in transmission. his illuminated if temperature is between (105˚C T 110˚C) and it is a attention.

This illuminated if temperature is over (110˚C) and it is a warning.

4 5. Retarder oil temperature This indicates the temperature of the oil in retarder. his illuminated if temperature is between (115˚C T 125˚C) and it is a attention. his illuminated if temperature is over (125 ˚C) and it T is a warning.

5 6. Fuel level This indicates fuel tank level from empty to full (0% - 100%) Tank capacity: DA30, approx. 335 liters

DA40, approx. 530 litres his illuminated if fuel level is below (5,1%) and it is T a attention.

6

his illuminated if fuel level is below (0,5%) and it is T a warning. This illuminated also, if the sensor failure is detected

NOTE Fill up with diesel when necessary, and at the end of the shift.

7. Information about transmission Display shows gear ranger 1st - 8th and driving direction ¨F¨ for forward or 1st - 4th ¨R¨ for reverse and ¨N¨for neutral.

7

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3. Operating controls

Instruments 8. Urea (AdBlue) level This indicates urea tank level from empty to full.

(0% - 100%) Only for dump trucks with Tier4 engine.

Tank capacity: DA30, approx.

38 liters

38 litres

DA40, approx.

This illuminated if adblue level is below (10%) and it is a attention.

8

This illuminated if adblue level is below (5%) and it is a warning.

NOTE Fill up with adblue when the fuel tank is filled, or if necessary.

If in the DA30 or DA40 Tier4 Stage3B trucks AdBlue tank is empty then, it is only possible to run the dump truck at max. 10 km/h until the AdBlue tank will be refilled.

9. Main driving statistic This table shows information about daily driving statistics, and the total sum.

The trip counters can be reset by using: MENU --> USER SETTINGS --> • RESET TRIP A COUNTERS • RESET TRIP B COUNTERS

9 10. Information about errors (Error codes) This table informs and defines the any possible errors from all vehicle systems.

NOTE If error codes are shown on the display, contact your Doosan in all case

10 11. Load wight indicator This indicates the weight of load on body in tons (t).

This illuminated if value of loads was reached: • DA30 - 30,0 t • DA40 - 41,0 t This illuminated if value of loads was reached: • DA30 - 32,0 t • DA40 - 43,0 t

11 Operating & Maintenance Manual

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3. Operating Controls

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3. Operating controls

Monitor warning / indicator symbols and lights Warning / Indicator symbols and lights are displayed on the main page of the Display

1

2

4

3

5

6

7

8

9

10

11

12

13

14

15

16

17 18 19 20 21 28

22 23 24 29 25

26

Pos. 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

27

Description Engine failure warning SCR failure warning Low engine oil pressure warning Low coolant level warning Air filter warning indicator Transmission failure warning Parking brake activated indicator Brake failure warning Hydraulic system failure warning Emergency steering warning General failure Battery charge warning Body down indicator Direction light indicator High beam indicator

Page 3-10 3-10 3-10 3-10 3-10 3-11 3-11 3-11 3-12 3-12 3-12 3-12 3-13 3-13 3-13

Pos. 16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

Description Page Main light indicator 3-13 Rear working lights 3-13 Working lights and extra high beam 3-13 Rotating beacon light 3-13 Lamp fault 3-14 Seat belt warning 3-14 Transmission Lock-up indicator 3-14 Automatic/Manual Transmission 3-14 status Retarder brake indicator 3-14 Engine brake indicator 3-14 Rear camera view button/Main 3-14 Menu button 3-14 Lubrication system warning 3-15 Gear shift restriction 3-15

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3. Operating Controls

Monitor warning / indicator symbols and lights 1. Engine failure warning, amber or red This illuminates when engine failure occurs. Stop the dump truck, turn off the engine and contact your Doosan dealer immediately.

If this is defined as a warning this will be an amber color, but if this is defined as an error this will be a red color.

If this illuminates: A. Stop the dump truck on a safe place.

B. Select neutral gear position and apply the parking brake.

C. Check and note the error codes on the display.

D. Contact your Doosan Dealer.

2. SCR failure warning, amber or red This illuminates when SCR system failure occurs.

If this is defined as a warning this will be an amber colour, but if this is defined as an error this will be a red colour.

3. Low engine oil pressure warning, red This illuminates when low oil pressure in engine.

WARNING In this event, stop the engine immediately

4. Low coolant level warning, red This illuminates when the coolant in the expansion tank it too low.

Stop the truck immediately and see chapter 7-17 Maintenance.

WARNING Engine damage may occur if truck is driven with little or no coolant

5. Air filter warning, red This illuminates when the engine air filtes is clogged and needs maintenance.

See 1000 hours service for procedure (section 7 maintenance)

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3. Operating controls

Monitor warning / indicator symbols and lights

6. Transmission failure warning, amber or red This illuminates when error has been detected.

If this illuminates: A. Stop the dump truck on a safe place.

B. Select neutral gear position and apply the parking brake.

C. Check and note the error codes on the display.

D. Contact your Doosan Dealer (a short explanation of the codes is listed under troubleshooting, chapter 5).

If this is defined as a warning this will be an amber color, but if this is defined as an error this will be a red color.

WARNING • If error codes are shown on the display, contact your Doosan Dealer in all cases.

• All error codes (also the special features) shown on the display will be stored in the memory of the transmission controller.

7. Parking brake activated indicator, red This illuminates when the parking brake is "on".

8. Brake system warning, amber or red When brake system hydraulic pressure is abnormal, lamp will illuminate.

Can also light when the starter switch is turned on, switches off when the fluid pressure is at a normal level. If the light does not switch off, check for leakage.

A warning buzzer will sound if the pressure is too low on the supply line.

If this is defined as a warning this will be an amber color, but if this is defined as an error this will be a red color.

If this illuminates: A. Stop the dump truck on a safe place.

B. Select neutral gear position and apply the parking brake.

C. Check and note the error codes on the display.

D. Contact your Doosan Dealer (a short explanation of the codes is listed under troubleshooting, chapter 5).

NOTE Do not drive a dump truck with the brake failure warning lamp illuminated.

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3. Operating Controls

Monitor warning / indicator symbols and lights 9. Hydraulic system failure, amber or red This illuminates when the error in hyraulic system has been detected.

If this is defined as a warning this will be an amber color, but if this is defined as an error this will be a red color.

If this illuminates: A. Stop the dump truck on a safe place.

B. Select neutral gear position and apply the parking brake.

C. Check and note the error codes on the display.

D. C ontact your Doosan Dealer (a short explanation of the codes is listed under troubleshooting, chapter 5).

WARNING Do not drive a dump truck with the hydraulic failure warning lamp illuminated.

10. Emergency steering warning, red Lights if the emergency steering system is abnormal.

11. General failure warning, amber or red This illuminates when general error has been detected.

If this is defined as a warning this will be an amber color, but if this is defined as an error this will be a red color.

If this illuminates: A. Stop the dump truck on a safe place.

B. Select neutral gear position and apply the parking brake.

C. Check and note the error codes on the display.

D. C ontact your Doosan Dealer (a short explanation of the codes is listed under troubleshooting, chapter 5).

12. Battery charge warning, red Lights if the battery charging voltage is too low (less than 24 volts).

Check alternator, multi-groove belt and regulator.

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3. Operating controls

Monitor warning / indicator symbols and lights

13. Body down indicator, green, amber or red Lights if body is lifted and it is only possible to run the dump truck to 10 km/h until the body is completely down.

Green color means correct function.

If this is defined as a warning this will be an amber color.

It if this is defined as an error this will be a red color.

14. Direction light indicator, green Flashes when direction indicator or hazard light is activated.

• Will flash fast if an external direction indicator 15. High beam indicator, blue This illuminates when the high beam lights are activated.

16. Main lights indicator, green This illuminates when the main lights are activated.

17. Rear working lights indicator, amber This illuminates when the rear working lights are activated.

18. Working and extra high beam lights idicator, amber This illuminates when the wroking and extra high beam lights are activated.

19. Rotating beacon indicator, amber This illuminates when the rotating beacon light is activated.

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3. Operating Controls

Monitor warning / indicator symbols and lights 20. Lamp fault, amber This illuminates when some bulb of direction, back-up and main lights are damaged.

21. Seat belt warning, amber This illuminates when driver has not fastened the safety belts.

22. Transmission lock-up indicator, green This illuminates when the automatic lock-up clutch for transmission is connected.

23. Automatic/Manual transmision status, amber green This shows which mode of transmission is active, letter A for automatic (green) mode and M for manual (amber) mode of transmission.

24. Retarder brake indicator, amber This illuminates when the retarder brake is engaged.

25. Engine brake indicator, amber This illuminates when the engine brake is engaged (Accelerator pedal released).

/

26. Rear camera view button / Home Push the button to toggle between rear cam view and main view.

NOTE The rear view camera will activate automatic when reverse gear is selected.

27. Menu button Press this button to activate the main menu screen.

After pressing this button will apear sub menu.

• User Settings • Detailed View • Service • Diagnostics • Software Update • Language

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3. Operating controls

Monitor warning / indicator symbols and lights

28. Lubrication system warning, amber or red This will illuminate when a failure occurs in the trucks lubrication system. Stop the truck immediately and check the main lubricator.

If this is defined as a warning this will be an amber color, but if this is defined as an error this will be a red color.

If this illuminates: A. Stop the dump truck on a safe place.

B. Select neutral gear position and apply the parking brake.

C. Check and note the error codes on the display.

D. Contact your Doosan Dealer (a short explanation of the codes is listed under troubleshooting, chapter 5).

NOTE If there is a failure in the system, it is only possible to run the dump truck to 7 km/h until the failure is corrected.

29. Gear shift restriction This illuminates when the truck is driven in condition when the transmission does not allow the gear shift.

Other buttons.

• Back button • Up button • Down button • Select button • DTC button • Start button

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3. Operating Controls

Groeneveld pump test

Located under the cover

General To test the system, a cycle test can be invoked with the pushbutton on the pump unit A cycle test can only be started when the system is not in the pump phase of a current greasing cycle. If the system is busy with a pump cycle, it will not react to the test pushbutton.

Twin

To perform a single-cycle test, act as follows: 1. Turn on the contact.

2. Hold the test pushbutton depressed for at least 2, but no more than 6 seconds.

This system will then perform a single-cycle test.

1

The single-cycle test will end when the first three phases of the greasing cycle have been completed (the pause phase is omitted), or when the contact is switched off. If, subsequently, the contact is switched on again, the normal greasing cycle will begin again with the pause phase of the cycle that was interrupted to perform the test.

(A or B).

Keep in mind that only one primary grease line is involved in an single-cycle test. If you want to test the other primary grease line, you must perform a second single-cycle test.

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3. Operating controls

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3. Operating Controls

Keypad, buttons and switches

Standard extra equipment and optional accessories are also shown and described.

1

2

3

Keypad When the ignition key is in posision 1 buttons on the keypannel will illuminate.

16 15

4

14 13

5

12 11

6

When buttons are pressed, the corresponding symbols will illuminate on the main display screen and above the key pad.

10 9 8 7 17

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3. Operating controls

Keypad, buttons and switches

1. Parking lights button

7.

Rear inter-axle differential lock button

Only for DA30 T2/T4, this is automatic engaged on DA40 T2/T4

2. Main lights button

8. Inter-axle diferential lock

3. Controls the engine rated speed • F1 inactive = 2100 rpm • F1 active = 1950 rpm

9. Etarder reducing button If this is engaged, operation of the retarder and engine exhaust brake are reduced to 50%.

Not available after the software update 1.095

4. No function

10. Fuel heating (Only T4)

5. Hazard lights button

11. Electrically heated driver’s seat button Push the switch to activate the heating of driver’s seat.

NOTE

6. Override button Stopps engine immediate when ignition key switch off.

Operating & Maintenance Manual

This is optional button and used only if the driver seat is not equipped with such

12. Heated mirrors button

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3. Operating Controls

Keypad, buttons and switches

13. Rear work lights button Push the button to activate the rear working lights.

14. Rotating beacon button Push the button to activate the rotating beacon on top of the cab roof.

15. Working lights and extra hight beam button Push the button to activate the working lights.

16. Cab light button Push the button to activate light in the cab.

17. Parking brake switch

0 1

Lock device

The parking brake is on (locked) when the switch is in the backward position. An indicator light (5) will light when the parking brake is on. Push the lock device to release the parking brake. In the forward position the parking brake is off (released). The parking brake must not be applied when the dump truck in motion unless in an emergency situation.

Indicator light (5) and a buzzer will sound if a gear is selected while the parking brake is on (locked).

CAUTION Do not drive the dump truck if the fluid pressure is below normal pressure (indicator brake system warnig light and buzzer).

The parking brake will not be fully released, and the service brakes may not have max. parking effect.

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3. Operating controls

Cab ventilation

Ventilation control panel The air conditioning system allows high level of security during driving together with a total comfort and a constant thermo balance is assured in the internal compartment independently from the external environment that changes continuously.

To choose your ideal climate during any season, it is sufficient to select the desired temperature in cab.

We Suggest to select temperatures between 20-23 °C. With this simple operation the microprocessor will maintain always the desired temperature in the internal compartment.

In any condition the air conditioning system will control the temperature, the air quantity towards in-vehicle in order to avoid continuous interventions with the manual controls, as in the case of manually operated air conditioners.

• Keep the door and window shut.

• Always open the nozzles when operating the dump truck.

• Direct the air flow so that it does not blow straight on uncovered skin.

• Always turn on the fan when operating the dump truck and adjust fan speed until it feels comfortable in the cab.

AUTO Pressing AUTO all the functions are automatically controlled.

The AUTO symbol will appear on the display.

According to the cab setting and external temperatures, the controller will monitor the connected devices (water valve, compressor, blower) in order to achieve and maintain the required cab temperature.

A/C Pushing A/C engages / disengages the compressor clutch.

When the symbol A/C appears on the display, then the cooling system will be in operation.

Conversely when the ECON symbol is lit, the compressor is turned off.

The automatic temperature controller will further monitor the system to hold the cab temperature in line with the set temperature, by making use of the fresh air and the heater capacity.

If cooling is required press A/C or AUTO.

NOTE When the outside temperature is below +3°C, the air conditioning system is disengaged to protect the compressor.

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3. Operating Controls

Cab ventilation Temperature Up/down The screen displays the cab temperature setting, the desired temperature in the cab.

Pressing ▲ will increase the displayed value.

Each touch ▲ on increases the value on the display by 1°C. The maximum value to be set is 28°C. Beyond 28°C, the display shows “HI” (High). In this case the control will run for the maximum cab temperature the HVAC system can deliver under the existing conditions.

Selecting “HI” = Fastest Way to reach a higher cab temperature Pressing ▼ will lower the display value (= desired cab temperature). Each touch on ▼ lowers the value on the display by 1°C. The minimum value to be set is 18°C. Below 18°C the display shows “LO” (Low) which means the control system goes for the lowest cab temperature that the HVAC can reach under the existing conditions.

Selecting “LO” = Fastest Way to reach a lower cab temperature

Fan up/down Pushing one of the ventilation bottoms will interrupt the Auto Blower Speed Control and bring it in manual use - the Controller continues to control for the set Temperature without airflow control. AUTO symbol is turned off.

Return to automatic control by pushing AUTO. Pressing increases the fan speed in steps to the maximum value.

Pressing zero.

decreases the fan speed in steps to

Pressing again when blower display is at zero stops the controller and the “OFF” symbol appears on the display - all functions are disabled.

Recirculation or fresh air mode When pushing , the actuator control device changes the state of the air intake.

When the symbol appears on the screen, the HVAC system operates with recirculation air from the cab only.

When the symbol does not show up on the screen, the HVAC system operates with 80% recirculation and 20% fresh air.

By manually changing the recirculation status, the system continues controlling the cab temperature, except when “AUTO” symbol is turned off.

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3. Operating controls

Cab ventilation Outside temperature display When pressing EXT for less of 2 seconds, the external temperature value will be shown on display for about 6 seconds.

You will know, when the EXT and symbols are lit, that the external temperature value is showing up on the display.

When the external temperature is close to 0°C, the symbol is lit to indicate the possibility of ice forming.

When pressing EXT for 3 seconds at least, the internal temperature value will be shown on display for about 6 seconds.

Defog mode 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.

Regulation control Prior to the inspection: • Check that the air inlets are not blocked by leaves.

• Check that the cab air louvers are opened to avoid evaporator freeze.

• Check the compressor drive belt tension: - A too high tension: early wearing of the compressor bearings - A too low tension: early wearing of the belt

NOTE 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

• The air conditioning system works only if the vehicle is running.

• While using the air conditioning system, keep all doors and windows closed.

AIR CONDITIONING CONTROL Commands must be set as follows: • Ventilation setting at maximum • Temperature setting at minimum • A/C symbol ON

5 min

NOTE Note: The temperatures were recorded with the vehicle staying in the workshop (not exposed to the direct sunlight) and with around 1100 rpm engine speed.

Place the thermometer in one of the air louvers, and check the cool air outlet temperature.

See tabel with the temperatures.

Check the thermostat stops the compressor and system operation before the outlet temperature is lower than 1°C.

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3. Operating Controls

Controls Column switch B C A

The column switch is a multi-function switch for main lights, horn, direction indicators and windscreen wiper/washer.

Main lights (A, B, C): A. Low beam.

B. High beam indicator will light.

C. High beam flash. Automatic return.

Horn Centre button automatic return.

R

Direction switch Right turn, all right direction indicators flash.

Indicator direction light flashes correspondingly.

Left turn. All left direction indicators flash.

Indicator direction light flashes correspondingly.

L

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Operating & Maintenance Manual

3. Operating controls

Controls Windscreen wiper. Turn handle. Positions: 0 OFF J interval I low speed II high speed

Windscreen washer

H

Push outer ring to activate the washer monitor. At the same time, the wiper wipes some times after releasing the ring.

Steering column The steering wheel is fitted on an adjustable column for comfortable reach and easy operation.

• Height adjustment - lift lever up to unlock.

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3. Operating Controls

Controls

• Tilt adjustment - push lever down to unlock.

• Confirm that the steering column is fixed before operating the truck.

WARNING Do not adjust position while driving!

Brake pedal The pedal controls the main brake (service brake). When depressing the pedal, the rear stop light will light. Braking effect depends on pedal position. Depress pedal gradually, and learn to associate braking requirements for loaded and unladen dump truck.

Do not use the pedal for long period retardations, i.e. loaded downhill. This will overheat and damage the disc brake.

CAUTION If warning for brake system failure lights up (brake system warning indicator), stop the dump truck immediately!

Throttle pedal (accelerator) The pedal controls the engine speed electronically.

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3. Operating controls

Controls

Gear selector The dump truck is equipped with a fully automatic transmission with 8 forward and 4 reverse speeds. Gear shift pattern is speed and engine load dependent. Preselection of gears is possible.

The main display will always show the engaged gear position.

Pos N: Neutral gear position Depress the knob on top of the gear selector when shifting from neutral to forward or reverse position.

Also, always depress the knob when shifting directly between forward and reverse direction.

Pos F: Forward drive position Automatic gear shift between 1st-8th gear according to speed and engine load.

For preselection of gear, push the selector to the right (+) for upshifting or to the left (-) for downshifting. The selected gear will then be engaged when the speed matches the set points.

If the gear selector is pushed either to the left or right, manual gear shifting will take place.

The gear selector must then be pushed in order to change gear.

Manual gear shifting will also take place if the knob on the top of the gear selector is depressed while driving in automatic. To return to automatic gear shifting while driving in manual, depress the knob on top of the gear selector.

Pos R: Reverse drive position: Manual gear shift between 1st-4th gear according to speed and engine load.

The transmission will always select the 1st reverse when the gear selector is set to "R". The selected gear is engaged directly if the dump truck is stationary.

The gear selector has to be pushed in order to change gear.

For preselection of gear, push the selector to the right (+) for upshifting or to the left (-) for downshifting.

See also chapter 5, Operating Instructions

NOTE The knob on top of the gear selector has three functions: 1. D epress the knob when shifting from neutral to forward or reverse position.

2. Depress the knob when shifting directly between forward and reverse direction.

3. Depress the knob to change between automatic and manual gear shifting.

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3. Operating Controls

Controls Tip control lever

Button Button

The lever controls the body lifting and lowering.

The lever has 3 positions: 1. Lower (body down/power down).

2. Hold (hold and floating position).

3. Lift (body up).

The lever are electronically locked in the lower position, and have spring return from lower to hold.

Always keep the lever in hold position during loading and driving.Check that the body is resting on the frame rubber pad during loading and driving.

A warning light (body down indicator) will light when the body is lifted (i.e. when the body is not resting on the frame rubber pads).

Button on top of lever increase engine rpm when depressed (1500 rpm when lifting and 1200 when lowering).

Starter switch The starter switch is key operated, and has 4 positions.

P = Park (key removable).

0 = Power off (key removable).

I = Power on (drive position).

II = Starting position (key returns back to pos. I when released).

WARNING Do not turn the key to off position if you do not intend to stop the engine. The engine has a key stop and requires neutral position on the gear selector to start again.

Cigarette lighter Push in to activate the heating function. Automatic return when hot.

Can also be utilised as a 24 Volt / 10 amp power source.

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3. Operating controls

Controls Emergency exit • This dump truck is fitted with two emergency exits.

• Left door and front side window on right hand side (A).

• If the door is blocked, you can get out through the front side window.

• Remove hammer (B) from storage location and break front side window.

A

B

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3. Operating Controls

Other cab equipment

Driver’s seat The seat is air-sprung with a separate air compressor and adjustable in height, tilt, back support and lengthwise position.

Adjust the seat to the desired position. Always use the safety belt when operating the dump truck.

Seat adjustment A. Backrest angle adjustment B. Armrest angle adjustment Can be lifted for easy access, and the inclination of the arm rests are adjustable for comfortable operating position.

C. Fore and aft slide adjustment Lift lever up and slide the seat to a suitable position - release lever.

D. Thigh support adjustment (3 positions) E. Seat heater The seat can be heated by pushing the switch.

F. Headrest fore and aft adjustment G. Adjustable damper control

WARNING For one seated occupant. Do not adjust seat when vehicle is in operation. Keep clear of all moving parts. Installation and maintenance should be carried out by authorised and competent personnel.

NOTE The driver seat with heating is as option The seat can be heated by pushing the switch. Refer to item 12 in button on keypad panel i this chapter.

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3. Operating controls

Other cab equipment

Instructor seat There is one seat for instructor, on the left side of the driver seat. The seat cushions are spring-loaded and will return to upright position when released. The seat are fitted with safety belt which is recommended for use during driving, both for safety and comfort.

Internal door opener • Push up handle to open the door.

External door opener/lock The door is fitted with lockable door opener.

• Depress the button on the handle grip to open the door.

• The door can be locked from outside by using the door key.

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3. Operating Controls

Other cab equipment

Side window, right front • To open the window: Press both lock arms and push forward position.

• To close the window: Press both lock arms again and pull the window to the close position.

NOTE Be aware not push and pull too hard this can cause the damage of the locking mechanism

Side window, left rear • To open the window: Lift both lock arms to a suitable position.

• To close the window: Push window completely upward and check that the window locks are in the locked position.

NOTE Be aware not push and pull too hard this can cause the damage of the locking mechanism

Opening side windows on the right side of the front and the left side of the rear are the as standard.

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3. Operating controls

Other cab equipment Safety equipment Ensure the safety equipment is present, always keep it on its storage place and make sure that it is in order: • First aid kit.

• Fire extinguisher, 2 kg, ABE class II powder.

(Distributor / Dealer fitted)

• Warning triangle (located in right hand side fender).

(Optional equipment)

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3. Operating Controls

Other cab equipment Ashtray

Retractable roller sun blind on front windscreen

Cab light The cab light has extra function, when error is detected will iluminate in red color and flashes

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3. Operating controls

Other cab equipment Radio/CD player The radio has following security features: Detachable panel, security warning sticker and identification number.

If any of the security features are missing, contact your local Doosan Dealer.

1. Detachable panel Take the detachable panel with you when leaving the dump truck. Keep it in its protective cover. Always replace the detachable panel before starting to drive.

• Remove the panel by depressing button 2.

2

• Replace the panel starting with the left-hand side of the radio. Then push the panel until it clicks into position.

2. Security warning stickers • This "security" warning sticker shall be fitted on your dump truck window.

3. Identification number • This radio has a unique identification number (printed on the "security card"). This card is required as proof of ownership if the radio is stolen, if the detachable panel is lost or if requesting service.

• The "security card" shall be removed before installing the detachable panel.

Do not keep the "security card" in your dump truck.

4. Operating Manual for the Radio/CD player For operation of the radio, see separate Operating Manual.

If the Operating Manual for the radio is missing, contact your local Doosan Dealer.

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3. Operating Controls

Operation of heater NOTE Before switching on the heather, the vehicle heather must be set to “hot”, and the vehicle heater fan must be set to the slowest speed (reduced current consumption)

day of the week

heater “on” indicator

time display memory location alarm indicator time

Standard Timer

program selection

instant reverse heating

The timer can be operated in that all flashing symbols can be adjusted by means of the “reverse” and “forward” buttons. If the buttons are not pressed within 5 seconds, the time displayed will be stored. If the “reverse” and “forward” buttons are pressed for more than 2 seconds, the fast timesetting mode is activated.

If the ignition is switched off while the heater is operating in the continuous mode, the remaining operating time of 15 minutes is displayed and the heater continues to operate for this period of time.

Switching the heater on: Manually by pressing the “instant heating” button (continious heating mode).Automatically by programming the heater starting time.

Switching the heater off: Manually by pressing the “instant heating”.

Automatically, after the programmed operating time has elapsed with the heater running, by programming the remaining operating time.

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Operating & Maintenance Manual

forward

3. Operating controls

Setting time/day of the week: Press the “time” button for more than 2 seconds - time of the day is flashing - and set the closck using the “reverse” and “forward” buttons. Day of the week is flashing - adjust day of the week.

Viewing the time: With ignition switched off, press the time button.

Programming the heater starting time: Press the “program selection” - the memory location is flashing using the “reverse” and “forward” buttons set start of the heater operating time. Day of the week is flashing - set day of the week.

By repetedly pressing the “program selection” button, memory loactions 2 and 3 can be programmed or the time display mode can be reached.

Recalling/erasing preset times: Repeatedly press the “program selection” button until the desired memory location is displayed. To erase the preset time, press the “program selection” button several times until the time of the day is displayed instead of the memory.

Programming duration of operating time: The heater must be switched off. Press the “reverse” button for 3 seconds - operating time is flashing - and set the desired operating time (10 to 120 minutes) using the “reverse” and “forward” buttons.

Setting the remaining operation time: Set the desired remaining operating time (1 to 120 minutes) using the “reverse” and “forward” buttons. The remaining operating time refers ti the time the heater still continiues to remain in operation. It can only be changed while the heater is in operation and the ignition switched off.

Setting the wakeup time: A wakeup time can only be programmed on the standard digital timer. The wakep time is not bound to a specific day of the week.

Repeatedly press the “program selection” button until the bell symbol appears on the display. Set the desired wakeup time using the “reverse” and “forward” buttons. The alarm clock turns off after 5 minutes or when one of the buttons is pressed.

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3. Operating Controls

Recalling/erasing the wakeup time: Repeatedly press the “program selection” button until the bell symbol appears on the display - read off wakeup time. To erase the wakeup time, press the “program selection” button until the bell symbol is no longer visible on the display.

Remote controll: Possible by means of an optional external “instant heating” button.

Troubleshooting In the event of a malfunction, fuses and electrical connections should be checked for proper condition and security. In the event of a malfunction, the heater will shut down in its fault lock-out mode. Following any fault lock-out condition, coded flashing signals will be emitted by the operation indicator, or a fault code will appear on the display of the timer. For details on the meaning of the fault code, refer to the last page. Before you consult a Webasto service center, try to deactivate the fault lock-out by switching the heater off and back on again. A fault lock-out condition may also be reset by briefly removing the 15 amp fuse (blue) with the heater in the switched-on state.

NOTE The heater will start operating as soon as the fuse is replaced!

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4. Running-in period

Running-in period

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4-1

4. Running-in period

Running-in period...........................................................................................................................4-1 1. Running-in operation...................................................................................................................4-3 2. Running-in services.....................................................................................................................4-4

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4. Running-in period

1. Running-in operation Each new dump truck requires careful operation the first 100 hours (refer to hour meter) to break in (run-in) all moving parts.

Follow instructions below during this period: 1. Start engine as described in “Operating Instructions” (chapter 5) . Run engine at low idle speed until pressure in the various circuits is normal (i.e. brake system warning light switched off, also see chapter 3).

2. Warm up by operating the dump truck at low load and reduced rpm until all gauges show normal range. Extend the warming up period in the winter (cold season).

3. During operation do not drive with constant high engine rpm and load, avoid heavy-duty work and high speed travelling.

4. Drive carefully and avoid sudden starts and stops, abrupt acceleration and turns.

5. Carefully perform the running-in services, see next page.

Take special care for the following points: • A warming up period until display screen show normal range is important - also after the dump truck has been run in.

• O perating up to the limit of the dump truck’s capacity during the running-in period, may prematurely reduce the performance potential.

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4. Running-in period

2. Running-in services Running-in service is to be carried out after operating the dump truck the first 8, 100 and 500 hours.

These services are most important for running in a new dump truck.

This is the owner’s responsibility.

2.1 First 8 hours: 1. Wheel nuts.

• Torque setting:

Check tightening of nuts.

450 Nm. Spanner: 32 mm

2. Lubricating.

Grease all lubricating points.

3. Battery:

Checking electrolyte level in the batteries, see 500 hours service, item 1.5.

Checking battery charge, see 1000 hours service, item 2.3.

4. Multi-groove belt: Checking multi-groove belt condition, see 1000 hours service,

item 2.4.

5. Carry on with the normal 8 hours service, listed in chapter 7, maintenance.

Since these points are important for the dump truck to work satisfactorily right from the start they are also listed below.

All items below refer to 8 hours / daily service in chapter 7.

1. General • Walk around check, before start • Check driver’s seat, before start 2. Engine • General condition check - look for leakages remedy as necessary • Drain the water separating fuel filter 6* • Check oil level, before start 1* • Check coolant level, before start 5* Coolant should be filled up when the engine is stopped after first stop.

It is recommended to fill up with the same mixture as filled from the producer 40% glycol / 60% water, see also 2000 hours service, item 1.2 check the coolant.

• Check fuel and urea tank (if fitted) level, before start 12* • Function check of the centrifugal cleaner, after operation 2* 3. Transmission • Check oil level, before operation 20* 4. Hydraulic system • Check oil level, before start 40* 5. Brake system • Parking brake, check braking (holding) capacity, before operation • Service brake (main brake), check braking (holding) capacity, before operation • Service brake (main brake), check function, before operation • Accumulators, check the oil pressure, before operation 6. Steering • Check function, before operation 7. Engine brake • Check function, before operation 8. Engine and retarder brake • Check function, before operation

Item 1.1 Item 1.2 Item 2.1 Item 2.2 Item 2.3 Item 2.4

Item 2.5 Item 2.6 Item 3.1 Item 4.1 Item 5.1 Item 5.2 Item 5.3 Item 5.4 Item 6.1 Item 7.1 Item 8.1

2.2 First 100 hours: 1. Change transmission oil.

20* 2. Replace transmission filter. 21* 3. Replace hydraulic filter.

42* 4. Run the Transmission Clutch Calibration (AEB) 5. Multi-groove belt: Checking multi-groove belt condition, see 1000 hours service, 6. Expander bolts: Checking torque setting on expander bolts on tip- and steering cylinders, see 500 hours service, 7. Retorque window wiper spindle nuts.

• Torque setting: 25 Nm (M8)

* Numbers refers to position on lubrication schedule, chapter 6 4-4

Operating & Maintenance Manual

item 1.1. item 1.1. item 2.1. item 1.2. item 2.4. item 5.1

4. Running-in period

2.3 First 500 hours: 1. Change oil in: (DA30) • Front differential.

• Rear differential.

• Tandem housings.

• Planetary drive (hubs).

30* 31* 32* 33*

See initial 500 hours service See initial 500 hours service DA30, See initial 500 hours service DA30, See initial 500 hours service DA30,

Item 1.1. item 2.1. item 3.1. item 4.1.

30* 31* 32* 33* 34*

See initial 500 hours service, See initial 500 hours service, See initial 500 hours service, See initial 500 hours service, See initial 500 hours service.

item 1.1. item 7.1. item 5.1. item 6.1. item 9.1.

See initial 500 hours service, See initial 500 hours service, Contact your local Doosan dealer.

item 8.1 item 8.2

2. Change oil in: (DA40) • Front differential.

• Rear differential.

• Tandem housings.

• Reduct. gears, front.

• Brake cooling tank 3. Check/adjust: • Valve clearance • Adjusting the unit injector • Hydraulic oil pressure.

4. Carry on with the normal 500 hours service, listed in chapter 7, maintenance.

• Change oil, engine • Clean centrifugal cleaner • Replace oil filter • External cleaning of the radiator • Check oil levels • Check brake lining thickness • Check wheel nuts torque • Check expander bolts, tip- and steering cyl.

• Air conditioner system, test operation • Check cab ventilation filter element • Check the automatic central lubrication system

item 1.1. item 1.2. item 1.3. item 1.4. item 2.1. item 3.1. item 4.1. item 5.1. item 6.1. item 6.2. item 7.1.

See chapter 7 for procedures and chapter 6 for fluid specifications.

* Numbers in brackets refer to position on lubrication schedule, chapter 6 Operating & Maintenance Manual

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5. Operating Instructions

Operating Instructions

Operating & Maintenance Manual

5-1

5. Operating Instructions

Operating Instructions...................................................................................................................5-1 Precautions on work sites.................................................................................................................5-3 Some simple rules to be observed prior to operation.......................................................................5-6 1. Starting the engine......................................................................................................................5-7 2. Operating the dump truck............................................................................................................5-9 3. Parking the dump truck................................................................................................................5-22 4. Stopping the engine....................................................................................................................5-22 5. Checks after stopping the engine................................................................................................5-23 6. Loading and tipping.....................................................................................................................5-23 7. Tyre handling...............................................................................................................................5-25 8. Cold weather...............................................................................................................................5-27 9. Long term storage.......................................................................................................................5-28 10. Battery power assistance............................................................................................................5-29 11. Towing the dump truck.................................................................................................................5-30 12. Manual release of parking brake.................................................................................................5-30 13. Manual release of the ball valve on tilting circuit.........................................................................5-31 14. Troubleshooting...........................................................................................................................5-32

5-2

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5. Operating Instructions

Precautions on work sites There are many different types of work sites, some of them could be: • Dusty areas • Rocky areas • Wet, swampy or muddy areas • Seashore or salty areas

• Altitude above 1000 m • Steep driving • Extremely hot areas

• Underground areas (mines) • Transit, long distance drive-away (more than 3 km) • Extremely cold areas

Rules and guidelines are listed below to increase the lifetime of the dump truck. Pay attention to these guidelines and let the safety always get first priority.

General • On work sites where extra heavy-duty operations are occurring, reduce the maintenance intervals and carry out greasing more frequently.

• Clean the machine regularly. Keep grease fittings, breathers and oil level gauges clean and avoid dirt to enter these items.

Dusty areas/Underground areas (mines) • Watch the air filter warning light, to see whether the engine air filter is clogged. Clean/replace the engine air filter at shorter intervals than specified, clean as often as necessary (see 1000 hours service for procedure).

Extremely dusty applications may require to clean the air filter every day!

• Clean the radiator core frequently, every week if necessary, to avoid clogging (see 500 hours service for procedure).

• Clean and replace the fuel filters frequently (see 1000 hours service for procedure).

• Check daily the cab ventilation filter and pre-filter. These filters will very soon be clogged in dusty areas, therefore it is necessary to clean and replace the cab ventilation filter and pre-filter more frequently than usual (see 40 and 500 hours service for procedure).

Never remove a filter element/pre-filter without replacing it with a new one!

• Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

Rocky areas • Check for damage to the undercarriage and for looseness, flaws, wear and damage in wheel bolts and nuts.

• Check tyres for damage and wear. Remove foreign object from the threads as soon as possible, these will sooner or later penetrate into the tyre. Also protect the tyres from falling stones during loading.

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5. Operating Instructions

Wet, swampy or muddy areas (see also chapter 2, item 15 - Wading) • The wear of the sealings will also increase when driving in wet or swampy areas, check and replace sealings as often as necessary.

• If mud sticks to the callipers or discs on parking brake, and the brakes are left in that condition, the wear of the lining will increase, therefore always wash the area well with water after operations. E.g. when clay is dried up it is hard as concrete, this will cause breakage and wear of the machine.

• Do not let the water flow through the grill or into the different breathers and air filters.

• Do not operate the dump truck in water/rivers permanently for along period.

And do not under no circumstances let the water flow through the grill.

Seashore or salty areas • Before starting working, check the tightness of plugs and valves.

• Spray exposed areas with anti-corrosive.

• Check the parking brake linings more often (see 500 hours service for procedure). When driving in wet salty/sandy areas the wear of the lining will increase.

• Check the sealings more often. The wear will increase in salty/sandy areas.

• Lubricate components more frequently than usual.

• Do not operate the dump truck in water/rivers for a long period of time.

• It is important to wash the machine immediately after use to protect the components from rusting and to remove dirt and sand.

See also item above “Wet, swampy or muddy areas” High altitude (above 2000 m) • Be aware that the engine power and torque will be reduced due to low air density.

• Do not remove the air filter!

NOTE The graphs of altitude power reduction are in chapter 8

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Operating & Maintenance Manual

5. Operating Instructions

Steep driving • When driving downhill and loaded, always use only the engine brake and retarder brake for retarding. The service brake (foot brake) must only be used for complete stop (see also chapter 2, item 13 - Operation of brakes and chapter 5, item 2.12 - Up, down and cross gradient travel).

• See also engine and retarder brake capacity chart at chapter 8.

Extremely hot areas • Observe the engine coolant temperature gauge, the engine coolant temperature warning light and the transmission oil temperature gauge. If the temperatures are at the limit,check the engine radiator for clogging (see 500 hours service) • Observe the air filter warning light on the display screen.

This will illuminate if the air filter is clogged. Clean/replace the engine air filter at shorter intervals than specified and clean as often as necessary (see 1000 hours service for procedure).

Extremely cold areas (see also chapter 5, item 8 - Cold weather) • Use the engine heater.

• Check that the correct oils are used (see oil specification sheet, chapter 6) • Check that there is enough glycol in the coolant (see 2000 hours service for freezing point and correct coolant) Transit, long distance drive-away (more than 3 km) • Check and adjust the tyre pressure of cold tyres before starting. Do not reduce pressure during driving.

• Generally replace the mineral based oil with fully synthetic oil.

A mineral based oil will rapidly break down lubrication ability and cooling ability when operated at high temperatures (120OC).

Replacing mineral based oil with a synthetic oil will improve the cooling capacity by 15%.

• Make sure that the interaxle differential is disconnected when driving, as the 50/50 torque split will generate a lot of heat increasing the risk of shaft wind up.

• Drive only without load.

• Drive for 2 hours and stop for a minimum of 30 mins. Drive another 2 hours and stop for a minimum of 1 hour. Repeat.

• Upper speed limit for this operation: 2280 rpm at 8. gear.

Must not be exceeded!

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5. Operating Instructions

Some simple rules to be observed prior to operation.

• Read and understand this Operating & Maintenance Manual before you begin to operate the dump truck.

• When the dump truck is operated, the door should be shut.

• Never operate the dump truck if you are under the influence of alcohol,medicines or other drugs.

• Check that the seat is adjusted for comfortable and safe operation of controls before operation.

• You must wear personal safety equipment for safe operation.

• Check that the steering column is adjusted for comfor table operation, confir m that it is fixed before operation. DO NOT ADJUST POSITION OF THE STEERING WHEEL WHILE DRIVING!

• Wear a helmet to protect your head.

• Always use the seat belt during driving!

If there is an instr uctor or passenger in the cab, be sure that they are seated on the instructor seat and are using seat belts!

• When you climb up or down from the dump truck, always climb facing towards the truck using the steps and handles. Always use two feet and one hand or vice versa.

• If instructor seat is not fitted, instructor or passenger may not stay in the cab during driving.

DO NOT JUMP!

5-6

• Do not climb on surfaces which are not intended for this, always use the surfaces which are provided with anti-slip coatings.

• Check that the brake system warning light is not illuminated before driving.

• The cab is the driver’s protection and conforms to the requirements for roll over protection (ROPS) and falling objects (FOPS), specified in the standard for these.

The precondition for providing protection is that the driver uses the seat belt and remains in the cab. Therefore, hold on to the steering wheel (as indicated) if the dump truck should roll over.

• The cab has two exits, one door and the front side window on the right hand side as emergency exit. The emergency exit can be used by removing the hammer from the storage location and break front side window.

Operating & Maintenance Manual

5. Operating Instructions

1. Starting the engine Before starting the engine in the morning, perform the Daily Service, see chapter 7.

Remember to connect the battery main switch on the front right hand fender next to the mount rail (if disconnected) otherwise there will be no power supply.

ON

1.1. Confirm that parking brake is ON

1.2. Confirm that gear selector is in neutral position

1.3. Turn the starter switch ON, pos 1 Check the warning lights illuminated on the display screen (1) before starting:

1

• parking brake • brake system - could light up if the fluid pressure is too low.

If the light does not switch off, check for possible fault.

If any of these lights do not light up, there is a fault in the electrical system. This should be checked and fixed before starting if necessary.

Before starting engine wait 2 sec on pos 1. Control system will inhibit any attempt to start engine until 2 sec has elapsed.

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5. Operating Instructions

1.4. Start the engine 1. Turn the starter switch key to the right, pos. II to engage the starter.

2. Hold until engine starts (Max. 30 sec).

3. Check that warning lights for engine oil pressure and battery charge switch off.

WARNING • Never use starter gas or similar agents to help start the engine. An explosion my occur in the in take manifold with a risk of personal injury • Only start the engine in a well ventilated area.

When operating the engine in an enclosed space, there should be an effective device to extract exhaust gases and crankcase gases

1.5. If engine does not start

55 Mins Mins

1. Turn starter switch OFF, and wait until engine has stopped completely before attempting to start again.

2. After that it must rest for at least 5 minutes before restart.

1.6. Starting in cold weather / at low temperatures When starting the engine in cold weather, ensure the engine has reached operating temperature before any work is carried out.

1. In cold weather, hold until engine start (min. 10 sec and max 30 sec).

2. Hold until engine starts (Max. 30 sec).

3. If engine does not start it must rest for at least 5 minutes before restart.

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Operating & Maintenance Manual

5. Operating Instructions

2. Operating the dump truck 2.1. Before operation When the engine is running properly and the fluid pressures are within operating range:

1

1. Clean/defrost the windows before driving.

6. Sound the horn as alert.

2. Fasten the seat belt before driving.

7. Depress the brake pedal.

3. Check that gauges and warning lights on the display screen (1) do not indicate any abnormalities.

8. Release the parking brake and confirm that the indicator light turns off.

OFF

4. Confirm low idle speed.

9. Select a suitable gear position at low idle (see item 2.3, Gear shifting).

5. Check that there are no persons or objects in front of the dump truck, or in the articulation area, before you drive off.

10. R elease the brake pedal and increase the engine speed by pressing the throttle pedal down.

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5. Operating Instructions

2.2. Warming up period When driving a cold dump truck, operate gently with reduced engine load and rpm to warm up until all gauges indicate operating range. This is important to avoid reduction in the dump trucks operating performance potential.

2.3. Gear shifting The transmission has automatic gear shift to match the travel speed. The shifting is electronically controlled and a lock-up clutch is fitted in the transmission to increase efficiency in all gears. Connection/disconnection is automatic but speed and engine load related.

Gear position N: Neutral gear position The engine will not start if the gear selector is out of neutral position.

When the gear selector is in neutral position it is always necessary to depress the knob on top of the selector to shift to forward or reverse position. Also, always depress the knob when shifting directly between forward and reverse direction.

Gear position F: Forward drive position The transmission shifts automatically between 1st and 8th gear, according to dump truck speed and engine load.

The transmission will normally start in 2nd gear, if the conditions are heavy, it will automatically shift down to 1st gear.

Automatic gear shift

Gear shift program The gear shift program is decided automatically by the dump trucks computer, the computer chooses the gear shift program that is most relevant to the throttle pedals position.

Shifting at low rpm happens when the pedal is partially depressed. If the throttle pedal is further depressed, the gear shift will take place at higher rpm. With the throttle pedal fully depressed, the gear shift will either be prevented or close to the maximum engine rpm. When the throttle pedal is released and the engine brake or the engine and retarder brake is engaged, the down shift will take place at high rpm.

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5. Operating Instructions

Preselection of gears.

Manual gear shift

The gears can be preselected by the driver as follows: Push the gear selector to the right (+) for upshifting or to the left (-) for downshifting.

When a gear is preselected and the gear selector is pushed either to the left or right, the gear system will switch to manual gear shifting. The gear selector must then be pushed in order to change gear. When the selected gear is engaged, the transmission will only operate in this gear until the selector is pushed to another position or changed back to automatic gear shift by depressing the knob on top of the gear selector.

When a gear is preselected and not engaged, the dig its on the gear display will flash.

Manual gear shifting To avoid repeated up and down shifting when driving in heavy conditions it is an advantage to use manual gear shift. When changing from automatic gear shift to manual gear shift, push the gear selector either to the left for downshift or to the right for upshift, or manual gear shift can be obtained by depressing the knob on top of the gear selector while driving in automatic. In manual gear shift mode the selector must be pushed in order to change gear. Preselection of gears is also possible in manual gear shift. When the selected gear is engaged the transmission will only operate in this gear until the selector is pushed to another position. If the dump truck is stationary, the selected gear will be engaged directly.

To return to automatic gear shift while driving in manual, depress the knob on top of the gear selector.

CAUTION With the dump truck stationary, do not engage a gear at high engine speed.

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5. Operating Instructions

Operating hints Different types of terrain require different operating techniques.

Automatic gear shift

• Use automatic gear shift, for normal travel.

• The knob on top of the gear selector is used for: • Shifting from neutral to forward or reverse position.

• Shifting directly between forward and reverse direction.

Manual gear shift

N

OFF

• In terrain, before uphill/ downhill driving, manually select a suitable position for the estimated speed in the area, avoid repeated up and down shift in hilly terrain.

• C h a n g i n g b e t w e e n automatic and manual gear shift.

• When selecting a gear from the neutral position and when shifting between forward and reverse gears:

• Neutral position must not be selected during driving.

• Stop the truck and release the throttle pedal completely.

• The star ter switch must NEVER be turned off (position 0) during driving, if you do not intend to stop the engine! The engine has key stop and requires neutral position on gear selector to restart.

• Depress the knob on the top of the gear selector, select the desired gear and wait until the gear is engaged before increasing the engine speed.

• Do not operate the gear selector with the throttle pedal depressed. This will cause a big shock, and will also reduce the life of the dump truck.

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5. Operating Instructions

2.4. Reversing (back-up) operations 1. Before reversing, make sure that no persons or objects are behind the dump truck or in the articulation area.

2. Stop the dump truck completely before selecting the reverse gear.

3. Depress the knob on top of the gear selector and place the gear selector in position R with engine running at low idle.

The transmission will always select 1st reverse.

4. Increase the engine speed.

The reverse drive position has only manual gear shift between 1st, 2nd, 3rd and 4th gear. The selector must be pushed in order to change gear. When a gear is engaged, the transmission will only operate in this gear until the selector is pushed to another position.

WARNING Be careful when reversing, the rear visibility is limited!

2.5. Normal operation Always operate the dump truck with caution. Careful driving is recommended for safe and comfortable operation. Regulate dump truck speed in accordance with the ground conditions and surrounding environments.

In manual gear shift mode, always drive allowing the lock-up clutch to connect.

If abnormal noise, vibration, smoke or odours occur during operation, check for possible faults and remedy.

Check at regular intervals that all gauges are indicating normal values, and that no warning lights are on.

• Transm. oil temp.: 50 - 105°C, max 120°C a short period • Transm. oil temp. at retarder brake operation: up to 140°C, max 150°C a short period

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5. Operating Instructions

2.6. Brakes There are four different brake systems on the dump truck. Check the brakes every day to ensure function.

Service brake (main brake) All hydraulic operated wet multiple disc brake on each wheel. There are two separate circuits. If a fault occurs in one of the circuits, the dump truck can still brake with the intact circuit. Self adjusting system.

Engine brake Electronically operated, speed dependent brake which uses solenoids to alter cylinder compression internally and gives high performance engine braking.

Efficient only when lock-up clutch is connected.

Retarder brake The integrated hydrodynamic retarder is installed in the basic transmission between converter and gear box.

The installation position of the retarder at the transmission input (so-called primary retarder) increases the brake torque at the output by the given transmission ratio. Thus a high retarder brake torque is available in the lower speeds which can be used almost until standstill of the vehicle. The retarder is usually controlled by actuating the brake pedal, a hand lever or automatically.

Parking brake Spring actuated, hydraulic released single disc brake on the rear prop. shaft. Self-adjusting system.

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5. Operating Instructions

2.7. Engine and retarder brake operation When the operator releases his foot off the accelerator, the exhaust brake is automatically engaged. When the operator presses the accelerator pedal exhaust brake is disengaged but the transmission retarder is automatically engaged (100%), with strongest pressed the accelerator pedal will reduce the action power from the retarder. Driving downhill with the accelerator pedal released, the engine rpm will increase, when the engine rpm exceeds acceptable speed the transmission retarder and exhaust brake are activated (100%), this will disengage when rpm’s drop to relevant values, the exhaust brake will continue to operate.

It’s called emergency retarder because the cooling capacity is not designed for continuous operation.

NOTE • To avoid engine over speed, the retarder brake and exhaust brake will automatically engage if the engine speed exceeds acceptable operating speed This will happen regardless to the accelerator pedal.

• Reduce the engine speed immediately!

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5. Operating Instructions

2.8. Braking/stopping the dump truck Learn to associate the braking requirements for loaded and unloaded machine.

(See also chapter 2. Safety Instructions) 1. Release the throttle pedal.

2. Apply the engine brake or the engine and retarder brake.

3. D epress the brake pedal gradually, until desired deceleration is obtained.

4. When the dump truck is completely stopped, move the gear selector to neutral.

5. Apply the parking brake.

2.9. Emergency braking If braking effect is lost in both brake circuits, the dump truck can be braked as follows: 1. Release the throttle pedal.

2. Apply the engine and retarder brake.

3. Set the parking brake to locked (on) position.

4. Move the gear selector to 1st gear manually as quickly as possible.

5. When the dump truck has stopped, immediately put wheel chocks under the wheels.

WARNING After an emergency stop: DO NOT CONTINUE! The parking brake MUST be checked as well as the reason for the service brake failure! Consult your Doosan Dealer.

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5. Operating Instructions

2.10. Steering • The dump truck has 2 frames. The steering movement is created by articulation of the frames in relation to each other. The steering is fully hydraulically controlled and there are no mechanical links between the steering column and the steering cylinders. The steering circuit has priority over the tipping circuit, ensuring hydraulic oil available to the steering at any time.

• The dump truck is equipped with an emergency steering system, which will deliver oil when the dump truck is in motion due to a ground-driven pump. It will then be possible to steer the dump truck if the engine stops. The steering movement will then be slower and the warning light for emergency steering will light.

Repair the fault before operating the dump truck again!

NOTE Mechanical ends tops are fitted in the steering cylinders.

Steering movement that will “hammer” these end stops must be avoided. Continuance of the steering actions against the end stops causes maximum pressure in the system - this must be avoided!

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5. Operating Instructions

2.11. a) Differentials DA 30 he dump truck has per manent 6-wheel drive T with 3 differentials.

1. Front differential, automatic differential. brake (limited slip type) Fitted to the transmission. Transfers the power to left and right front wheels.

The differential will automatically provide highest torque to the wheel which has best grip. The locking ratio is 45%, i.e. the differential is capable of compensating for a 1:2.64 difference in friction between left and right wheels.

1

2. Inter axle differential, 100% lockable torque divider integrated in the transmission. Transfers the torque by 1/3 to the front axle and 2/3 to the rear axle. The differential lock can improve dump truck performance and should be used to avoid wheel spinning in severe conditions, i.e. slippery surfaces. Engage the differential lock before entering an area with a slippery surface, soft ground, or if the dump truck is stuck in the terrain. The differential lock must not be used when driving on firm ground!

2

The criteria for engaging the centre differential lock is: • Vehicle speed <18km/h • Transmission input torque < 1000Nm The centre differential lock will automatically disengage if vehicle speed >20km/h.

3

CAUTION Use the differential lock to avoid spinning on front and rear axle.

3. Rear differential, power shift lock (manual) The differential lock can improve dump truck performance and should be used to avoid wheel spinning in severe conditions, i.e. slippery surfaces.

Engage the differential lock before entering an area with a slippery surface, soft ground, or if the dump truck is stuck in the terrain. The differential lock must not be used when driving on firm ground!

The criteria for engaging the rear differential lock (DA30 only) is: • Vehicle speed <8km/h • Transmission input torque must be in range -500Nm to +1000Nm • Center differential lock must also be engaged.

The center and rear differential lock buttons on the panel are requests for diff-lock. The differential lock are engaged only if conditions are in valid ranges. If differential lock is released automatically due to exceeded protection conditions then the panel buttons (requests) will also be forced off.

The rear differential lock will automatically disengage if vehicle speed >12km/h or if centre differential lock is released.

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5. Operating Instructions

2.11. b) Differentials DA 40 The dump truck has per manent 6-wheel drive with 3 differentials.

1. Front differential, automatic differential. brake (limited slip type) Fitted to the transmission. Transfers the power to left and right front wheels.

1

2

The differential will automatically provide highest torque to the wheel which has best grip. The locking ratio is 45%, i.e. the differential is capable of compensating for a 1:2.64 difference in friction between left and right wheels.

2. Inter axle differential, 100% lockable torque divider integrated in the drop box. Transfers the torque by 1/3 to the front axle and 2/3 to the rear axle. The differential lock can improve dump truck performance and should be used to avoid wheel spinning in severe conditions, i.e. slippery surfaces. Engage the differential lock before entering an area with a slippery surface, soft ground, or if the dump truck is stuck in the terrain. The differential lock must not be used when driving on firm ground!

The criteria for engaging the centre differential lock is: • Vehicle speed <18km/h • Transmission input torque < 1000Nm

3

The centre differential lock will automatically disengage if vehicle speed >20km/h.

CAUTION Use the inter-axle differential lock to avoid spinning on front and rear axle.

3. Rear differential, automatic diff. brake (limited slip type) Fitted in the rear axle housing. Transfers the power to left and right tandem drive.

The differential will automatically provide highest torque to the wheel which has best grip. The locking ratio is 45%, i.e. the differential is capable of compensating for a 1:2.64 difference in friction between left and right wheels.

The rear differential lock buttons on the panel are requests for diff-lock. The differential lock are engaged only if conditions are in valid ranges. If differential lock is released automatically due to exceeded protection conditions then the panel buttons (requests) will also be forced off.

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5. Operating Instructions

2.12. Up, down and cross gradient travel • When travelling on gradients, consider the ground condition, and maintain a safe speed according to the grade of the path, the surface, degree of curves and road width.

• Operate the dump truck sensibly and avoid cross gradient travel. Select a low speed and negotiate the terrain without exaggerated steering movements and sudden braking.

• Before star ting downhill, release the throttle pedal and slow down the dump truck to a safe speed for the downhill slope. Move the gear selector to a suitable position (1st, 2nd or 3rd).

Rule: S elect the same gear for operating downhill as you would for operating up the same hill.

• D o n o t u n d e r a n y circumstances drive the dump truck with raised body.

• Long time engagement and unnecessary use of the service brakes can cause excessive wear and a possibility of loss of braking effect due to over-heated brakes.

• Keep engine speed at the upper area, 1500 - 1900 rpm in heavy conditions and for hill travel. Select a manual gear position for steep hill travel.

• If use of the engine brake and retarder brake is insufficient to keep the dump truck within a safe speed, reduce the speed by depressing the brake pedal. The travel must then continue in a lower gear.

• Do not park or leave the d u m p t r u ck o n gra d e s o r s l o p e s, t h e r i s k fo r spontaneous rolling is high!

PARKING PARKING

To avoid engine over speed, the retarder brake and exhaust brake will automatically engage if the engine speed exceeds acceptable operating speed • P a y a t t e n t i o n t o t h e transmission oil temperature when the retarder brake is applied.

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Operating & Maintenance Manual

• ALWAYS keep the engine speed below max. allowed r pm when travelling downhill! The retarder brake (emergency retarder) will be automatically engaged.

5. Operating Instructions

2.13. Important operating instructions

On

On

N

• The dump truck must not coast with gear selector in neutral position.

• Engine speed within 1500 - 1900 rpm with engaged lockup is recommended during driving.

• Engine speed must be reduced, and the dump truck must be stopped completely before changing between reverse and forward gears.

• The retarder brake (emergency retarder) will be automatically engaged if the engine speed exceeds the acceptable operating speed, will also increase transmission retarder braking to100%, to avoid over speed of the engine.

• Do not keep turning against the mechanical end stops, or force it into this point when making maximum turns.

• Do not continue to operate the dump truck if a warning lamp lights, a gauge shows abnormal value, or if the warning buzzer sounds.

• There is no braking effect from transmission when the engine is stopped.

• Always operate the dump truck within the rated limits and carry out maintenance according to the scheduled program. Overloading and lack of maintenance reduces safety and the life time of the dump truck is reduced.

• Select neutral gear and apply the parking brake when leaving the dump truck. Never leave the dump truck with a gear engaged!

• In case of problems with the dump truck, stop the vehicle and contact your local Doosan Dealer to amend the fault.

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5. Operating Instructions

3. Parking the dump truck 1. Avoid parking with loaded body.

On

2. Do not park on grades or slopes.

3. Park on a safe ground, where it will not freeze in place, sink down, etc. A change of weather may affect the ground.

4. Move the gear selector to neutral position.

5. Apply the parking brake.

6. Lower the body completely.

7. Neutralise all operating controls.

8. Secure the dump truck from spontaneous rolling by adding wheel chocks under the wheels before leaving the dump truck.

4. Stopping the engine 1. Stop the dump truck.

2. Before stopping the engine, check that the main warning lights for engine failure is not on or flashing. See chapter 3, Operating Controls for procedure if the warning lights are on or flashing.

3. Ensure the transmission is in the neutral position.

4. Turn the key in starter switch to OFF position.

5. If the dump truck has been driven with a heavy load and the key in starter switch be turned to position OFF the cooling mode is activated to max 3 minutes after then the engine should be stop. Is possible to stops engine immediately after the depress the override button if this is necessary.

6. Remove the key from starter switch.

WARNING If engine is stopped suddenly before it cools down, engine life maybe shortened.

Never stop the engine immediately after driving except in case of emergency.

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5. Operating Instructions

5. Checks after stopping the engine 1. Lock the sliding windows and the cab door.

2. Turn off the battery main switch.

3. Check for leakage of oil or coolant.

4. Fill up the fuel tank. Make sure that the filler cap and the area around the filler opening is clean to avoid contamination of the fuel.

5. Remove any waste paper or other flammable material which may cause fire in the engine compartment.

6. Remove any mud stuck to the chassis.

6. Loading and tipping 6.1. Loading • The body must be lowered completely before loading materials. The tip control lever shall stay in hold (float) position.

• When loading large rocks, cover the body bottom with gravel or start with the smallest stones first.

• During loading, the parking brake should be applied and gear selector should stay in neutral position.

• Before driving off, check that no danger can occur during travel. Maintain an even load distribution, avoid unbalanced loads.

• Never overload the dump truck. The operator’s safety will be considerably reduced and lifetime of the dump truck will drop.

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5. Operating Instructions

6.2. Tipping 1. Place the dump truck on a level ground. Check that the tipping may take place safely.

2. The gear selector must be in neutral position, and the parking brake must be applied.

3. Move the tip control lever to body “up” position and increase the engine speed. The body will raise. The tipping speed is proportional with the engine speed.

4. Reduce the engine speed before the body reaches the top position.

5. To stop the tipping movement, release the tip control lever. It will then automatically return to hold position.

6. Move the tip control lever to “down”, and the body will go down. The tip lever will magnetically hold in position.

The tipping cylinders are double acting. The lowering speed is proportional with the engine speed.

7. The tip control lever shall stay in hold (float) position when not operated.

NOTE For safety reasons, the system slows down the tipping speed when the load starts to pull the hoist cylinders backwards. This feature notifies the operator and reduces chance for “sticky” load lifting the front half of the truck.

WARNING • Reduce tipping speed when dumping large rocks!

• Do not load material into the body if the body is raised!

• Do not drive a empty or loaded truck with a raised body!

• Do not raise body near electrical power lines! See Chapter 2. SAFETY INSTRUCTIONS • Avoid tipping on cross-gradients!

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5. Operating Instructions

7. Tyre handling General This is a general instruction for the standard tyres in the table under item 7.2. Contact the tyre supplier or your local Doosan supplier for exact specifications.

Off-road tyres produce more heat during operation than ordinary car tyres, therefore the tyres must be used correctly to obtain long lifetime and safe operation. Please note that the following can cause overheating of tyres: • Too low tyre pressure • Overloading • Driving long distances non-stop • Travelling at high speed

CAUTION Extremely low temperature (below -40°C) requires special operation!

7.1. Difference in tyre diameter If it is necessary to change a wheel as a result of puncture or in emergencies. Doosan allows up to 5% difference in the tyre diameter on the same side of the tandem. But the most ideal situation in all cases is to have the same tyre diameter on the same side of the tandem. This is strongly recommended.

7.2. Correct tyre pressures Tyre pressure’s mainly depend on operation speed and load. Road configuration, flotation/traction requirements, risk of cutting, hacking, shock damage and ambient temperatures are also factors to consider.

Both too high and too low tyre pressure may result in damage and shortened lifetime of the tyres. Tyre pressure checks and corrections must be carried out on cold tyres.

Basic pressure for cold tyres (based on max. load and max. speed):

Model

DA30

DA40

Front (bar {psi})

Rear (bar {psi})

max. 50km/h

max. 50km/h

Bridgestone VLT

4.5 {65.3}

4.75 {68.9}

Michelin XADN

3.75 {54}

4.0 {58}

Goodyear GP2B

3.75 {54}

4.0 {58}

Triangle TL528

5.25 {76}

5.25 {76}

Techking ETLT

3.5 {51}

4.5 {65}

Bridgestone VLT

3.5 {51}

4.0 {58}

Michelin XADN

3.0 {43.5}

3.5 {51}

Goodyear RL2+

3.0 {43.5}

3.5 {51}

Triangle TB516

5.25 {76}

5.25 {76}

Techking ET6A

3.5 {51}

4.7 {68}

Type

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5. Operating Instructions

7.3. Specified loading Do not overload the dump truck. Maintain an even load distribution, avoid unbalanced loads. Protect tyres from falling stones during loading.

7.4. Proper maintenance Perform tyre inspections according to Maintenance schedule.

Also roads and driving paths should be maintained to achieve max. tyre serviceability.

Damaged, excessively worn or aged tyres should be replaced. Remove foreign objects from the treads, these will sooner or later penetrate into the tyre.

Removal or repairing of tyres should be performed by a tyre specialist to avoid unsafe working conditions.

WARNING Always let the air out of the tyre before removing foreign objects and before demounting or repairing! See also chapter 2, Safety Instructions (High pressure)

7.5. Transit, long distance drive-away on road This special type of driving requires special operation: • Check and adjust the tyre pressure on cold tyres before starting. Do not reduce pressure during driving.

• Drive only without load.

• Drive 2 hours and stop for minimum 30 min. Drive another 2 hours and stop for minimum 1 hour. Repeat.

• Upper speed limit for this operation: 2280 rpm at 8th gear. Must not be exceeded!

• Must not have diff lock engaged.

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5. Operating Instructions

8. Cold weather Cold weather operation (below 0 °C) requires special care to avoid problems and to maintain high comfort and safety.

• The viscosity of oils in engine, transmission, differentials, and hydraulic system should be of a suitable viscosity for the lowest expected ambient temperature, see Oil Specification Sheet.

• The coolant must contain anti-freeze to avoid ice in the cooling system and to protect against corrosion, see chapter 7, maintenance, 2000 Hours Service.

• As the temperature drops, the battery capacity drops accordingly. The batteries must be in good condition and fully charged when the dump truck is operated in low temperatures.

• Fuel must be of a low pour point, and the fuel tank must be filled up at the end of the shift. 0.5 - 2% alcohol (isopropanol) can be added to avoid condensation.

• The washer fluid should contain a mix of alcohol (isopropanol) and water which at least is sufficient to avoid icing in the tubes.

• At very low temperatures (below -10 oC) use of engine heater can be necessary to avoid starting difficulties. It is recommended to use an engine heater (optional equipment) at low temperatures. The engine heater has an electrical element which heats the engine coolant.

• Extend the warm-up period to secure that component lubrication is obtained. The dump truck shall be operated with light load and reduced rpm during warming up.

• Pay special attention to the ground surface. In case of snow and ice, use snow chains on the wheels to secure the wheel grip.

• If the dump truck is equipped with exhaust-heated body, this should be connected to avoid material freezing to the body.

• Run the A/C compressor one a week to perform internal seals lubrication.

• Start engine, making sure it is warm enough before running the AC (the compressor). This will allow the refrigerant stored as liquid on the bottom of the system to become gas.

When the compressor sucks liquid it can damage the weak valves. (see also chapter 3 Operating controls)

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5. Operating Instructions

9. Long term storage If the dump truck shall be stored for a longer period of time, special preparation must be carried out to avoid deterioration and damage. Store it preferably indoors in a dry and ventilated room or outdoors under shelter.

9.1. Before storage: 1. N eutralise all operating controls, place the gear selector in neutral position, the retarder brake switch must be turned OFF and apply the parking brake.

2. Thoroughly wash and clean the dump truck.

3. Completely fill the fuel tank.

4. R eplace oil and filters with new and lubricate all nipples. Check viscosities to match the expected ambient temperature.

5. I f the ambient temperature is expected to drop below 0oC, always add antifreeze to the cooling water.

6. Fully charge the batteries and disconnect terminals.

Preferably stored separately in a cold place (0- 10oC).

7. Cover all cylinder piston rods with rust protecting fluid.

8. Inflate the tyres to correct pressure. (See chapter 8).

9. Lock the sliding windows, door, fender hatches and bonnet.

9.2. During storage: Operate the truck once a month by driving it i.e. until engine temperature reaches normal operating temperatures. This will lubricate all moving parts. At the same time check for leakages and recharge the batteries. Grease the nipples.

NOTE Check oil and fluid levels before starting the engine! Drive slowly and with care the first 5 minutes or 1 km.

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5. Operating Instructions

10. Battery power assistance In case of discharged batteries, the dump truck can be started by connecting charged batteries, 24 volts with capacity approx. equal to the discharged batteries.

• If the batteries have been discharged, check the reason why (are the batteries defective?, Is there a short circuit somewhere on the dump truck? etc.)

• Discharged batteries should be charged as soon as possible.

• Check the electrolyte level and density after charging the batteries.

Connection:

A 4

3

2

1. Turn off the battery main switch on the right hand side fender.

2. C onnect first cable (A) from positive (+) terminal on discharged batteries....

Fully charged batteries

B

Vehicle’s Low 5 batteries Chassis of vehicle with low battery

3. .... to the positive (+) terminal on the assisting battery.

4. Connect second cable (B) from negative (-) terminal on assisting battery....

5. . ... to chassis on the dump truck with the discharged batteries, some distance from the batteries.

6. Turn on the battery main switch and start the engine in the normal way.

Disconnection: Disconnect cables in the opposite order, 5 - 4 - 3 - 2.

CAUTION • Use cables with min. 25 mm2 cross section.

• Connect in sequence described above.

• Good clamp contact is essential.

• Do not stand near a battery when connecting the cable to the chassis.

• Do not disconnect the original battery cables.

Operating & Maintenance Manual

5-29

5. Operating Instructions

11. Towing the dump truck • The dump truck can be towed by fitting a wire/chain to the eyes on the front/rear of the dump truck.

• Check that the wire/chain is capable of towing the load.

• The towing distance must not exceed 10 km, and the maximum allowed speed is 10 km/h!

• The engine must run at low idle to steer the dump truck in the normal way. If the engine is stopped, the steering movement will be heavier and slower than normal because there is no oil flow from the main hydraulic pump.

• The maximum towing force is: • Front: 100 kN (each) • Rear: 200 kN

CAUTION •

I f fluid pressure is lost, the service brake will not function and the parking brake will be engaged.

• An engaged parking brake can be loosened even if there is no fluid pressure in the system, see item 12.

• It is not possible to start the engine by towing!

12. Manual release of parking brake If the parking brake must be disengaged when hydraulic pressure is not available, the following procedure should be followed: 1. Secure the dump truck with wheel chocks so that it will not move as the parking brake is disengaged.

2. Raise the body and secure it with the body support (see chapter 2 - safety instructions).

3. Loosen the jam nut that locks the clevis to the cylinder pull rod.

4. Turn the cylinder pull-rod to expose additional clevis threads.

This will reduce spring pressure on the brake. Continue turning the pull rod until there is clearance between the linings and disc. At this point the parking brake will no longer function and the dump truck can be moved to a repair facility.

5. Repair the dump truck so that hydraulic pressure is available to the parking brake.

6. Remove the cylinder from the brake and screw the clevis into the cylinder pull rod until the centre of the clevis pin is 70-73 mm from the mounting face of the cylinder (no pressure).

7. Torque the jam nut to 13.6-20.3 Nm to lock the clevis to the cylinder pull-rod. 8. Reinstall the cylinder onto the brake.

Torque the cylinder mounting nuts to 40.5-54.5 Nm. 9. R einstall the clevis pin and check for proper brake adjustment.

DANGER All braking systems are out of function when the parking brake is manual released. Extreme care must be taken to avoid spontaneous rolling.

5-30

Operating & Maintenance Manual

5. Operating Instructions

13. Manual release of the ball valve on tilting circuit If the body is lifted and cannot be lowered by the tip control lever, i.e. hydraulic pressure has been lost, the ball valve may be manually released.

1. The ball valve is located on top of hydraulic tank on the left side of the cab.

2. Open the hydraulic tank hatch.

3. Turn the valve lever to the vertical position.

4. Wait until the body is in the lowered position.

5. Turn the valve lever to the horizontal position.

Operating & Maintenance Manual

5-31

5. Operating Instructions

14. Troubleshooting If the action below does not solve the problem or the fault cannot be found, contact Doosan dealer. *= Always contact your Doosan Dealer.

Area of dump truck Symptom/Problem

Dump truck will not start

Starts but engine cuts out suddenly, runs un-evenly or hunts.

Low output

Engine Overheated (Warning light)

Low coolant temperature

Low oil pressure

Blue smoke, oil consumed

Black or white smoke

Oil in coolant or coolant in oil

5-32

Cause

Remedy/Solution

Main switch disconnected

Turn on

Out of fuel

Refill fuel, bleed system

Low battery current

Recharge

Blown fuse

Check circuit, replace fuse

Defective wiring

Check connections, wires

Hydrostatic lock

Repair *

Starter motor defective

Replace *

Electronic controller or sensors defective

Check/repair *

Fuel system disturbance

Check fuel lines, bleed system

Condensated water in diesel

Drain tank

Bad fuel quality

Change fuel

Low fuel level

Refill fuel

Fuel filters clogged

Replace filters

Air filter clogged

Replace or clean

Fuel tank breather clogged

Clean tank cover

Wrong injection setting

Adjust *

Injector defective

Repair/replace *

Turbo charger defective

Repair/replace *

Worn engine or internal damage

Overhaul *

Electronic controller or sensors defective

Check/repair *

Low coolant level

Add coolant, check for leakages

Fan belt problem

Tighten/replace

Air in cooling system

Bleed system

Dirt inside cooling system

Clean and replace coolant

Radiator fins clogged/damaged

Clean

Thermostat faulty

Replace *

Sensor/gauge defective

Replace *

Coolant pump worn

Overhaul *

Sensor/gauge defective

Replace *

Thermostat stuck open

Replace *

Too low oil level

Add oil, check for leakage

Incorrect oil type

Change to correct oil type *

Sensor/gauge defective

Replace *

Oil pressure red - valve faulty

Overhaul *

Worn oil pump

Overhaul *

Too high oil level

Adjust to specified level

Incorrect oil type

Change to correct oil type*

Worn engine or internal damage

Overhaul *

Clogged air filter

Replace or clean

Fuel pump/injection system worn or faulty

Adjust/repair *

Cylinder gasket defective

Replace *

Turbocharger defective

Repair/replace *

Internal leak in engine cooler

Replace *

Cylinder gasket defective

Replace *

Worn engine or internal damage

Overhaul *

Operating & Maintenance Manual

5. Operating Instructions

Area of dump truck Symptom/Problem

Knocking noise Engine

Main warning light illuminates

Too high temperature

Will not drive in any gear or only possible to drive in some gears

Transmission

Low oil pressure

Noise

Main warning light illuminates

Cause

Remedy/Solution

Bad fuel quality

Change fuel

Valves incorrectly adjusted

Adjust

Injectors incorrectly adjusted

Adjust *

Injector defective

Replace *

Worn engine or internal damage

Overhaul *

Engine/engine controller failure

Stop the dump truck at a safe place, check the error codes and contact your Doosan dealer.

Too high oil level

Adjust to specified level

Incorrect oil type

Change to correct oil type *

Cooling circuit failure

Check/repair *

Lock-up fault

Overhaul *

Worn oil pump

Overhaul *

Too low oil level

Add oil, check for leakage

Blown fuse

Check circuit *

Convertor prop. shaft

Replace *

Electronic controller detection failure, neutral engaged

Check/repair *

Electronic controller or sensors defective

Check/repair *

Flywheel damper separated

Replace *

Drive line failure

Check/repair *

Internal transmission failure

Overhaul/replace *

Automatic central lubrication failure

Check/repair *

Too low oil level

Add oil, check for leakage

Incorrect oil type

Change to correct oil type *

Sensor/gauge defective

Replace *

Pressure control valve failure

Check/repair *

Worn oil pump

Overhaul *

Internal transmission failure

Overhaul/replace *

Too low oil level

Add oil, check for leakage

Incorrect oil type in differential(s)

Change to correct type *

Worn transmission or internal damage

Overhaul/replace *

Transmission/transmission controller failure

Stop the dump truck at a safe place, check the error codes on the gear display and contact your Doosan dealer.

Operating & Maintenance Manual

5-33

5. Operating Instructions

Area of dump truck Symptom/Problem Brakes

Cause

Remedy/Solution

Poor braking effect or truck pull to one side when braking

Insufficient oil pressure

Check charging and system*

Worn out brakes

Overhaul/replace *

Emergency steering light

No oil flow from emergency pump

Check and repair *

Low hydraulic pressure

Add oil, check for leakage

Air trapped in hydraulic system

Bleed system *

Contaminated oil

Change oil and flush system *

Incorrect oil type

Change to correct oil type *

Steering cylinders internal leak

Overhaul *

Orbitrol or steering valve failure

Check and repair *

Low hydraulic oil level

Add oil, check for leakage

Clogged oil filter

replace

Clogged tank strainer or breather

Replace/clean

Low oil pressure

Check/repair *

Worn oil pump

Check/repair *

Tip valve failure

Overhaul *

Main warning light illuminates

Hydraulic failure

Stop the dump truck at a safe place, and check the error codes on the main display and contact your Doosan dealer.

Main warning light illuminates

Lubrication system failure

Check the error codes on the main display

Main switch disconnected

Turn on

Batteries discharged

Recharge

Battery terminals/wiring defective

Repair *

Fan belt problem

Tighten/replace

Defective/worn alternator

Replace *

Defective wiring

Check connections, wires *

Defective shock absorber

Replace *

Defective rubber suspension

Replace (DA30) *

Articulation turning ring worn

Overhaul *

Engine or transmission mountings

Replace

Fan or flywheel loose/imbalance

Check/repair *

Defective elastic coupling

Check/repair *

Prop. shaft failure

Check/repair *

Drive line problem

Check/repair *

Truck will not go straight ahead, uneven steering movement or periodically sticking

Hydraulic system Not possible to tip or activate slow tipping

Lubrication system

No electrical power Electrical system Charge warning light on

Uncomfortable travel (jumping)

Chassis Vibrations

5-34

Operating & Maintenance Manual

5. Operating Instructions

Operating & Maintenance Manual

5-35

6. Lubricants

Lubricants

Operating & Maintenance Manual

6-1

6. Lubricants

Lubricants.......................................................................................................................................6-1 Lubrication schedule DA30 T2/T4/Stage 3B.....................................................................................6-3 Overview of oil and lubrication points DA30 T2/T4/Stage 3B...........................................................6-4 Oil specification sheet DA30 T2/T4/Stage 3B...................................................................................6-5 Filling capacities DA30 T2/T4/Stage 3B...........................................................................................6-6 Lubrication schedule DA40 T2/T4/Stage 3B ...................................................................................6-7 Overview of oil and lubrication points DA40 T2/T4/Stage 3B...........................................................6-8 Oil specification sheet DA40 T2/T4/Stage 3B...................................................................................6-9 Filling capacities DA40 T2/T4/Stage 3B...........................................................................................6-10 Transmission oil list...........................................................................................................................6-11 Axles oil list.......................................................................................................................................6-14

6-2

Operating & Maintenance Manual

6. Lubricants

Lubrication schedule DA30 T2/T4/Stage 3B Complete instructions in section 7. Maintenance.

Pos.

1st service

Component Hours -->

100

500

Service interval 8

40

500

1000

2000

4000

Min. once a year

VISCOSITY GRADE/ lubricant class 15W-40 API CI-4, ACEA E7

ENGINE

1

Engine oil

C

R

2

Centrifugal cleaner

C

Cl

3

Engine oil filter

4

Fuel filter (2 - only T4)

5

Coolant/cooling system

C

6

Water separator

D

R R C

R

C/R*

40% Coolant

R

ENGINE RELATED

10

Air filter, outer element -Inner element: replace every 2 years

11

Batteries (2)

12

Fuel tank

13

Urea tank

14

Urea filling point

15

Urea filter

Cl/R*

Cl/R*

C

C

C Only for T4

C

Only for T4 Only for T4

R TRANSMISSION

20

Transmission oil

R

21

Filter (2)

R

C

R

R

R

R

R

R

10W ZF TE ML 03A/03B/03C/03H/03K

DRIVE LINE

30 31 32 33

80W-90 ZF TE-MI 05C/05D

Front differential oil

R

C

Rear differential oil

R

C

R

R

SAE 85W-90 API GL-5, ZF TE-ML 05C

Tandem housing oil (2)

R

C

R

R

SAE 85W-90 API GL-5, ML-L-2105B

R

R

R

Planetary hub (6)

SAE 85W-90 API GL-5, MIL-L-2105B

HYDRAULIC

40

Hydraulic oil

41

Breather element on tank

42

Filter

C

R

ISO VG46

R R

R

LUBRICATION POINTS

50

Door and fender hatches (8 points)

L

51

Cab hinges (4 points)

L

52

Cardan shaft (2 points)

L-X

53

Cardan shaft (2 points)

L-X

55

Cardan shaft (2 points)

L-X

56

Cardan shaft (2+2 points)

L-X

57

Park Brake

L

58

Tilt support

L

NLGI 2

MISCELLANEOUS

70

Cab ventilation filter, external

80

Hydr. pump, tiltable cab

100

Cab ventilation filter, internal

110

Receiver - dryer filter

120

Refrigerant AC system

Cl/R*

C/R*

Cl/R*

R

ISO VG15

C

R C/R*

R - 134a

Not all items are shown in the illustration on the next page

R=Replace C=Check Cl=Clean L=Lubricate D=drain *=or when required L-X= Universal joints: Pump grease until it purges out of all spider bearing block seals.

Operating & Maintenance Manual

6-3

6. Lubricants

Overview of oil and lubrication points DA30 T2/T4/Stage 3B The numbers refer to table on previous page.

6-4

Operating & Maintenance Manual

6. Lubricants

Oil specification sheet DA30 T2/T4/Stage 3B This table presents guidelines for oil, coolant, fuel, lubricants and other fluids best suited for good performance and long life.

Component

Kind of fluid

Ambient temperature -4 14 32 50 68 86 °F -4 14 32 50 68 86 -20 -10 0 10 20 30 °C -20 -10 0 10 20 30 °C SAE 50 SAE 5W-30 SAE 15W-40

Engine oil pan

Fuel Tank Tank

Cooling system

Engine oil

Winter Diesel fuel

Summer - Diesel

Water + antifreeze

Engine Oil

SAE 15W-40

Gear oil

Hubs (6) Gear oil with Limited-slipadditives

SAE 85W-90

According to: API GL-5

SAE 85W-90 90/85

+ Lubrizol max. 1,5 % 1,5 %

SAE 90

*=max. 2% (weight) VI-Improver and pour point depressant in the basic gear oil.

ZF TM-ML 05C/05D

Other gear oils as above* ISO VG 32 ISO VG 46

Hydraulic oil Hydraulic tank

DEXRON IID

ATF ATF

Engine oil

SAE 10W

Hydraulic pump tiltable cab tiltable cab

Only mineral based oils Viscosity approx.20 cSt at normal operating temp.

Range: 10-250 cSt, max. 850 cSt at cold start.

Hydraulic oil: HM or HV oils (ISO 6743/4, CETOP RP 91H) or H-LP oils (Din 51524).

• Contact Contact oil supplier when operating in temperature below -25º below -25º • W Warm arm up in neutral after starting at temperature near lower limitation limitationofofthe theoil. oil.

• If If using Biological oil contact your Doosan Dealer before use. before use.

The oil must be approved by Doosan Infracore Norway AS. AS. Lithium saponfield with EP-additive Consistency NLGI - 0/1/2

Lubricator Automatic Central lubr. system

When changing oil, it is recommended to run the transmission clutch calibration (AEB-tester). used !

Only oils in the transmission oil list can be used !

Oils of the API CI-4 plus, CJ-4, SM, or ACEA specification, Specifications) category E9 (Also in combination with the listed listed Specifications) are not permitted for this lubricant class. Oils of these specifications are listed in the 03K lubricant class.

NOTE: Min. 20 minutes 20 minutes warming warming up up period period in neutral position is required position is required when ambient temperature is within this area:

HYP LS SAE 85W-90

Rear diff

Front diff.

standards Acc. to: ASTM and ISO standards Centane number: min. 49.

Sulphur contents: max. 0.3% (weight).

Max 2% isopropanol additive 30-50% Nitrate-free glycol antifreeze is recommended.

See 2000 hours service.

SAE 20W-20

Tandem housing

The engine oil should at least meet the requirements for one of the following oil classisications - - ACEA E5 and E7 - - API CI-4 (For (For fuel fuel with with maximum maximum 15ppm 15ppm (0,0015%) (0,0015%) sulphur sulphur content) content) -- TThe he Total TotalBase BaseNumber Number(TBN) (TBN)should shouldbe beaaminimum minimumofof 12-13 12-13(ASTM (ASTM2896) 2896) If If fuel fuel contains contains more more than than 0.3% 0.3% (weight) (weight) sulphur: sulphur: reduce reduce the the oil oil change change interval. interval.

Make sure the oil sustain all temperature variations up until next oil change.

Ask your local Doosan Dealer oil supplier

SAE 10W ZF transmission

Remarks

Universal grease

Hydraulic oil

See specification specification on on the the next next page. page.

NOTE: See

ISO VG 15

NOTE :IfIfthe thecab cabshould shouldbe betilted tiltedby byuse useofofthe thehydraulic hydraulicpump pump NOTE: a temperatures below -20°C, use oil fluid 4 Aero Shell or similar a temperatures

See remarks

Operating & Maintenance Manual

6-5

6. Lubricants

Description

ASTM test Method

NLGI Grade

D217

Min/Max

Specification

Std

2

Thickener type

Min

Lithium Complex

Solid Additives, Moly

Max

5% 0,3 bar

Remarks -25°C to +130°C No Graphite

Oxidation Stability

D942

Max

Water washout

D1264

Max

5%

Dropping point

D1264

Min

140°C

Rust protection

D1743

Copper corrosion

D4048

Max

1B

Base oil viscosity

D445

Min

600 cSt

Four ball (EP) weld point

D2596

Min

400 kg

Four ball wear

D2266

Max

0,6 mm

@ 100hrs @ 79°C

Pass @ 40°C 1hr @ 75°C/1200rpm/40kg

The grease quality is important due to potential damage and wear in bearings, any failure in the tandem and articulation bearing will create a high repair cost.

Use of Grease with wrong specification will affect warranty claims.

Make sure that you meet the specifications, and have extra focus at:

1. F our ball (EP) weld point.

2. F our ball wear.

Filling capacities DA30 T2/T4/Stage 3B All capacities are measured in litres (dm3), and are approximate values. To achieve correct level: check at dip stick, level eye, level plug etc.

Description: Specified capacity: Total tank/reservoir volume or total capacity from empty.

Refil amount: Refill volume after normal fluid draining. The differences are fluid left in components, piping etc.

Component/Fluid

Specified capacity (litres)

Refill amount (litres)

DA30 T2/T4/Stage 3B

DA30 T2/T4/Stage 3B

Engine oil

32

36

Engine coolant

45

38

Fuel Tank

335

As required

Transmission oil*

72

63

Rear differential

16

16

Front differential

9,4

9,4

Tandem housing (each)

2 x 48

2 x 48

Front reduction gear (each)

2 x 11

2 x 11

Rear reduction gear (each)

4 x 7

4 x 7

Hydraulic system

205

123

Windscreen washer tank

4,5

4,5

38

38

®

Adblue tank

* = Check level when engine runs at low idle.

Do not run engine without oil in the transmission.

6-6

Operating & Maintenance Manual

6. Lubricants

Lubrication schedule DA40 T2/T4/Stage 3B Complete instructions in section 7. Maintenance.

Pos.

1st service

Component Hours -->

100

500

Service interval 8

40

500

1000

2000

4000

Min. once a year

ENGINE

1

Engine oil

C

R

2

Centrifugal cleaner

C

Cl

3

Engine oil filter

4

Fuel filter (2 - only T4)

5

Coolant/cooling system

C

6

Water separator

D

VISCOSITY GRADE/ lubricant class

15W-40 API CI-4, ACEA E7

R R C

R

C/R*

40%

R

ENGINE RELATED

10

Air filter, outer element -Inner element: replace every 2 years

11

Batteries (2)

12

Fuel tank

13

Urea tank

14

Urea filling point

15

Urea filter

Cl/R*

Cl/R*

C

C

C Only for T4

C

Only for T4 Only for T4

R TRANSMISSION

20

Transmission oil

R

21

Filter (2)

R

C

R

R

R

R

10W ZF TE-ML 03A/03B/03C/03H/03K

DRIVE LINE

30

Front differential oil

R

C

R

R

31

Rear differential oil

R

C

R

R

32

Tandem housing oil (2)

R

C

33

Front reduction gear oil (2)

R

C

34

Separate brake cooling tank, front

R

35

Separate brake cooling filter, front

R

80W-90 ZF TE-ML 05C/05D

R R

R R

10W-30 ZF TE-ML 05F/05G/05H

R

HYDRAULIC

40

Hydraulic oil

41

Breather element on tank

42

Filter

C

R

ISO VG46

R R

R

LUBRICATION POINTS

50

Door and fender hatches (8 points)

51

Cab hinges (4 points)

L

52

Cardan shaft (2 points)

L-X

53

Cardan shaft (2 points)

L-X

55

Cardan shaft (2 points)

L-X

56

Cardan shaft (2+2 points)

L-X

57

Park Brake (1 point)

L

58

Tilt support (1 point)

L

L NLGI 2

MISCELLANEOUS

70

Cab ventilation filter

80

Hydr. pump, tiltable cab

90

Suspension cylinder

100

Cab ventilation filter, internal

110

Receiver - dryer filter

120

Refrigerant AC system

Cl/R*

C/R* ISO VG15

C

ISO VG32

C Cl/R*

R R C/R*

R - 134a

Not all items are shown in the illustration on the next page

R=Replace C=Check Cl=Clean L=Lubricate D=drain *=or when required L-X= Universal joints: Pump grease until it purges out of all spider bearing block seals.

Operating & Maintenance Manual

6-7

6. Lubricants

Overview of oil and lubrication points DA40 T2/T4/Stage 3B The numbers refer to table on previous page.

12

6-8

Operating & Maintenance Manual

6. Lubricants

Oil specification sheet DA40 T2/T4/Stage 3B This table presents guidelines for oil, coolant, fuel, lubricants and other fluids best suited for good performance and long life.

Component Component

Kind of fluid

Ambient Ambienttemperature temperature -4 14 32 50 68 86 -4 14 32 50 68 86 °F°F -20 -10 0 10 20 30 °C -20 -10 0 10 20 30 °C SAE 50 SAE 5W-30

SAE 15W-40 Engine oil pan pan

Engineoil oil Engine

Remarks The engine oil should at least meet the requirements for one of the following oil classifications: - ACEA E5 and E7 - API CI-4 The Total Base Number (TBN) should be a - The zminimum of 12-13 (ASTM2896) 2896) minimum of 12-13 (ASTM If fuel contains more than 0.3% (weight) sulphur: reduce the oil change interval.

Make sure the oil can sustain all temperature variations up until next oil change.

Ask your local Doosan Dealer or oil supplier

Winter

Acc. to: ASTM and ISO standards Cetane number: min.49.

Sulphur contents: max. 0.3%(weight) Max 2% isopropanol additive

Fuel Tank Tank

Diesel fuel

Cooling Cooling system system

Water + antifreeze

30-50% Nitrate-free glycol antifreeze is recommended. See 2000 hours service.

Engine Oil

When changing oil, it is recommended to run the transmission clutch calibration (AEB-tester).

Only oils in the transmission oil list can be used !

Oils of the API CI-4 plus, CJ-4, SM, or ACEA specification, category E9 (Also in combination with the listed Specifications) are not permitted for this lubricant class. Oils of these specifications are listed in the 03K lubricant class.

NOTE: Min. 20 minutes warming up period in neutral position is required when ambient temperature is within this position is area:

Summer-Diesel Summer-Diesel

SAE 10W ZF transmission transmission

SAE 15W-40 15W-40 SAE 20W-20

Tandem housing, planetary reduction gear, cooling brake cooling tank Front diff.

Rear diff.

Gear oil

Gear oil oil with with Limited-slipLimited-slipadditives additives

SAE 10W-30

*=max. 2% (weight) VI-Improver and pour point depressant in the basic gear oil.

SAE 90

ISO VG VG 32 32

Hydraulic oil

ISO VG VG 46 46 Hydraulic tank

DEXRON IID IID

ATF

Engine oil oil Engine

SAE 10W

Hydraulic Hydraulic pump, tiltable cab tiltable cab

Only mineral based oils Viscosity approx. 20 cSt at normal operating temp.

Range: 10-250 cSt, max. 850 cSt at cold start.

Hydraulic oil: HM or HV oils (ISO 6743/4, CETOP RP 91H) or H-LP oils (DIN 51524).

• C ontact oil supplier when operating in temperature Contact below -25°C Warm • W arm up in neutral after starting at temperature lowerlimitation limitationof ofthe theoil. oil . near lower • IIff using Biological oil contact your Doosan Dealer before use.The Theoil oilmust mustbe beapproved approvedby byDoosan DoosanInfracore Infracore before use.

Norway AS. Lithium saponfield with EP-additive Consistency NLGI - 0/1/2.

Consistency NLGI - 0/1/2.

Lubricator Automatic Automatic lubr.

Central lubr. system

According to: API GL-4 ZF TE-ML 05F/05G/05H

NOTE: See specification on the next page

Universal grease

ISO VG VG 15 15 Hydraulic oil

See remarks

Operating & Maintenance Manual

NOTE: If the cab should be tilted by use of the hydraulic pump at temperatures below -20°C, use oil fluid 4 Aero Shell or similar

6-9

6. Lubricants

Description

ASTM test Method

Specification

Remarks

Std

2

-25°C to +130°C

Thickener type

Min

Lithium Complex

Solid Additives, Moly

Max

5%

No Graphite

0,3 bar

@ 100hrs @ 79°C

NLGI Grade

D217

Min/Max

Oxidation Stability

D942

Max

Water washout

D1264

Max

5%

Dropping point

D2265

Min

140°C

Rust protection

D1743

Copper corrosion

D4048

Max

1B

Base oil viscosity

D445

Min

600 cSt

Four ball (EP) weld point

D2596

Min

400 kg

Four ball wear

D2266

Max

0,6 mm

Pass @ 40°C 1h @ 75°C/1200rpm/40kg

The grease quality is important due to potential damage and wear in bearings, any failure in the tandem and articulation bearing will create a high repair cost.

Use of Grease with wrong specification will affect warranty claims.

Make sure that you meet the specifications, and have extra focus at:

1. F our ball (EP) weld point.

2. F our ball wear.

Filling capacities DA40 T2/T4/Stage 3B All capacities are measured in litres (dm3), and are approximate values. To achieve correct level: check at dip stick, level eye, level plug etc.

Description: Specified capacity: Total tank/reservoir volume or total capacity from empty.

Refil amount: Refill volume after normal fluid draining. The differences are fluid left in components, piping etc.

Component/Fluid

Specified capacity (litres)

Refill amount (litres)

DA40 T2/T4/Stage 3B

DA40 T2/T4/Stage 3B

Engine oil

45

45

Engine coolant

50

42

Fuel Tank

530

As required

Transmission oil*

72

63

Rear differential (→ 8X0659)

46

43

Rear differential (8X0660 →)

53

53

Front differential

9,4

9,4

Tandem housing (each)

2 x 140

2 x 125

Front reduction gear (each)

2 x 7.5

2 x 7.5

Separate brake cooling tank

12

12

Hydraulic system

275

209

Windscreen washer tank

4.5

4.5

38

38

®

Adblue tank

* = Check level when engine runs at low idle.

Do not run engine without oil in the transmission.

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6. Lubricants

Transmission oil list This list comes from the ZF website and is updated every 3 months. Please check the date of publication of the ZF transmission oil list, if necessary please go to the ZF website: https://www03apps.zf.com/interoelepdf/TE-ML%2003_en0701.pdf (03A, 03B, 03C) to download the latest version of the ZF transmission oil list.

Date of version 01-05-2012 Lubricant class 03A Mineral oil-based engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL or ACEA, categories A, B, E) Viscosity class: SAE 20W-20 / 30 / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40 Note: Oils of the API CI-4 plus, CJ-4, SM, or ACEA specification, category E9 (Also in combination with the above mentioned Specifications) are not permitted for this lubricant class. Oils of these specifications are listed in the 03K lubricant class.

Lubricant class 03B Engine oil (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL or ACEA, categories A, B, E) Viscosity class: SAE 10W / 5W-30 / 5W-40

Manufacturer

Trade name

FUCHS PETROLUB AG, MANNHEIM/D

FUCHS TITAN UNIVERSAL HD SAE 10W

GINOUVES GEORGES SA, LA FARLEDE/F

YORK 730 SAE 10W

GS CALTEX CORPORATION, SEOUL/ROK

DOOSAN DX 10W

IPIRANGA PRODUTOS DE PETRÓLEO S, RIO DE JANEIRO/BR

ULTRAMO TURBO 10W

KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL

Q8 T 400 SAE 10W

KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL

Q8 T 520 SAE 10W

LLK FINLAND OY, HAMINA/FIN

TEBOIL POWER D SAE 10W

LUBRICATION ENGINEERS, INC., FORT WORTH, TEXAS/USA

MONOLEC GFS ENGINE OIL SAE 10

MORRIS LUBRICANTS, SHREWSBURY/GB

RING FREE XHD 10W

PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I

PAKELO PKO HD 4 SAE 10W

PANOLIN AG, MADETSWIL/CH

PANOLIN EXTRA DIESEL 10W

PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL

AKCELA ENGINE OIL 10 (SAE 10W)

PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL

AKCELA SUPER 10 (SAE 10W)

PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL

AMBRA SUPER 10 (SAE 10W)

PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL

URANIA C SAE 10 W

SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D

SRS REKORD 10W

TOTAL LUBRIFIANTS S.A., PARIS/F

GULF PUBLIC WORKS 10W

TOTAL LUBRIFIANTS S.A., PARIS/F

TOTAL RUBIA S 10W

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6. Lubricants

Transmission oil list Lubricant class 03C Off highway lubricants Viscosity grades: SAE 5W-30 / 5W-40 / 10W / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-20 / 20W-40 / 30

Manufacturer

Trade name

ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D BAYWA AG, MÜNCHEN/D BAYWA AG, MÜNCHEN/D BP INTERNATIONAL, PANGBOURNE, READING/GB BP INTERNATIONAL, PANGBOURNE, READING/GB BUCHER AG LANGENTHAL, LANGENTHAL/CH BUCHER AG LANGENTHAL, LANGENTHAL/CH CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB

ADDINOL FLUID TO-4 SAE 30 ARAL FLUID TO-4 SAE 10W ARAL FLUID TO-4 SAE 30 BAYWA MOTORENÖL HDC SAE 30 TECTROL UTTO - TO BP AUTRAN 410 SAE 10W BP AUTRAN 430 SAE 30 GEAR OIL MEGA TO-4 SAE 10W GEAR OIL MEGA TO-4 SAE 30 CASTROL TFC 410 SAE 10W CASTROL TFC 430 CASTROL TRANSMAX OFFROAD 10 SAE 10W

CASTROL INTERNATIONAL, PANGBOURNE READING/GB CATERPILLAR INC., PEORIA/USA CATERPILLAR INC., PEORIA/USA CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B CHEVRONTEXACO, GHENT/B ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA FABRIKA MAZIVA FAM A.D, KRUEVAC/SRB FABRIKA MAZIVA FAM A.D, KRUEVAC/SRB FUCHS PETROLUB AG, MANNHEIM/D GINOUVES GEORGES SA, LA FARLEDE/F KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL LLK FINLAND OY, HAMINA/FIN LLK FINLAND OY, HAMINA/FIN LUBRICANT OIL COMPANY, SINOPEC, BEIJING/CN MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK MAGNA INDUSTRIAL CO. LIMITED, HONG KONG/HK MAZIVA ZAGREB D.O.O, ZAGREB/HR MAZIVA ZAGREB D.O.O, ZAGREB/HR

CASTROL TRANSMAX OFFROAD 30 SAE 30 CAT TDTO SAE 10W CAT TDTO SAE 30 CHEVRON DRIVE TRAIN FLUID HD SAE 10W CHEVRON DRIVE TRAIN FLUID HD SAE 30 TEXACO TRANSMISSION & DRIVE TRAIN TO-4 OIL SAE 30 TEXACO TRANSMISSION AND DRIVE TRAIN OIL SAE 10W CALTEX TORQUE FLUID 414 CALTEX TORQUE FLUID 434 CALTEX TORQUE FLUID 434A TEXTRAN HD 10W TEXTRAN HD 30 ROTRA CT 30 ESSOTRANS/EXXTRANS 10W ESSOTRANS/EXXTRANS 30 MOBILTRANS HD 10W MOBILTRANS HD 30 TANSHIDO TO-4 SAE 30 TRANSHIDO TO-4 SAE 10W TITAN UTTO TO-4 SAE 30 YORK 792 SAE 30 EL-4117 Q8 TO-4 FLUID SAE 10W Q8 TO-4 FLUID SAE 30 TEBOIL FLUID TO-4 SAE 10W TEBOIL FLUID TO-4 SAE 30 SINOPEC GREAT WALL TRANS FLUID 30 OMEGA 696 SAE 10W OMEGA 696 SAE 30 INA TRANSMATIK 10W INA TRANSMATIK 30

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6. Lubricants

Manufacturer

Trade name

MORRIS LUBRICANTS, SHREWSBURY/GB MORRIS LUBRICANTS, SHREWSBURY/GB OMV REFINING & MARKETING GMBH, WIEN/A OMV REFINING & MARKETING GMBH, WIEN/A PETRONAS LUBRICANTS BELGIUM NV, AARTSELAAR/B PRISTA OIL EAD, ROUSSE/BG PRISTA OIL EAD, ROUSSE/BG RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E

LIQUIMATIC CT 10W LIQUIMATIC CT 30 OMV CONSTRUCT TO-4 SAE 10W OMV CONSTRUCT TO-4 SAE 30 CATRALUBE 30 PRISTA TO-4 10W PRISTA TO-4 30 RAVENOL CATOEL TO-4 SAE 10W RAVENOL CATOEL TO-4 SAE 30 TRANSMISIONES TO-4 SAE 10W

REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D

TRANSMISIONES TO-4 SAE 30 SHELL DONAX TC 10W SHELL DONAX TC 30 SHELL DONAX TCS SHELL SPIRAX S4 CX 10W SHELL SPIRAX S4 CX 30 SHELL SPIRAX S6 CXME 10W-40 SRS GETRIEBEFLUID ZFC SRS WIOLIN 410 SRS WIOLIN 430

Extreme low temperature grease for automatic central lubrication system: SHELL

Retinax CS 00 (-40°C)

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6. Lubricants

Axles oil list This list comes from the ZF website and is updated every 3 months. Please check the date of publication of the ZF transmission oil list, if necessary please go to the ZF website: https://www03apps.zf.com/interoelepdf/TE-ML%2005_en1433.pdf (05C, 05D, 05F, 05G, 05H) to download the latest version of the ZF transmission oil list.

Date of version 01-05-2012 Lubricant class 05C Gear oil with limited-slip-additives Viscosity grades: SAE 75W-90 / 75W-110 / 75W-140 / 80W-90 / 80W-110 / 80W-140 / 85W-90 / 85W-110 / 85W140 / 90 Manufacturer (05C)

Trade name (05C)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GH 80W-90 LS ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GH 85W-90 LS ARAL AG, BOCHUM/D ARAL GETRIEBEÖL HYP LS 85W-90 AVIA MINERALÖL-AG, MÜNCHEN/D AVIA HYPOID 90 LS BAYWA AG, MÜNCHEN/D TECTROL MULTIGEAR LS 90 BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR LIMSLIP 90 BUCHER AG LANGENTHAL, LANGENTHAL/CH GEAR OIL UNIVERSAL LS SAE 90 BUCHER AG LANGENTHAL, LANGENTHAL/CH LS UNIVERSAL SAE 85W/140 BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL UNIVERSAL LS 80W/90 CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AXLE Z LIMITED SLIP 90 CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL HYPOY LS 90 CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL LSX CEPSA LUBRICANTS S.A., MADRID/E CEPSA AURIGA LS 80W90 CHEVRONTEXACO, GHENT/B CALTEX GEAR OIL ZF SAE 80W-90 CHEVRONTEXACO, GHENT/B GEARTEX LS 80W-90 CHEVRONTEXACO, GHENT/B GEARTEX LS 85W-90 CLAAS KGAA MBH, HARSEWINKEL/D CLAAS AGRISHIFT BLS 90 EMKA SCHMIERTECHNIK GMBH, BRETZFELD-SCHWABBACH/D MULTIGEAR LSA 85W90 ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENGEN GEARLUBE EP 90 LS - SAE 80W-90 ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA MP/S, SAE85W-90 EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO GEAR OIL LSA 85W-90 EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILUBE LS 85W-90 FINKE MINERALÖLWERK GMBH, VISSELHÖVEDE/D AVIATICON HYPOID LS 90 FUCHS PETROLUB AG, MANNHEIM/D TITAN GEAR LS 90 GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS G-TRUCK LS 80W-90 GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS G-TRUCK LS 85W-140 GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS G-TRUCK LS 85W-90 GRUPA LOTOS SA, GDANSK/PL LOTOS TITANIS LS GL-5 SAE 85W/140 GRUPA LOTOS SA, GDANSK/PL LOTOS TITANIS LS GL-5 SAE 80W/90 GS CALTEX CORPORATION, SEOUL/ROK DIC LS GEAR OIL 80W/90 GUANGXI LIUGONG PREMIUM-GRADE LUB. OIL LTD./CN LIUGONG LIMITED SLIP AXLE OIL (85W90) GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR LS 90 HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENDALL SPECIAL LIMITED SLIP AXLE GEAR LUBE 80W/90 HARMS MINERALÖLE, PRISDORF/D OILFINO VARIUS G 400 LS SAE 85W-90 HINDUSTAN PETROLEUM CORP LTD., MUMBAI/IND HP GEAR OIL LS 80W90 HINDUSTAN PETROLEUM CORP LTD., MUMBAI/IND HP GEAR OIL LS 90 HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 90 GL INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR SUPER LS 80W-90 INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR SUPER LS 90 JOHN DEERE, WATERLOO/USA JOHN DEERE GEAR LUBRICANT W/LS ADDITIVE (80W-90)

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KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KOMPRESSOL-HYPOID LS SAE 90 KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 45 SAE 90 LIEBHERR HYDRAULIKBAGGER GMBH, KIRCHDORF/D LIEBHERR GEAR BASIC 90 LS LLK FINLAND OY, HAMINA/FIN TEBOIL HYPOID LS SAE 80W-90 LUBRICANT OIL COMPANY, SINOPEC, BEIJING/CN SINOPEC ZLS 85W/90 GL-5 MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL GTL LS 90 MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL LIMITED SLIP HYPOID GEAR OIL LS SAE 90 MOL-LUB KFT., ALMÁSFÜZITÖ/H MOL HYKOMOL LS 85W-90 MOL-LUB KFT., ALMÁSFÜZITÖ/H MOL HYKOMOL LS 85W140 NORTHLAND PRODUCTS COMPANY, WATERLOO/USA POSI-GRIP 85W140 JDZF NORTHLAND PRODUCTS COMPANY, WATERLOO/USA POSI-GRIP JDZF 80W90 NOVA STILMOIL SPA, MODENA/I GEARING WONDER LS SAE 85W90 OEST, GEORG MINERALÖLWERK, FREUDENSTADT/D OEST GETRIEBEÖL HYPOID LS 90 OK NEDERLAND, STAPHORST/NL OK CARDAN OIL MP-B-LS SAE 80W/90 OK NEDERLAND, STAPHORST/NL QUINTOL CARDAN OIL LS-90 OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL LS SAE 85W-90 ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR LS 80W-90 PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UNIVERSAL GEAR EP/LS SAE 85W/140 PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UNIVERSAL GEAR EP/LS SAE 80W/90 PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I UNIVERSAL GEAR EP/LS SAE 85W/90 PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY LS 90 PETROGAL S.A., LISBOA/P GALP LS 90 PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AKCELA AXLEPOWER (80W90) PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AKROS AXLEGEAR 80W-90 PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AMBRA AXF 80W90 PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AMBRA STF (80W90) PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL TUTELA W90/LS (SAE 80W-90) PHI OIL GMBH, ST. GEORGEN BEI SALZBURG/A SUPERGEAR BRONZE 85W90 LS PROFI-TECH GMBH, GINGEN/D PROFI-CAR HYPOID PERFORMANCE GEAR SAE 90 LS PTT PUBLIC COMPANY LIMITED, BANGKOK/TH PTT LIMITED SLIP (SAE 80W-90) RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL SPERRDIFF.-GETR.-OEL LS 90 REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E REPSOL CARTAGO EP AUTOBLOCANTE SAE 80W90 SASOL OIL, RANDBURG/ZA DIFFERENTIAL OIL LIMITED SLIP 80W-90 (80W-90) SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX S3 ALS 80W-90 SHELL TONGYI PETROLEUM CHEMICAL CO.LTD, BEIJING/CN LINGXIAN 85W90 SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS WIOLIN RSH SWD LUBRICANTS GMBH & CO. KG, DUISBURG/D SWD SYNKROL 5 LS SAE 80W90 SWD LUBRICANTS GMBH & CO. KG, DUISBURG/D SWD SYNKROL 5 LS SAE 85W90 TOTAL LUBRIFIANTS S.A., PARIS/F ELF TRACTELF BLS 90 TOTAL LUBRIFIANTS S.A., PARIS/F FINA TRANSFLUID LS 80W-90 TOTAL LUBRIFIANTS S.A., PARIS/F GULF LS REAR AXLE OIL 80W-90 TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL DYNATRANS DA 80W-90 TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL DYNATRANS DA 85W-140 TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL DYNATRANS LS 80W-90 UNIL OPAL, SAUMUR CEDEX/F UNIL OPAL GEAR AB-EP SAE 85W90 VOLVO CONSTRUCTION EQUIPMENT, ESKILSTUNA/S LIMITED SLIP GEAR OIL 85W-90 YACCO, ST PIERRE LES ELBEUF/F BVX LS 200

Lubricant class 05D Gear oil with limited-slip-additives Viscosity grades: SAE 75W-90 / 75W-110 / 75W-140 / 80W-90 / 80W-110 / 80W-140 / 85W-90 / 85W-110 / 85W-140 / 90 Manufacturer (05D)

Trade name (05D)

AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D ARAL AG, BOCHUM/D AVIA MINERALÖL-AG, MÜNCHEN/D

AGIP HLZ, SAE 75W-140 ARAL GETRIEBEÖL BS-LSX SAE 75W-140 AVIA HYPOID 75W-140 LSX

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6. Lubricants

BP INTERNATIONAL, PANGBOURNE, READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL INTERNATIONAL, PANGBOURNE READING/GB EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D

BP ENERGEAR SHX-ZR 75W-140 CASTROL SAF-XJ 75W-140 CASTROL SYNTRAX LIMITED SLIP 75W-140 MOBIL GEARLUBE VS 500 SRS GETRIEBEFLUID BMS PLUS

Lubricant class 05F Universal Tractor Transmission Oil (UTTO) Manufacturer (05F)

Trade name (05F)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL UTTO SAE 10W30 ARAL AG, BOCHUM/D ARAL FLUID HGS 10W-30 AVIA MINERALÖL-AG, MÜNCHEN/D AVIA HYDROFLUID DLZ BAYWA AG, MÜNCHEN/D TECTROL UTTO - HF BAYWA AG, MÜNCHEN/D TECTROL UTTO - ZF (20W40) BP INTERNATIONAL, PANGBOURNE, READING/GB ADAMOL TRANSMISSION-TRAKTOROIL SAE 10W-30 BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER TRANSMISSION 10W-30 BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER TRANSMISSION CVT 10W-30 BP INTERNATIONAL, PANGBOURNE, READING/GB BP TERRAC SUPER TRANSMISSION CVT 80W BP INTERNATIONAL, PANGBOURNE, READING/GB BP TRACTRAN TF 10 10W-30 BP INTERNATIONAL, PANGBOURNE, READING/GB BP VANELLUS AGRI SUPER TRANSMISSION BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX UTTO CF BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX FARMER POLY 304 CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI TRANS PLUS 10W-30 CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI TRANS PLUS CVT 10W-30 CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI TRANS PLUS CVT 80W CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL AGRI TRANS PLUS SAE 80W CATERPILLAR INC., PEORIA/USA CATERPILLAR MULTIPURPOSE TRACTOR OIL (MTO) 10W-30 CEPSA LUBRICANTS S.A., MADRID/E CEPSA AURIGA TE 55 (SAE 10W-30) CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA CHEVRON 1000 THF (SAE 10W-30) CHEVRONTEXACO GLOBAL LUBRICANTS, SAN RAMON/USA TEXACO TDH OIL (SAE 10W-30) CHEVRONTEXACO, GHENT/B TEXTRAN TDH PREMIUM CLAAS KGAA MBH, HARSEWINKEL/D CLAAS AGRISHIFT GA 12 CNH, BURR RIDGE/USA CASE TRANSAXLE FLUID, 80W-140 CNH, BURR RIDGE/USA NEW HOLLAND TRX FLUID, 80W-140 CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F POLYTRANS KM (20W40) CONOCOPHILLIPS COMPANY, HOUSTON/USA 76 HYDRAULIC/TRACTOR FLUID CONOCOPHILLIPS COMPANY, HOUSTON/USA KENDALL HYKEN 052 DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR GEAR OIL UTTO ENGEN PETROLEUM LTD., CAPE TOWN/ZA ENGEN AGRIFLUID ENI S.P.A. REFINING & MARKETING DIVISION, ROME/I AGIP ROTRA MULTI THT EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILFLUID 424 EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBILFLUID 426 FUCHS PETROLUB AG, MANNHEIM/D AGRIFARM UTTO MP FUCHS PETROLUB AG, MANNHEIM/D TITAN UTTO ZF SAE 20W-40 GAZPROMNEFT-LUBRICANTS, LTD, MOSCOW/RUS G-SPECIAL UTTO 10W-30 GINOUVES GEORGES SA, LA FARLEDE/F YORK 676 10W30 GUANGXI LIUGONG PREMIUM-GRADE LUB. OIL LTD./CN LIUGONG DEDICATED TRANSMISSION OIL (10W30) GULF OIL INTERNATIONAL, PITTSBURG/USA GULF MPTF 10W-30 JOHN DEERE, MANNHEIM/D JOHN DEERE HY-GARD JOHN DEERE, WATERLOO/USA JOHN DEERE HY-GARD KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 2000 KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 2100 KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 2200 LIEBHERR HYDRAULIKBAGGER GMBH, KIRCHDORF/D LIEBHERR GEAR PLUS 20W-40 LLK FINLAND OY, HAMINA/FIN TEBOIL WETOL MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSHIDROL JD 50 MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSHIDROL ZF 20W-40 OK NEDERLAND, STAPHORST/NL OK HTU PLUS OK NEDERLAND, STAPHORST/NL QUINTOL REAR AXLE FLUID F.I.D.

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Operating & Maintenance Manual

6. Lubricants

PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 10W/30 PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO UTTO FLUID 4D SAE 20W/40 PANOLIN AG, MADETSWIL/CH PANOLIN JD 303 PETROBRAS DISTRIBUIDORA S.A., DUQUE DE CAXIAS/BR LUBRAX UNITRACTOR PETROGAL S.A., LISBOA/P GALP TRALUB 807S PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AKCELA NEXPLORE (SAE 10W-30) PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AKCELA TRANSAXLE FLUID (SAE 80W-140) PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AMBRA MULTI G PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AMBRA TRX 20W-40 PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL AMBRA TRX 80W-140 PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL ARBOR MTF 10W-30 (SAE 10W-30) PETRONAS LUBRICANTS INTERN., KUALA LUMPUR/MAL ARBOR TRW 140 SPECIAL (SAE 80W-140) PHI OIL GMBH, ST. GEORGEN BEI SALZBURG/A GEAR OIL UTTO SILVER 10W30 RAVENSBERGER SCHMIERSTOFFVERTRIEB GMBH, WERTHER/D RAVENOL GETRIEBEÖL UTTO REPSOL YPF LUBRICANTES Y ESPECIALIDADES, MADRID/E AGRO ORION SAE 10W30 SAME DEUTZ-FAHR DEUTSCHLAND GMBH, LAUINGEN/D DF UTTO 10W30 SAME DEUTZ-FAHR DEUTSCHLAND GMBH, LAUINGEN/D SDF UTTO 10W30 SASOL OIL, RANDBURG/ZA UNIVERSAL TRACTOR TRANSMISSION OIL 68 (SAE 80W) SAVITA OIL TECHNOLOGIES LIMITED, MUMBAI/IND SAVSOL 315 HAT SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL DONAX TD SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL DONAX TDS 10W-30 SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX S4 TXM SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL SPIRAX S6 TXME SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D SRS HYDROFLUID N STRUB + CO AG, REIDEN/CH VULCOTRAC UTTO SAE 20W-40 TOTAL LUBRIFIANTS S.A., PARIS/F ELF TRACTELF BF 16 TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL DYNATRANS LS 20W-40 TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL DYNATRANS MPV TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL DYNATRANS MPWB UNIL OPAL, SAUMUR CEDEX/F FLUID VO VALVOLINE EUROPE, DORDRECHT/NL VALVOLINE UNITRAC 80W VOLVO CONSTRUCTION EQUIPMENT, ESKILSTUNA/S VOLVO WETBRAKE TRANSAXLE OIL (WB101) WOLF OIL CORPORATION N.V., HEMIKSEM/B WOLF UTTO 170 VOLVO BM SAE 10W30

Lubricant class 05G Universal construction-machinery oil Manufacturer (05G)

Trade name (05G)

ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D

ZF-POWERFLUID

Lubricant class 05H Biodegradable lubricants Viscosity grade: SAE 75W-80 Instructions on the use of biodegradable lubricants: The oil manufacturer´s change-over directives included in the product description are to be observed when change-over to biodegradable lubricants is effected.

Manufacturer (05H)

Trade name (05H)

PANOLIN AG, MADETSWIL/CH

PANOLIN BIOFLUID LS

Operating & Maintenance Manual

6-17

7. Maintenance

Maintenance

Operating & Maintenance Manual

7-1

7. Maintenance

Maintenance....................................................................................................................................7-1 Maintenance precautions.................................................................................................................7-3 Maintenance table............................................................................................................................7-5 Initial 100 Hours Service .................................................................................................................7-8 Initial 500 Hours Service..................................................................................................................7-12 8 Hours / Daily Service.....................................................................................................................7-17 40 Hours / Weekly Service...............................................................................................................7-25 500 Hours Service............................................................................................................................7-28 1000 Hours Service..........................................................................................................................7-43 2000 Hours Service..........................................................................................................................7-57 4000 Hours Service..........................................................................................................................7-68 Yearly recommended maintenance..................................................................................................7-72

7-2

Operating & Maintenance Manual

7. Maintenance

Maintenance precautions • Always prepare the dump truck before starting any maintenance adjustments or other work on the dump truck, see Service Position in the Safety Instructions chapter (Chapter 2).

• Fuel and oil are dangerous substances.

Never handle fuel, oil, grease or oily clothes in places where there is any fire or flame. In case of fire, always know the location and how to use fire extinguishers and other fire fighting equipment.

• Wear a well-fitting helmet, safety shoes and working clothes. When drilling, grinding or hammering always wear protective goggles.

• Flames should never be used instead of lamps. Never use a naked flame to check leaks or level of oil, fuel, anti-freeze or electrolyte.

• Park the dump truck on firm, flat ground. Apply the Articulation Lock.

• Exhaust gas is dangerous. When working inside, be particularly careful to have good ventilation.

• When wor king with others, choose a group leader and follow the leader’s instructions. Do not perform any maintenance beyond the agreed work.

• Thoroughly wash the engine. In particular, be careful to clean the filler caps, grease fittings and the area around the dipsticks.

Be careful not to let any dirt or dust into the system.

• Always stop the engine when performing maintenance near moving parts.

• Wash the dump truck, be careful not to wet electrical components or inside cab.

• During maintenance, do not allow any unauthorised person to stand near the dump truck.

• Always use Doosan genuine parts for replacement.

• U n l e s s y o u h a v e s p e c i a l instructions to the contrar y, maintenance should always be carried out with engine stopped.

If maintenance is carried out with the engine running, there must be two persons present: One operating the engine, and the other performing the maintenance.

In such a case, never touch any moving parts.

• A l way s u s e t h e g r a d e s o f grease and oil recommended by the manufacturer. Choose the viscosity specified for the ambient temperature. See chapter 6.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-3

7. Maintenance

• When adding oil or checking the oil level, check that the oil is at the correct level.

• Always use pure oil or grease, and be sure to use clean containers.

• After greasing up, always wipe off the old grease which was forced out.

• Empty the hydraulic accumulators by operating the brake pedal repeatedly while the engine is stopped. (Approximately 30 times for the foot break and approximately 6 times for the parking break.)

• When changing the oil or filter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials.

• When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into the oil.

• When removing parts containing O-rings, gaskets or seals, clean the mounting surface and replace with new sealing parts.

• Before draining the oil, warm it up to a temperature of 30o to 40o C. Be aware of possible internal pressure when opening any drain, level or filling plug. Hot oil can spurt out and inflict personal injury.

• When lubricating oil or cooling water has been drained, keep an eye on the instrument panel so that the dump truck is not operated without oil or cooling water.

• Be particularly careful when removing the expansion tank cap. If this is done immediately after using the engine, there is a danger that boiling water and steam may spurt out.

• In case of difficult maintenance, refer to your Doosan Dealer.

• After replacing oil, filter element or strainer, bleed the air from the circuit.

• When the strainer is located in the oil filler, the strainer must not be removed while adding oil.

• I n case of difficult maintenance, refer to your Doosan dealer.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-4

Operating & Maintenance Manual

7. Maintenance

Maintenance table Initial 100 Hours Service 1. Transmission

2. Hydraulic System 3. Wheel nuts

1.1. C hange oil 20* Replace filter element 21*, at least once a year

8

1.2. Run the Transmission Clutch Calibration (AEB) 2.1. Replace hydraulic return filter element 42*.

3.1. Check tightness

10 11 12

1.1. Change oil 30* DA30 and DA40 2.1. Change oil 31* DA30 3.1. Change oil 32* DA30 4.1. Change oil 33* DA30 5.1. Change oil 32* DA40 6.1. Change oil 33* DA40 7.1. Change oil 31* DA40 8.1. Check/adjust the valve clearance 8.2. Check/adjust the unit injector (Only T2) 9.1. Change oil 34* DA40

12 13 13 14 15 15 16 16 16 16

1.1. Walk around check, before start 1.2. Check driver's seat, before start 2.1. G eneral condition check - look for leakages remedy as necessary 2.2. Drain the water separating fuel filter 6* 2.3. Check oil level, before start 1* 2.4. Check coolant level, before start 5* 2.5. Check fuel level, before start 12* 2.6. Function check of the centrifugal cleaner, after operation 2* 2.7. Check urea (AdBlue) level before start 13*

17 17

Initial 500 Hours Service 1. Front differential 2. Rear differential 3. Tandem housing 4. Planetary drive (hubs) 5. Tandem housings 6. Front reduction gear 7. Rear differential 8. Engine 9. Brake system 8. Hours / Daily Service 1. General 2. Engine

18 18 19 19 20 20 21

3. Transmission 4. Hydraulic system 5. Brake system

3.1. Check oil level, before operation 20* 21 4.1. Check oil level, before start 40* 22 5.1. P arking brake check braking (holding) capacity, before operation22 5.2. S ervice brake (main brake) check braking (holding) capacity, before operation 22 5.3. Service brake (main brake) check function, before operation 23 5.4. Accumulators check the oil pressure, before operation 23 6. Steering 6.1. Check function, before operation 24 7. Engine brake 7.1. Check function, before operation 24 8. Engine/retarder brake 8.1. Check function, before operation 24 40 Hours / Weekly Service 1. Cab ventilation 1.1. Clean internal filter element and prefilter 100*, 70* 1.2. Air conditioner system 2. Tyres 2.1. Check tyre pressures, before operation 3. A utomatic central 3.1. Check the lubricant level in the reservoir. lubrication (Groeneveld lubrication system) 3. A utomatic central 3.1. Check the lubricant level in the reservoir. lubrication (Lincoln lubrication system) 4. C ontinue with all items in 8 Hours/Daily Service

25 25 26 26

27

27

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-5

7. Maintenance

Maintenance table 500 Hours Service 1. Engine

1.1. Change oil 1* 1.2. Clean centrifugal cleaner 2* 1.3. Replace oil filter 3* 1.4. External cleaning of the radiator, at least once a year 5*

28 29 32 33

2. Drive line 3. Brake system

2.1. Check oil levels 3.1. Check lining thickness 3.2. How to adjust the parking brake.

4.1. Check wheel nuts torque.

5.1. Check expander bolts.

34 36 37 38 38

4. Wheels 5. Tip- and steering cylinders 6. Cab ventilation

6.1. Air conditioner system, test operation 6.2. Check/replace cab ventilation filters 70*, 100* 7. Automatic central 7.1. Check the system lubrication (Groeneveld lubrication system) 7. A utomatic central 7.1. Check the system lubrication (Lincoln lubrication system) 8. Lubrication 8.1. Fender hatches 8.2. Cab rear hinges

39 40 41

9. Wheel nuts

42

9.1. Check tightness

10. Continue with all items in 40 Hours Service

41

42 42 42

1000 Hours Service 1. Driver’s seat 2. Engine

1.1. General safety check 2.1.1. Replace fuel filter PDE 4* 2.1.2. Renewing water separating fuel filter 6* 2.1.3. Bleed the fuel system: 2.2. Replace fuel filter XPI 4* 2.2.3. Bleeding the fuel system XPI 2.3. Check battery 2.4. Check multi-groove belt condition, at least once a year 2.4.1. Inspect the multi-groove belt.

2.5. Air filter 10* 3. Transmission 3.1. C hange oil 20* Replace filter element 21*, at least once a year 3.2. Run the Transmission Clutch Calibration (AEB) 4. Hydraulic system 4.1. Replace breather element 41* 4.2. Replace hydraulic return filter element 42*.

5. Front differential 5.1. Change oil, at least once a year 30* 6. Rear differential 6.1. Change oil, at least once a year 31* DA40 7. Front reduction gears 7.1. Change oil, at least once a year 33* DA40 8. Electrical system 8.1. Check wiring 9. Urea filter 9.1. Replace the urea filter 10. Continue with all items in 500 Hours Service

43 43 44 44 45 46 45 46 46 47 49 51 51 52 53 54 55 55 56 56

2000 Hours Service 1. Engine

1.1. Check/adjust valve clearance (5 cylinder) DA30 1.1. Check/adjust valve clearance (6 cylinder) DA40 1.2. Check/adjust the unit injector 1.3. Check the coolant, at least once a year 5* 1.3.1. Check the appearance of the coolant 1.3.2. Coolant with glycol only: Check glycol content 1.3.3. Coolant with only anti-corrosive: Check protection against corrosion

* Numbers refer to positions on the lubrication schedule, chapter 6 7-6

Operating & Maintenance Manual

59 60 61 62 63 63 64

7. Maintenance

Maintenance table

2. Brake system

2.1. Oil change in the brake cooling tank 34* 2.2. Inspect brake lines, at least once a year.

3. Tandem housing 3.1. Change oil 32* DA30 4. Rear differential 4.1. Change oil 31 or at least once a year DA30 5. Planetary drive (hubs) 5.1. Change oil 33 or at least once a year DA30 6. Continue with all items in 1000 Hours Service

65 65 66 67 67 67

4000 Hours Service 1. Cooling system

1.1. Internal cleaning, every 2 years 5* 1.2. Change coolant, every 2 years 5* 2. Hydraulic system 2.1. Change oil 40* 3. Tandem housing 3.1. Change oil 32* DA40 4. Cab ventilation 4.1. Air conditioner system 5. Continue with all items in 2000 Hours Service

68 69 70 71 71 71

Yearly recommended maintenance 1. Transmission 2. Drive line 3. Tanks 4. Hydraulic system 5. Exhaust system 6. Bearings

1.1. General condition check 2.1. General condition check 3.1. General condition check 4.1. Inspect the hydraulic hoses 5.1. Safety check 6.1. Check clearance

72 72 72 73 73 73

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-7

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

1. Transmission 1.1. Change oil 20* Replace filter element 21*, at least once a year • Changing transmission oil, replacement of transmission filter shall also be carried out every 1000 hours.

Drain oil: 1. The dump truck must be standing on level ground.

2. The oil must be at operating temperature.

3. U nscrew the filling cover/dipstick (located under hydraulic tank cover).

4. R emove cover plate under the transmission, by removing the 4 M12 bolts.

5. Remove cap.

6. Place drain hose with connection on drain nipple.

7. Once transmission oil is emptied remove hose and replace cap.

CAUTION

nipple Drain nipple

Use gloves when checking the oil level or filling oil. The exhaust pipes and nearby area may be hot and fingers and hands could be burnt.

Cap

Rear cover cover

Replace filter elements (located on the left hand side): Access to the filters through the engine bottom guard 8. Open the engine bonnet.

9. Clean well around the filters.

10. Place a suitable container beneath the filters to catch spillage.

11. Unscrew the filter elements.

12. Check for wear particles in the oil.

13. Apply oil to the seals on the new elements.

14. Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-8

Operating & Maintenance Manual

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

Fill new oil: 22. Fill new oil, according to the transmission oil list and oil specification sheet (chapter 6), through the filling tube.

23. Insert the filling cover /dipstick again and turn handle clockwise to tighten the sealing.

Check: 24. S tart the engine and check oil level (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage!

25. Warm up the oil and check for leaks. Re-check level and adjust if necessary.

NOTE • Do not overfill! Both too high and too low level can cause serious internal damage!

• For rough operation conditions the oil and the filter element must be changed more often (every 500 hours)

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-9

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

1

1.2. Run the Transmission Clutch Calibration (AEB)

AEB = Automatic Filling Parameter Adjustment To optimise the transmission, run the AEB-Tester.

1. Pusch MENU on the display screen.

2. Select SERVICE. 3. Select Transmission Clutch Calibration (AEB).

4. Follow the procedure described on the display screen.

2

3

NOTE • Transmission Clutch Calibration must be performed after every oil change in transmission!

* Numbers refer to positions on the lubrication schedule, chapter 6 7-10

Operating & Maintenance Manual

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

2. Hydraulic System 2.1. Replace hydraulic return filter element 42*.

• Replacement of hydraulic return filter element shall also be carried out every 1000 hours of operation.

1. Accumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the filter. Procedure is described in chapter 2, item 27.

2. The filter is located on the back of the hydraulic tank.

Remove the cover to get into the filter.

3. Clean well around the filter housing.

4. Place a suitable container beneath the draining hose to catch spillage.

5. Use a filter key to unscrew the old filter (counterclockwise).

Remove also the old O-ring.

The old filter contains 4 litres oil. Discard the filter element, and oil according to environmental requirements.

6. Check for wear particles in the oil.

7. Clean the O-ring groove, apply oil to the new O-ring and install it.

8. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more.

9. Fill 4 litres hydraulic oil, as specified in chapter 6, lubricants, through the oil filler on the top of the filter unit (under the cover on the top of the hydraulic tank).

10. Screw the oil plug back into place and clean off any oil spill.

11. Start engine and check for leaks.

The accumulators will be recharged with oil when the engine is re-started.

Fill 4 litres hydraulic oil throguh the oil filler.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-11

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

3. Wheel nuts 3.1. Check tightness

Torque setting 450 Nm.

Initial 500 Hours Service

Maintenance to be performed after the first 500 hours only.

1. Front differential DA30 and DA40 1.1 Change oil, at least once a year 30* 1. Access to the drain plug through transmission bottom guard.

2. Open level / filling plug (1), special spanner in tool kit.

3. Unscrew drain plug (2).

4. Drain the oil into a suitable container.

5. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 6. Fill new oil, according to the oil specification sheet (chapter 6), through the level / filling plug, level shall be at lower edge of hole when dump truck is horizontal.

7. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

CAUTION

Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

1

2

* Numbers refer to positions on the lubrication schedule, chapter 6 7-12

Operating & Maintenance Manual

7. Maintenance

Initial 500 Hours Service

Maintenance to be performed after the first 500 hours only.

2. Rear differential DA30 2.1 Oil change 31* *R eplacement of rear differential oil shall also be carried out every 2000 hours of operation.

1. The oil should be at working temperature prior to draining. Take care, there is a risk of scalding.

2. Clean the areas around the screw plugs 31a, 31b, 31c.

3. Remove oil filler plug 31a, then open the drain plug 31c and drain the oil.

4. Clean the oil drain plug 31c magnet of debris before refitting the plug. Fill with new oil (refer to the lubrication table) until the oil exits from the control opening 31b.

5. Replace control plug 31b.

31a

31b

6. Replace filling plug 31a. The tightening moments for the plug is 70+10Nm.

31c

3. Tandem housing DA30

32a 32b

3.1. Oil change 32* * Replacement of tandem housing oil shall also be carried out every 2000 hours of operation.

1. The oil should be at working temperature prior to draining.

Take care, there is a risk of scalding.

2. Ensure that the tandem housing is placed horizontally and the axle remains still for 30 minutes to allow oil contamination to rest.

32c

3. Remove and clean the filling plug 32a, the level plug 32b, and clean the area around them.

32b

Inside tandem housings

4. Remove the drain plug 32c, clean off the magnet of any grime then replace the plug.

5. Fill the tandem housing with oil until oil exits from the level control opening (32b).

6. Replace the level control plug and the filling plug. The tightening moment for both plugs is 70+10Nm. 7. After test driving, check that the oil is at lower edge of the level plug.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-13

7. Maintenance

Initial 500 Hours Service Maintenance to be performed after the first 500 hours only.

33a

4. Planetary drive (hubs) DA30 4.1. Oil change 33* Bottom drain position

* Replacement of planetary drive oil shall also be carried out every 2000 hours of operation.

1. The oil should be at working temperature prior to draining. Take care, there is a risk of scalding.

2. Turn the hub to bottom drain position (hub out side).

3. First open plug 33a to ventilate the hub then plug 33b to drain the oil. Use an extension tool and a container with minimum filling volume of 11L.

33b

Hub inside

4. Turn the hub and remove plug 33c (hub inside).

Use an extention tool and a container with a minimum filling volume of 2L. 5. Replace plug 33c then turn the hub to horizontal fill and control position (hub outside).

6. Fill the hub with oil through position 33a until it reaches the level of 33b. Wait 5 minutes then refill with oil again until it reaches the level of 33b.

33c

7. Replace plug 33b and 33a. The tightening moment for both plugs is 70+10Nm.

33a

33b

Fill and control position

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-14

Operating & Maintenance Manual

7. Maintenance

Initial 500 Hours Service Maintenance to be performed after the first 500 hours only.

5. Tandem housing DA40 5.1. Change oil 32* 1. T he dump truck and tandem housings must be horizontal.

2. Unscrew drain plugs (1) on the inside of the housings.

3. Drain the oil into a suitable container.

4. Clean plugs, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the filler plugs (2) to correct level.

2

6. Clean plugs, replace seals if necessary and reinstall.

• Tightening torque: 80 Nm.

1

7. After test driving, check that level is at lower edge of the level plug.

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

6. Front reduction gear DA40 6.1. Change oil, at least once a year 33* • Change front reduct. gear oil shall also be carried out after the first 500 hours of operation.

1. The dump truck must be horizontal.

1

2. Turn the hub, so that the plug is pointed downwards.

3. Unscrew the plug (1).

4. Drain the oil into a suitable container.

5. Turn the hub 90 o, so that the level indicator is horizontal (2).

2

6. Fill new oil, according to the oil specification sheet (chapter 6), through level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

7. Clean plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 8. Re-check oil level after test driving.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-15

7. Maintenance

Initial 500 Hours Service Maintenance to be performed after the first 500 hours only.

7. Rear differential DA40 7.1. Change oil, at least once a year 31* 1. Open level/filling plug (1).

2. Unscrew drain plug (2) underneath the housing.

3. Drain the oil into a suitable container.

4. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

6. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

1

CAUTION

2

Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

8. Engine 8.1. Checking and adjusting the valve clearance.

• Contact Doosan Dealer for checking/adjusting of the valve clearance. (see item 1.1. 2000 hours service)

8.2. Checking and adjusting injectors.

• Contact Doosan Dealer for checking/adjusting of the injector. (see item 1.2. 2000 hours service)

9. Brakes 9.1. Change oil in the brake cooling tank (only DA40) • See item 2.1. in 2000 hours service

* Numbers refer to positions on the lubrication schedule, chapter 6 7-16

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be perfomed every 8 hours of operation or daily.

1. General 1.1. Walk around check, before start • Check for leaks at the engine (see also item 2.1), transmission, differentials, reduction/tandem housings, tanks, hydraulic hoses and lubrication system.

• General check for loose bolts on the driveline, specially on radiator, engine/transmission brackets and at the prop. shaft flanges.

• Check for damage, wear and other abnormalities on the visible parts of frames, body, tyres, cylinders, etc.

• Check lights. Replace burnt out bulbs.

If leakages, loose bolts, damages or other abnormalities are observed, remedy if necessary (before operation). If necessary contact your local Doosan Dealer.

1.2. Check driver’s seat, before start • Check function.

• Check all seat adjustments for easy operation.

• Check function of the air valve.

• Check safety belt for proper lock functions.

See chapter 3, seat adjustment, for more detailed information.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-17

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2. Engine

5 Cylinders (DA30)

2.1. General condition check - look for leakages Remedy as necessary 1. Start the engine.

2. Look for leakage of oil, coolant, fuel, air and exhaust.

3. Tighten or change leaking connections. Check the overflow holes (1) which show whether the O-rings between the cylinder liner and crankcase are leaking, see figure. a. If coolant is leaking out, the O-rings are leaking. b. If oil is leaking out, the liner shelf is leaking.

4. A small amount of leakage from the overflow holes during the engine’s running-in period is normal. (Seals and O-rings are lubricated with soap or oil when fitted).

This leakage normally stops after a time.

6 Cylinders (DA40)

If there is a large amount of leakage - contact your Doosan Dealer.

2.2 Drain the water separating fuel filter 6* The water separating fuel filter is located on the left hand side of the engine.

Drain the filter by unscrewing the tap in the bottom of the filter.

Draining tap

* Numbers refer to positions on the lubrication schedule, chapter 6 7-18

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2.3. Check oil level, before start 1* • If the engine has been running: Let the engine remain stationary for at least 1 minute before checking the oil level.

• The dipstick (1) is found on the left hand side of the engine.

2

• The correct level shall be between upper and lower mark on the dip stick (1) (dump truck on level ground).

• Fill up with oil (2) if level has dropped to the lower mark. See oil specification sheet, chapter 6 for correct oil type.

• Check level correctness.

1 2 1

2.4. Check coolant level, before start 5* • The level in the expansion tank shall be between minimum and maximum when the dump truck is on level ground. See marks.

Refill with coolant of correct mixture if level is lowerthan minimum.

• If large quantities are required to correct the level, check and remedy the cause in such a case.

CAUTION Be careful when removing the filler cap of a hot engine.

Hot coolant and steam can spurt out!

Never add large amounts of cold coolant when engine is hot. The temperature difference can cause cracks in the engine.

Always top up with pre-mixed coolant.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-19

7. Maintenance

8 Hours / Daily Service To be perfomed every 8 hours of operation or daily.

2.5. Check fuel level, before start 12*

1

1. Turn on the starter switch key (to pos. 1) and check on the fuel gauge (display screen) that there is enough fuel (1).

2. Fill up with fuel if necessary (2).

NOTE Always make sure that there is enough fuel in the tank.

NEVER run out of fuel, fuel injectors (T2 only) will be damaged.

2

2.6. Function check of the centrifugal cleaner, after operation 2* The rotor rotates very fast, and will normally carry on rotating after the engine is stopped.

1. Stop the engine when it is hot.

2. Listen for spinning sound from rotor, or feel if cleaner housing vibrates.

3. The rotor normally rotates 30 - 60 seconds after the engine has stopped.

4. If not, dismantle and check the cleaner, see 500 hours service.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-20

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

1

2.7. Check urea (AdBlue) level, before start 13*(Only T4) 1. Turn on the starter switch key (to pos. 1) and check on the urea gauge (display screen) that there is enough urea (1).

2. Fill up with urea if necessary (2).

WARNING

2

Running the engine without reductant violates emissions legislation and will damage the SCR system

3. Transmission 3.1. Check oil level, before operation 20* 1. The dump truck must be standing on level ground.

2. The gear selector shall be in neutral and confirm that the parking brake is ON. MAX

MIN

3. Run the engine at low idle.

4. To check the transmission oil level, see on the oil sight glass (old solution) or dipstick (new solution).

5. Check level:

Cold oil, 40°C: Hot oil, 80°C:

lower mark upper mark

6. If necessary correct the level by adding oil according to the transmission oil list (chapter 6) through the filling tube.

50 warm

100 cold

CAUTION

MAX

Do not overfill with oil! Both too high and too low level can cause serious internal damage!

MIN

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-21

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

4. Hydraulic system 4.1. Check oil level, before start 40* 1. Read the oil level in the oil level gauges (located on the back of the hydraulic tank).

• The upper gauge shows max. level at warm oil • The lower gauge shows min. level at cold oil.

2. Fill up with oil (see oil specification sheet, chapter 6) if necessary.

Oil filler located on the top of the hydraulic tank.

NOTE The dump truck must be horizontal and dump body completely lowered!

5. Brake system 5.1. Parking brake Check braking (holding) capacity, before operation 1. Apply the parking brake (indicator light).

2. Set the gear selector in 1st gear.

3. Increase the engine speed slowly.

4. The parking brake must be able to keep the dump truck stationary at engine speeds up to 1300 rpm. If not, check parking brake system and contact your Doosan Dealer.

5.2. Service brake (main brake) Check braking (holding) capacity, before operation 1. Apply the parking brake (indicator light).

2. Depress the brake pedal.

3. Release the parking brake.

4. Set the gear selector in 1st gear.

5. Increase the engine speed slowly.

6. The service brake must be able to keep the dump truck stationary at engine speed up to 1300 rpm. If not, check the brake system and contact your Doosan Dealer.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-22

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

5.3. Service brake (main brake) Check function, before operation 1. Apply the parking brake (indicator light).

2. Stop the engine.

3. Check for hydraulic oil leakage at accumulators, pipes and hoses.

4. Start the engine and release the parking brake.

5. Check that the brake system warning light (chapter 3) does not illuminate.

6. Drive the dump truck slowly on firm, level ground and depress the brake pedal firmly.

7. Check that the braking effect is good and equal.

5.4. Accumulators Check the oil pressure, before operation 1. The dump truck must be parked on a horizontal ground.

2. Apply the parking brake.

3. Start the engine and let it run at low idle until the accumulators are fully charged (warning light off).

4. Stop the engine.

5. R elease the parking brake, wait 5 sec. Apply the parking brake, wait 10 sec. Release the parking brake again, wait 5 sec. Apply the parking brake again, wait 10 sec. Continue until the brake warning light comes on.

6. Recharge the accumulators by starting the engine and let it run at low idle until the accumulators are fully charged (warning light off).

7. Stop the engine 8. With the parking brake applied, check the service brake as follows:

WARNING Accumulators contain oil under high pressure!

• Always empty the accumulators before working on or opening the hydraulic system.

• Procedure: • Stop the engine.

• Operate the brake pedal repeatedly until the accumulators are empty.

Accumulators can also be emptied through the accumulator test connectors.

Be aware of that the accumulators will be recharged with oil when the engine is restarted.

9. Apply the service brake pedal, hold for 10 sec. Release the brake pedal and wait 5 sec. Apply the brake pedal again and hold for 10 sec. Then release the brake pedal again and wait 5 sec.

Continue until the brake warning light comes on.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-23

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

6. Steering 6.1. Check function, before operation 1. Turn the steering wheel at an even speed until end stop, both sides.

2. Check that the movement is uniform.

7. Engine brake 7.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

2. Apply the engine brake by releasing the throttle pedal.

3. Check that the exhaust sound changes.

4. Check the indicator light for function and note the braking power.

5. Depress the throttle pedal again and note that the engine brake goes off (i.e no braking power, exhaust sound changes and the indicator light switches off).

8. Engine and retarder brake 8.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

2. Apply the retarder brake by depressing the retarder brake switch and release the throttle pedal. The engine brake will also then apply.

3. Check that the exhaust sound changes.

4. Check the indicator lights for function, both engine and retarder brake and note the braking power.

5. Depress the throttle pedal again and notify that both the engine and retarder brake goes off (i.e no braking power and the indicator lights switches off).

* Numbers refer to positions on the lubrication schedule, chapter 6 7-24

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40h 1. Cab ventilation 1.1. Clean internal filter element and prefilter 100*, 70* 1. Open cover (1) by the removing two screw.

2. Remove the pre-filter (2), and clean it with compressed air.

• Replace if necessary 3. Remove cab ventilation filter element (3) and clean it with compressed air.

• Replace if necessary 4. Reassemble the opposite way.

2 3

1

5. Adjust the check interval if another requirement is experienced.

6. Check the condenser, clean it if necessary.

NOTE Never start driving without prefilter. The heater could be damaged.

1.2. Air conditioner system • The equipment must be used for at least five minutes every week, to distribute oil in the system, this prevent leaks and ensure that the seals are lubricated • See operating controls, chapter 3, cab ventilation, about how to use the air conditioner.

• This must also be done during cold weather operation.

NOTE At ambient temperatures below + 4° C the air conditioner will not engage. Warm up the cab before operating the air conditioner for 10 minutes.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-25

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

2. Tyres 2.1. Check tyre pressures, before operation When the pressure shall be measured, the dump truck must be unloaded.

Measure the pressure for cold tyres with a tyre pressure gauge and adjust if necessary. For tyre pressure recommendation, see chapter 8 - Technical data, and chapter 5 - Operating instructions.

WARNING Stand behind the tread when checking the inflation pressure.

Pressures inside tyres are substantial and an explosion can cause damage and serious personal injury.

Located under the cover

3. a) Automatic central lubrication (Groeneveld lubrication system, fitted as standard) 3.1. Check the lubricant level in the reservoir.

R efill the reservoir if the level has dropped to a minimum The reservoir must also be refilled if the indicator light flashes for 2 minutes (0.5s on/0.5s off) at the beginning of each cycle.

1. Remove the dust cap from the filler coupling.

2. Carefully clean the filler coupling and the coupling on the filler tube.

3. Fit the filler connector on the filler coupling.

Filler coupling

4. Fill the reservoir up to the maximum level indicated on the reservoir. Use only grease as specified in chapter 6, lubricants.

5. Remove the filler connector and fit the dust cap.

NOTE • Do NOT use grease which contains graphite, teflon or molybdenum • Even if the automatic central lubrication is installed, do not forget that there are still some greasing points that must be greased by hand, these are the door, fender hatches and the cab rear hinges

* Numbers refer to positions on the lubrication schedule, chapter 6 7-26

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

Located under the cover

3. b) Automatic central lubrication (Lincoln lubrication system, fitted as option) 3.1. Check the lubricant level in the reservoir.

Refill the reservoir if the level has dropped to a minimum.

1. Carefully clean the filler nipple and the coupling on the filler hose.

2. Fit the filler hose on the filler nipple.

3. Fill the reservoir up to the maximum level indicated on the reservoir. Use only grease as specified in chapter 6, lubricants (Use pump supplied with dump truck).

4. Remove the filler hose.

NOTE Filler nipple

• Do NOT use grease which contains graphite, teflon or molybdenum • Even if the automatic central lubrication is installed, do not forget that there are still some greasing points that must be greased by hand, these are the door, fender hatches and the cab rear hinges.

• If system has been empty you may have to activate pump manually to clear air and codes from system.

WARNING • The grease must be free from impurities and must not change consistancy over time.

• Always switch off power when filling the reservoir tank.

• Risk of bursting reservoir tank if you overfill!

• If reservoir tank has been completely emptied it could take up to 10 minutes for the lubrication sytem to acheive full output again.

4. Continue with all items in 8 Hours / Daily Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-27

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.

Engine

1.1. Change oil 1* Change oil more often if the engine is subjected to particulary demanding operation, such as a dusty environment, poor fuel quality or if deposits in the centrifugal oil cleaner are thicker than 28 mm.

1. Remove the cap on the drain plug, install the draining hose (tool kit) and drain the oil when the engine is hot.

Access through the drain hole in engine bottom guard (1).

1

2. When all oil is drained, remove the draining hose and re-install the cap.

3. Reinstall the cover for drain hole in engine bottom guard.

2

4. Fill oil through filler (2). Do not overfill!

5. Check oil level on dip stick (3).

CAUTION • The oil may be hot! Wear protective gloves and eye protection.

• The oil filler cap must always be in place when starting and running the engine to prevent oil being ejected.

2 3

3

* Numbers refer to positions on the lubrication schedule, chapter 6 7-28

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.2. C lean centrifugal cleaner 2* (at the same time as oil change, item 1.1)

1. Clean the cover. Unscrew the nut and remove cover.

CAUTION Open the cover with care. The oil and inner parts may be hot!

2. Lift out the rotor assembly and loosen the nut for the rotor cover three turns.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-29

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

M20

3. If the rotor nut is jammed: Turn the rotor upside down and fasten the nut in a vice. Turn the rotor approximately one and a half turns anticlockwise by hand or use an M20 bolt as illustrated.

x 1.5

4. G ently tap the nut with the hand or with a plastic hammer to separate the rotor from bottom plate.

5. Undo the nut and remove the rotor cover.

6. Carefully prise the strainer loose from the bottom plate.

7. Scrape off the deposits from the inside of rotor cover.

• If there are no deposits, this shows that the cleaner is not working.

• Clean more frequently if deposits are thicker than 20 mm.

8. Clean all parts in diesel fuel.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-30

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

9. Place a new O-ring in position in the rotor cover.

• T he O-ring must not be damaged. Change if necessary.

10. Assemble the rotor.

11. Tighten rotor nut firmly by hand.

12. Reinstall the rotor.

• Check that it rotates easily.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-31

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

13. Check that the O-ring in the cover is not damaged.

Hard or damaged O-ring must be replaced.

14. Tighten cover firmly by hand.

15. If the nut is tightened too hard (for instance by using tools), the cover, nut or rotor shaft may be damaged!

16. Replace damaged parts!

17. Function check The rotor rotates very fast, and will normally carry on rotating after the engine is stopped. a. Stop the engine when it is warm. b. Listen for spinning sound from rotor, or feel if cleaner housing vibrates. c. The rotor normally rotates 30 - 60 seconds after the engine has stopped. d. If not, dismantle and check the cleaner.

1.3. R eplace oil filter 3* (at the same time as oil change, item 1.1) 1. Unscrew the filter cover with a closed tool with hexagon driver, e.g. 36 mm.

2. Lift out the filter housing cover with filter element. The filter housing will drain automatically once the filter has been removed.

3. Deatch the old filter from the cover by holding the cover and carefully tapping the entire filter element against something hard. Remember that there will be oil splashes.

4. Fit the new filter and tighten filter cover to 25 Nm.

NOTE • Do not use an adjustable spanner or other open tool as there is risk of damaging the filter cover.

• Use only genuine filter!

• Clean the centrifugal oil cleaner when renewing the oil filter. Otherwise, the oil filter will be blocked and resistance in the filter will increase. If this happens, an overflow valve in the filter retainer opens and lets the oil pass without being filtred.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-32

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.4. E xternal cleaning of the radiator, at least once a year 5* If necessary, the cooling system should be cleaned more often.

1. Clean externally the radiator fins and hoses by using a brush.

The radiator can also be washed with water from the backside.

2. Check that the radiator is not blocked on the air side and that the fins are not damaged.

3. Carefully scrape the deposit away from the radiator fins. If necessary, a paraffin-based engine cleaner may be used.

4. Check the fins, rubber hoses, clamps and pipes for corrosion, damage and leakages.

5. Bent fins can be carefully straightened, e.g. using asteel wire brush.

CAUTION The cooling system must not be cleaned using caustic soda. It can damage aluminium parts.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-33

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

2. Drive line 2.1. Check oil levels • M easurements must be carried out when dump truck is parked on a horizontal ground.

• Check that oil level is near the bottom edge of the plugs.

• Refill with oil if level is too low.

• I f the dump truck tandem housing is angled, the reading will be incorrect.

CAUTION Be aware of possible internal pressure when the oil is hot!

1. Front differential 30* Use a hexagonal key to unscrew the upper filling/ level plug.

• Plug torque: 150 Nm

2. Rear differential 31* DA40 Use a hexagonal key to unscrew the filling/level plug at the rear of housing.

• Plug torque: 80 Nm.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-34

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

2. Rear differential 31* DA30 Use a hexagonal key to unscrew the filling/level plug at the rear of housing.

• Plug torque: 80 Nm.

3. Tandem housings 32* Use a hexagonal key to unscrew the level plugs on the inside of the housing.

• Plug torque: 80 Nm.

4. Front reduction gears 33* Turn the hubs until level indicator is horizontal. Use a hexagonal key to unscrew the plugs. DA40 • Plug torque: 80 Nm.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-35

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

4. Front reduction gears 33* Turn the hubs until level indicator is horizontal. Use a hexagonal key to unscrew the plugs. DA30 • Plug torque: 80 Nm.

3.

Parking brake

Parking brake

3.1. Check lining thickness • C hecking of brake lining thickness shall also be carried out after the first 500 hours of operation.

1. Parking brake: Lift body and apply the body support. Remove the protection on the top of the parking brake and check thickness of linings. Change when approaching limit.

• I n connection with replacement perform adjustment, see next page.

Standard lining thickness: Parking brake: 20.0 mm.

Min. thickness: Parking brake: 5.1 mm.

CAUTION This applies to normal driving. For rough operating conditions with much braking and/or driving in water, the brake linings should be checked more often!

* Numbers refer to positions on the lubrication schedule, chapter 6 7-36

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3.2. How to adjust the parking brake.

To be performed in connection with replacement of parking brake linings.

1

• B efore removing the parking brake linings, do as follows: 1. Apply the parking brake.

2. Lift the body.

3. Apply the body support (1) (see also safety instructions, chapter 2).

4. Stop the engine.

5. Secure the dump truck with wheel chocks (see also safety instructions, chapter 2) 6. Release the parking brake by the parking brake switch.

7. R emove the adjuster plug and washer from the cylinder bracket.

Washer-adjuster Washer-adjuster plug plug

Adjuster plug Adjuster plug

8. Use a 6 mm allen wrench to adjust the brake (turning the allen wrench in clockwise direction). Stop turning the allen wrench when you feel resistance, which indicates that the adjuster pistons are fully retracted.

• W hen you de-adjust the brake (increase disc clearance)you will hear a “clicking” sound and feel a “pulsing” sensation during the adjustment.

• To ensure that the automatic adjustment will occur: Adjust the brake an additional 1/4 turn after you reach the resistance point.

• Do not use an air gun to adjust or de-adjust the parking brake!

Components could be damaged.

9. The parking brake linings can now be replaced.

• A fter installation of new parking brake linings, do as follows:

Allen wrench

1. A djust the caliper by reducing the caliper-to-disc clearance to ZERO (turning the allen wrench in counter clockwise direction).

2. Check that the load plate fully contacts the lining backing plate.

3. To increase the disc clearance, turn the allen wrench SEVEN CLICKS in clockwise direction, which sets the initial clearance.

4. Install the adjuster plug and washer.

• Tightening torque: 11-17 Nm 5. Apply and release the parking brake 15-20 times to allow the adjuster to set the final caliper clearance.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-37

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

4.

Wheels

4.1 Check wheel nuts torque.

Torque setting 450 Nm.

5.

Tip- and steering cylinders

5.1 Check expander bolts.

• Checking of the expander bolts torque setting shallalso be carried out after the first 100 hours ofoperation.

Torque setting: • Tip cylinder bolt: 346 Nm • Steering cylinder bolt: 346 Nm • The torque must be checked on both sides of the bolts.

• Be aware of the lubrication nipples on the bolts when checking the torque.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-38

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

6.

Cab ventilation

6.1. Air conditioner system, test operation 1. Start the engine.

2. P ress down the air conditioner switch (see also chapter 3) and open all nozzles.

3. Check that the temperature in the cab decreases.

• If the temperature does not decrease: • Check whether the fuse is burnt out. if yes, replace the fuse.

• If the fuse is not burnt out, there can be a failure or too little refrigerant in the system: CONTACT YOUR LOCAL DOOSAN DEALER

WARNING • If the air conditioning system does not work properly, contact your Doosan Dealer.

• Always use safety glasses or goggles, gloves, boiler suit and protective footwear when inspecting, servicing and repairing the air conditioning system.

• Refrigerant R134a has a property that can cause frostbite if it comes into contact with bare skin or eyes.

• Always work on the air conditioning system in well ventilated places.

• The system contains refrigerant R134a under pressure. Repair and refilling of the refrigerant circuit must only be done by accredited personnel.

• Dispose of waste oil/fluids in an environmentally friendly manner!

• High concentration of the refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst unconsciousness. Very high concentration of the gas can even cause cardiac insufficiency.

Do not smoke when servicing the air conditioning system!

• Be careful with all hoses connected to the air conditioning system. There is always a certain over pressure in the system. Therefore, never undo hoses or the filler opening on the compressor except during repairs to the system.

• If there is any suspicion of leakage, the system must not be filled up - leave the leakage site and contact your Doosan Dealer for repairs.

• Get your Doosan Dealer to check the air conditioning system yearly and refill refrigerant, if necessary.

• See also chapter 2, Safety Instructions

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-39

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

6.2. Check/replace cab ventilation filters 70*, 100* 1. Open cover (1) by removing 2 screws.

2. Remove the pre-filter (2) • Replace if necessary.

3. Remove cab ventilation filter element (3) and replace 4. Reassemble the opposite way.

5. Adjust the check interval if another requirement is experienced.

2

1

3

* Numbers refer to positions on the lubrication schedule, chapter 6 7-40

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Located under the cover /RFDWHG XQGHU WKH FRYHU

7. b) Automatic central lubrication (Groeneveld lubrication system, fitted as standard) 7.1. Check the system • Check the pump for damage and leakage.

• Check the grease lines for damage and leakage.

• C heck, if possible, the condition of the grease points the system serves. Sufficient fresh grease should be present.

• C heck the operation of the system. Perform a cycle test (see chapter 3 for how to perform a cycle test).

Note that every time you perform a cycle test, grease is supplied to the grease points.

• Clean the pump-unit and its surroundings.

NOTE • If you use a high-pressure air or water to clean the dump truck, do not spray directly onto the pump unit.

Water or dirt might enter the pump-unit through the breather.

Located under the cover /RFDWHG XQGHU WKH FRYHU

7. a) Automatic central lubrication (Lincoln lubrication system, fitted as option) 7.1. Check the system • Check the pump for damage and leakage.

• Check the grease lines for damage and leakage.

• C heck, if possible, the condition of the grease points the system serves. Sufficient fresh grease should be present.

• C heck the operation of the system. Perform a cycle test (see chapter 3 for how to perform a cycle test).

Note that every time you perform a cycle test, grease is supplied to the grease points.

• Clean the pump-unit and its surroundings.

NOTE • If you use a high-pressure air or water to clean the dump truck, do not spray directly onto the pumpunit.

Water or dirt might enter the pump-unit through the breather openings.

• For cleaning the system use benzine or petroleum.

Do not use tri-perchloroethylene or similar sol-vents.

Also do not use polar organic solvents such as alcohol, methylacohol, acetone or similar.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-41

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

8.

Lubrication Grease lubrication points until pure grease is forced out of the components. Wipe off.

8.1. Fender hatches, 8 lubricators 50* There are 2 lubricators on right hand side fender, 2 lubricators on left hand side fender and 2 lubricators on the cover upon the hydraulic tank (one per hinge) These lubricators must be manually greased, even if the automatic central lubrication is fitted.

8.2. Cab rear hinges, 4 lubricator 51 * There is 1 lubricator on each side of the cab and 1 lubricator on the right and left side of the front attachment These lubricators must be manually greased, even if the automatic central lubrication is fitted.

9.

Wheel nuts 9.1 Check tightness

10. Continue with all items in 40 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-42

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

1.

Driver’s seat

1.1. General safety check • C heck for play in seat gliders. Max. allowed in length or sideways 1 mm. Grease the gliders.

• Check shock absorbers for oil leakages.

• Check seat mounting to the dump truck.

• C heck safety belt and lock mechanism for wear and damage.

• Check that no pins are loose / worn in the seat base.

• Replace worn/damaged parts.

2.

Engine

2.1 R eplace fuel filter PDE 4* Replace water separating fuel filter PDE 6*

CAUTION Observe extreme cleanliness when working with the fuel system. Otherwise operational interruption may easily occur and the injection equipment may be damaged.

2.1.1. Renewing the fuel filter, 9 liter and 13 liter PDE. 1. Unscrew the filter cover with a closed tool with hexagon driver, e.g. socket 36 mm, so as not to damage the filter cover.

Water separating fuel filter

Fuel filter

2. Lift out the filter cover and filter element. The filter housing will drain automatically. This applies only if the fuel tank is lower than the engine. Otherwise the fuel shut-off cock must be closed first.

3. Undo the removed filter element from the cover by carefully bending it to one side.

4. Renew the O-ring in the cover. Lubricate the O-ring with Oring grease.

5. Check that the filter housing is drained of fuel.

Contaminated fuel may enter the injectors if the drainage does not work.

6. Press a new filter element into the snap fastener in the cover.

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.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-43

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.1.2. Renewing the water seperating filter 1. Close the shut-off cock in the fuel pipe and position a container under the filter.

2. Open the drain tap in the filter cover and let the fluid run down into the container.

3. Unscrew the filter cover.

4. Unscrew the filter from the filter head.

5. Discard the old filter and use a new filter.

6. Lubricate the O-ring in the filter cover with engine oil.

7. Screw the filter cover onto the new filter by hand. Make sure that the drain tap is fully closed.

8. Lubricate the O-ring on the filter with engine oil.

9. Fill the width of the filter with clean fuel.

10. Screw the filter into position until the O-ring rests against the filter head. Tighten the filter another 1/2-3/4 turn by hand.

11. Open the shut-off cock and check the system for leaks.

1. Shut-off cock 2. Drain tap

12. Bleed the fuel system.

2.1.3. Bleeding the 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 litres (0.8 US gallons).

2. Open the bleed nipple and pump with the hand pump until fuel comes out of the hose. If the fuel system is empty, it is necessary to pump approximately 100 strokes in order to draw up the fuel. Depending on the installation, a much greater number of pump strokes may be required before fuel comes out.

3. Pump until fuel without air bubbles comes out, approximately 20 strokes.

4. Close the bleed nipple and remove the hose.

5. Transfer the plastic hose to the fuel manifold bleed nipple 2.

6. Open the fuel manifold ventilating valve.

7. Pump with the hand pump until fuel without air bubbles comes out, approximately 50 strokes.

8. Close the bleed nipple on the fuel manifold and remove the plastic hose.

9. Pump approximately 20 strokes with the hand pump until the overflow valve opens. A hissing sound should be heard.

10. Start the engine. The engine should be easy to start.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-44

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2 Replace fuel filter XPI 4* Replace water separating fuel filter XPI 6* 2.2.1. Renewing the fuel filter XPI

NOTE Engines with XPI have dual fuel filters in the form of a water separating suction filter and a pressure filter.

NOTE Collect all fuel coming out when renewing the fuel filter according to environmental regulations.

A Water separating suction filter B Pressure filter

To ensure that the filter housings are drained properly, the filter covers must be removed as follows: Start with the water separating suction filter (A)! Do not open the pressure filter cover (B) until the filter housing for the water separating filter (A) is completely drained.

Do not use an adjustable spanner or other open tool to undo the filter covers, as this risks damaging the filter covers.

1. Make a mark on the water separating suction filter cover.

Unscrew the cover 3 to 4 turns using a closed tool with hexagon driver, e.g. socket 36 mm.

2. Unscrew the filter cover and lift it up slowly with the filter element.

3. Make sure the suction tool is completely drained before starting work. Draw out remaining fuel and any particles using suction tool or a similar tool.

4. Keep the suction tool hose in the filter housing for the water separating suction filter.

5. Make a mark on the pressure filter cover. Unscrew the cover 3 to 4 turns using a closed tool with hexagon driver, e.g. socket 36 mm. Draw out fuel which may drain into the water separating suction filter housing when the pressure filter is detached.

6. Unscrew the pressure filter cover and lift it up slowly with the filter element.

7. Fuel from the pressure filter housing will flow into the water separating suction filter housing. Leave the suction tool in the water separating suction filter housing until it is completely drained of fuel.

8. Move the suction tool to the pressure filter housing. Draw out remaining fuel and particles.

9. Undo the old filter elements from the covers by carefully bending them to one side

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-45

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2.2 Fuel filter fitting

Check that there is no remaining packaging material stuck to the filters.

1. Unpack the new filter elements and the supplied O-rings.

2. Fit the new O-rings to the covers. Lubricate the O-rings with O-ring grease.

3. Press the filter elements into the snap fasteners on the covers

NOTE Fit the filter element to the filter cover before positioning it in the fuel filter housing. The filter element can otherwise be damaged.

Open the bleed nipple to prevent back pressure in the filter housings when the filter elements are screwed on.

4. Press down the filter element with the filter cover into the fuel filter housing.

5. Screw on the filter cover. Use a closed tool with hexagon driver, e.g. socket 36 mm.

6. Check that there is no gap between the filter cover and the filter housing. If there is a gap, repeat the procedure and make sure that the bleed nipple is open.

2.2.3 Bleeding the fuel system XPI 1. Open the bleed nipple at the high pressure pump and connect a clear plastic hose from suction tool or similar tool.

2. Drain the suction tool. Hold the suction tool straight and draw out a full container of fuel. Bleeding is now complete.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-46

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.3. C heck battery clamping and battery terminals for tightness and corrosion 11* Clean if necessary, apply acid-free Vaseline on the terminals and re-tighten the clamps.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-47

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.4. C heck multi-groove belt condition, at least once a year

1

• Checking of multi-groove belt condition shall also be carried out after the first 8 and 100 hours of operation.

• S top the engine to inspect the multi-groove belt (1), see item 2.4.1 for procedure.

• C hange the belt (1) if damaged or worn, see figures 1-3 below.

• C heck that the automatic belt tensioner (2) is in proper working order and keeps the multi-groove beltsufficiently tightened.

2

1 2.4.1. Inspect the multi-groove belt.

• L oosen the multi-groove belt from the belt pulleys but leave it around the fan shaft so that the direction of rotation for the multi-groove belt is not changed.

• C heck the multi-groove belt carefully. If the multi-groove belt has one or more cracks, as shown in fig. 1, it should be replaced.

• A lso check the wear on the multi-groove belt as shown in fig. 2 and 3.

NOTE Do not change the direction of rotation of the multi-groove belt if it is refitted.

Small superficial cracks in the belt can be accepted

Fig. 2 T he multi-groove belt shows signs of wear. Can be refitted.

Fig. 1 A t large and deep cracks or if small pieces are missing, the belt should be replaced.

Fig. 3 T he wear is down to the chord. The multi-groove belt must be replaced.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-48

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.5. Air filter 10* The air filter is located on the top of the engine, under the bonnet.

• Always stop the engine before servicing the air filter.

• Open the bonnet and apply the bonnet catcher.

• C leaning and replacement of outer and inner element, see this page and next page.

1

2

Outer element: Clean element every 1000 hours of operation or if the air filter warning light illuminates at full load on the engine.

3

• R eplace the outer element after 5 times of cleaning, or at the latest after 2 years.

1. Loosen all clamps and remove the cover (fig. 1).

2. Remove outer element with a light turning movement (fig. 2). Do not remove inner element when cleaning outer element!

Fig. 1

3. To blow out the filter element, use tube with a bent end which is attached to a compressed air gun; the end of the tube must be bent by approx. 90°. It must be of sufficient length to reach down to the bottom of the filter element. Blow out the filter element using dry compressed air (max. 5 bar) by moving the tube up and down inside the filter element until there is no more dust coming out (fig. 3).

• Never wash out or brush out the outer element. When blowing out make sure that no dust is allowed to enter the inside area of the outer element.

Fig. 2

max. 5bar

4. Punch a mark in the edge of the inner element each time the outer element is cleaned.

5. C heck the cleaned element for damage of the paper element and of the rubber seals.

• C racks and holes in the paper element can be discovered by shining through light from an electric bulb (fig. 4).

6. Never carry on using a damaged outer element. In case of doubt, always install a new outer element.

Fig. 3

7. Reinstall the outer element, the cover, and fasten all the clamps. Turn the cover so that the dust cap is pointed downwards (max angle: 15°).

See also precautions on next page

Fig. 4 * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-49

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Servicing the dust cap The dust cap require very little maintenance. Possible dust packs to be removed by squeezing the cap (fig. 5).

Fig. 5

Inner element (safety element) • R eplace element every 5th cleaning of the outer element, or after 2 years.

• Do not clean the inner element and do not reuse it after it has been taken out. Only open the seal in order to replace the inner element.

Fig. 6

1. Loosen all clamps and remove the cover.

2. Remove outer element.

3. Remove the inner element; Use a suitable tool (e.g. screwdriver) to push through the seal of the inner element from the inside to the outside and pull both the straps upwards (fig. 6).

4. Use both straps to take hold of the inner element and then pull out with a light turning movement (fig. 7).

5. Install a new inner element into the housing.

6. Install a new or cleaned outer element.

7. Reinstall the cover, and fasten all the clamps. Turn the cover so that the dust cap is pointed downwards (max angle: 15°).

Fig. 7

CAUTION • Do not attempt to reinstall a cleaned inner element.

• Do not clean or replace the elements when the engine is running.

• Replace the outer element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning.

• Do not use an element in which folds, gasket or seal are damaged.

• When cleaning the element, do not hit or hammer it.

• Do not dismantle the inner element unnecessarily.

• Punch a mark in the edge of the inner element each time the outer element is cleaned.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-50

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

3.

Transmission

3.1. C hange oil 20* Replace filter element 21*, at least once a year • Changing transmission oil, replacement of transmission filter shall also be carried out after the first 100 hours of operation.

Drain oil: 1. The dump truck must be standing on level ground.

2. The oil must be at operating temperature.

3. Unscrew the filler plug (located behind the cab).

4. R emove cover plate under the transmission, by removing the 4 M12 bolts.

5. Remove cap.

6. Place drain hose with connection on drain nipple.

7. Once transmission oil is emptied, remove hose and replace cap.

Drain Drain nipple nipple

Cap Cap

Rear Rear cover cover

Replace filter elements (located on the left hand side): Access to the filters through the engine bottom guard 8. Remove the engine bottom guard (front cover).

9. Clean well around the filters.

10. Place a suitable container beneath the filters to catch spillage.

11. Unscrew the filter elements.

12. Check for wear particles in the oil.

13. Apply oil to the seals on the new elements.

14. Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand. continued next page

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-51

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Fill new oil: 15. Fill with new oil, according to the transmission oil list and oil specification sheet (chapter 6), through the filling tube.

16. Insert the filler plug again and turn handle clockwise to tighten the sealing.

Check: 17. S tart the engine and check oil level (see daily maintenance, for procedure) at low idle. Both too low and too high of a level can cause serious internal damage!

18. Warm up the oil and check for leaks. Re-check level and adjust if necessary.

NOTE • Do not overfill! Both too high and too low of a level can cause serious internal damage!

* Numbers refer to positions on the lubrication schedule, chapter 6 7-52

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

1

3.2. R un the Transmission Clutch Calibration (AEB) AEB = Automatic Filling Parameter Adjustment To optimise the transmission, run the AEB-Tester.

1. Pusch MENU on the display screen.

2. Select SERVICE. 3. Select Transmission Clutch Calibration (AEB).

4. Follow the procedure described on the display screen.

2

3

NOTE • Transmission Clutch Calibration must be performed after every oil change in transmission!

4.

Hydraulic system

4.1. Replace breather element 41* • A ccumulators contain oil under high pressure! Empty the accumulators, before unscrewing the element.

Procedure is described in chapter 2, item 27.

• U nscrew the old element on the hydraulic tank (under the cover).

• C heck the o-ring for deterioration, apply oil and screw on a new element.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-53

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

4.2. Replace hydraulic return filter element 42*.

• Replacement of hydraulic return filter element must also be carried out after the first 100 hours of operation.

1. A ccumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the filter.

Procedure is described in chapter 2, item 27.

2. The filter is located on the back of the hydraulic tank.

Remove the cover to get into the filter.

3. Clean well around the filter housing.

4. Place a suitable container beneath the draining hose to catch spillage.

5. U se a filter key to unscrew the old filter (counter clockwise). Remove also the old O-ring. The old filter contains 4 litres oil. Discard the filter element, and oil according to environmental requirements.

6. Check for wear particles in the oil.

7. Clean the O-ring groove, apply oil to the new O-ring and install it.

8. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more.

9. Fill 4 litres hydraulic oil, as specified in chapter 6, lubricants, through the oil filler on the top of the filter unit (under the cover on the top of the hydraulic tank).

10. Screw the oil plug back into place and clean off any oil spill.

11. Start engine and check for leaks. The accumulators will be recharged with oil when the engine is re-started.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

Fill 4 litres hydraulic oil through the oil filler.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-54

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

5.

Front differential

5.1 Change oil, at least once a year 30* • Change front diff. oil shall also be carried out after the first 500 hours of operation.

1. Access to the drain plug through transmission bottom guard.

2. Open level / filling plug (1), special spanner in tool kit.

3. Unscrew drain plug (2).

4. Drain the oil into a suitable container.

5. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 70 Nm. 6. Fill new oil, according to the oil specification sheet (chapter 6), through the level / filling plug, level shall be at lower edge of hole when dump truck is horizontal.

7. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 150 Nm.

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

1

2

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-55

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

6.

Rear differential (DA40)

6.1. Change oil, at least once a year 31* • Change rear diff. oil shall also be carried out after the first 500 hours of operation.

1. Open level/filling plug (1).

2. Unscrew drain plug (2) underneath the housing.

3. Drain the oil into a suitable container.

4. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

1

6. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

CAUTION

2

Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-56

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

7.

Front reduction gears (DA40)

7.1. Change oil, at least once a year 33* • Change front reduct. gear oil shall also be carried out after the first 500 hours of operation.

1. The dump truck must be horizontal.

2. Turn the hub, so that the plug is pointed downwards.

1

3. Unscrew the plug (1).

4. Drain the oil into a suitable container.

5. Turn the hub 90 o, so that the level indicator is horizontal (2).

6. Fill new oil, according to the oil specification sheet (chapter 6), through level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

7. Clean plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

2

8. Re-check oil level after test driving.

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

8.

Electrical system

8.1. Check wiring The wiring harness must not be damaged. Check that the cables on the articulation hinge and on the rear frame/ body are not squeezed, have sharp bends or loose/bad connections.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-57

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

9.

Urea filter (Only T4)

9.1. Replace the Urea filter

1. Remove the cover under the right fender.

2. Remove the cover on the rear of the reductant tank.

3. Place a suitable container underneath.

4. Unscrew the filter cover. Use a 46 mm socket.

5. Lift out the filter cover and filter element.

6. Renew the filter element and ch eck the O-ring and insulation.

7. Wipe clean with lukewarm water before you refit the filter cover to remove any crystals.

8. Screw on the filter cover again. Tightening torque 80 Nm.

10. Continue with all items in 500 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-58

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation 1.

Engine

1.1. Check/adjust valve clearance (5 cylinders) (DA30) • C hecking/adjusting valve clearance shall also be carried out after the first 500 hours of operation.

• C ontact Doosan Dealer for checking/adjusting of the valve clearance • T he checking/adjusting of the valve clearance must only be carried out by qualified personnel.

• T he air filter and air filter bracket has to be removed before adjustment takes place.

Openings for taking readings on the flywheel housing.

Adjust if necessary: • Inlet: 0,45 mm • Exhaust: 0,70 mm see instruction sign on one of the rocker covers.

Valves should be adjusted when the engine is cold, at least 30 minutes after operation.

Readings can be taken from the flywheel through openings in the flywheel housing either from above or below depending on access when fitting.

“TDC up” or “TDC down” is found on the flywheel. Both openings are fitted with a blanking piece at delivery.

From below

Special tool is used when turning from below.

Valve transition

Valve adjustment

TDC down 72/432

1 5

144/504 216/576 TDC down

3

144/504

1

288/648

2

Special tool is used when turning from above.

252/612 324684

3 4

108/468 TDC up

5

216/576

324/684 36/396

4

72/432

TDC up 252/612

2

288/648

From above

36396 108/468

• T urn the flywheel in the engine’s direction of rotation so that TDC up or TDC down is visible in the flywheel housing window.

• I f there is valve clearance on cylinder 1, start valve adjustment as indicated in the table.

• I f there is valve transition on cylinder 1, work should start at row six of the table.

Tightening torque for lock nut 35 Nm (26 lbf ft).

WARNING Remove ignition key when working on the engine! To avoid a SERIOUS RISK OF INJURY!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-59

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation 1.1. Checking and adjusting valve clearance (6 cylinders) (DA40) • Checking/adjusting valve clearance shall also be carried out after the first 500 hours of operation.

• C ontact Doosan Dealer for checking/adjusting of the valve clearance.

• T he checking/adjusting of the valve clearance must only be carried out by qualified personnel.

• T he air filter and air filter bracket has to be removed before adjustment takes place.

Openings for taking readings on the flywheel housing.

Adjust if necessary: • Inlet: 0,45 mm • Exhaust: 0,70 mm see instruction sign on one of the rocker covers.

Valves should be adjusted when the engine is cold, at least 30 minutes after operation.

Readings can be taken from the flywheel through openings in the flywheel housing either from above or below depending on access when fitting.

“TDC up” or “TDC down” is found on the flywheel. Both openings are fitted with a blanking piece at delivery.

Option 1

Special tool is used when turning from below.

From below

Valve transition

Valve adjustment

From above

TDC down

1

6

TDC up

120/480

5

2

300/660

240/600

3

4

60/420

TDC down

6

1

TDC up

120/480

2

5

300/600

240/600

4

3

60/420

• T urn in the engine’s direction of rotation so that TDC down or TDC up is visible in the flywheel housing window.

• C heck the valve transition and start adjusting as indicated in the table.

Special tool is used when turning from above.

Tightening torque for adjusting screw 35 Nm (26 lbf ft).

NOTE Checking and adjusting the valve clearances should also be done after first 500 hours of operation.

WARNING Remove ignition key when working on the engine!

To avoid a SERIOUS RISK OF INJURY!

* Numbers refer to positions on the lubrication schedule, chapter 6 7-60

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation Option 2 Set cylinder 1 exactly at TDC after the compression stroke.

Adjust the following valves.

Cyl.1

Intake and exhaust

Cyl.2

Intake

Cyl.3

Exhaust

Cyl.4

Intake

Cyl.5

Exhaust

Turn the crankshaft exactly one revolution. Adjust the following valves

B

1 a

A

Cyl.2

Exhaust

Cyl.3

Intake

Cyl.4

Exhaust

Cyl.5

Intake

Cyl.6

Intake and exhaust

1.2. Checking and adjusting injector (Only T2) The unit injectors are adjusted using setting tool 512264 or a digital sliding caliper.

1. Fit the setting tool with the metal plate around the unit injector.

WARNING Measurement A=69.9+/-0.1 (2.75 in) (2.75 in) (1.53 in) Measurement B=38.8 (1.53 in)

Be very careful when checking the unit injector if the measurement is outside the setting dimension. The spring is pre-tensioned and can come loose, causing personal injury.

2. When adjusting, undo the lock nut around the adjusting screw and adjust the unit injector with the adjusting screw 1. he unit injector is correctly set when the small piston 2 is T level with the flat upper surface of the tool. Use a finger to check. Setting dimension is 69.9 +/- 0.1 mm (2.75 in).

1

2

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-61

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation

Coolant: Demineralized water + Anti-freeze or Demineralized water + Anti-corrosive (see text)

1.3. Check the coolant, at least once a year 5*

NOTE Coolant composition: If there is a danger of freezing: • At least 35% glycol by volume (15 litres by total volume) • Max. 60% glycol by volume (30 litres by total volume) If there is no danger for freezing: • 10% anti-corrosive by volume (5 litres by total volume)

As a cooling agents need to be used mixtures of ethylene glycol with demineralized water!

It is forbidden prolonged contact of heat exchangers with rain water or condense water, because this may lead to oxidizing and/or corrosion of the exposed surfaces.

The demineralized water quality should respect the following parameters: • pH=6,5-8; • suspended solids <50ppm; • chlorine concentration <100 ppm; • total hardness (expressed in CaCO3) <200ppm; • sulphates concentration <100 ppm;

WARNING • Ethylene glycol is highly dangerous if consumed and can prove fatal.

• Avoid contact with the skin.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-62

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation 1.3.1. Check the appearance of the coolant, at least once a year • T ake a little coolant in a vessel and check that it is clean and clear.

• I f the coolant is contaminated or cloudy: Consider changing the coolant.

• The water for the coolant should be free of dirt.

• Use demineralized or destiled water with a pH of 6, 5 - 8.

1.3.2. Coolant with glycol only:

Check glycol content, at least once a year

Freezing point (°C)

Antifreeze

- 16

30 % 15 L

- 22

35 % 18 L

- 27

40 % 20 L

- 36

45 % 23 L

- 46

50 % 25 L

Total volume: 50 litres

If there is risk of ambient temperature below 0°C, use only glycol as protection against corrosion in the coolant.

• C ooling system with glycol must contain at least 30% glycol by volume (15 litres by total volume) to offer sufficient protection against corrosion.

• 30% glycol by volume (15 litres by total volume) provides antifreeze protection down to -16°C. If more protection is required, see the table for calculating the necessary amount of glycol. The amount of glycol (antifreeze) is determined acc. to lowest expected temperature. Always be sure that it is enough glycol (anti-freeze) mixed with the water in the cooling system to avoid freezing, see table.

We recommend only nitrite-free anti-freeze glycols with the following supplier designation: • BASF Glysantin G48 • Always fill up the anti-freeze if the glycol content drops below 30% by volume (15 litres by total volume). A glycol content above 60% by volume (30 litres by total volume) will not improve the protection against corrosion.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-63

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation

NOTE • The coolant should be mixed before it is filled into the cooling system. Never top up with only water or only glycol.

• The recommended glycols must not be mixed with glycol which has nitrite-based anti-corrosive nor with other anti-corrosive.

This could cause sludging and reduced cooling capacity.

• The coolant should be changed when the cooling system is cleaned. Every 4000 hours or every 4 years.

1.3.3. Coolant with only anti-corrosive: Check protection against corrosion, at least once a year There must always be sufficient anti-corrosive (inhibitor) in the coolant to protect the cooling system against corrosion.

• If there is no danger of freezing use only Anti-corrosive.

• The inhibitor in the Anti-corrosive must be nitrite-free with the following supplier designation: • BASF Glysacorr G93.

• The correct level of Anti-corrosive is 10% by volume (5 litres by total volume).

• Fill with Anti-corrosive as indicated on the packaging.

• F illing up with 1% by volume (0.5 litres by total volume) of Anti-corrosive should be done after every 2000 operating hours.

• Never fill up with water only or Anti-corrosive only. Lost fluid should always be replaced by pre-mixed coolant: water + 10% Anti-corrosive by volume.

• Anti-corrosive content must not be lower than 5% by volume or exceed 30% by volume.

NOTE • Anti-corrosive must not be mixed with glycol.

• Mixing or over concentration can cause sludging and reduce cooling capacity.

• Any coolant filter must not contain inhibitor.

• The coolant should be changed when the cooling system is cleaned.

Every 4000 hours or every 4 years.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-64

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation 2.

Brake system

2.1 Oil change in the brake cooling tank 34* * Replacement of brake cooling oil tank shall also be carried out after first 500 hours service.

1. The dump truck must be horizontal.

2. Unscrew the dipstick (in the old version unscrew the three screws of the top cap) from the brake coolant tank (1).

1

3. Unscrew the cap of drain plug and place the drain hose (2) through the opening in the fender placed from the bottom.

4. Drain the oil from tank into a suitable container.

5. Once tank is emptied remove hose and reinstall the drain cap.

6. Unscrew the plug (3) on both sides of truck.

7. Drain the oil from the hubs into suitable containers.

8. Clean the plug (3), replace O-ring if necessary and reinstall.

• Tightening torque: 60 Nm.

2

9. Fill new oil, according to the oil specification sheet (chapter 6), through filling point on the tank, about the 12 liters (10 liters for old version) after that start the engine and refill to the correct level.

10. Recheck oil level by dipstick (old version by level gauge) after test driving .

CAUTION The oil my be hot ! Wear protective gloves and eye protection.

3

2.2. Inspect brake lines, at least once a year.

Replace pipes, hoses and fittings which are corroded (deep seated rust), deteriorated (aged), leaking or otherwise damaged.

CAUTION Check more often when operating in salty conditions or similar environment that may affect the brake system!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-65

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation

3.

32a

Tandem housing DA30

3.1 Oil change 32* 32b

* Replacement of tandem housing oil shall also be car -ried out after first 500 hours service.

1. The oil should be at working temperature prior to draining.

Take care, there is a risk of scalding.

2. Ensure that the tandem housing is placed horizontally and the axle remains still for 30 minutes to allow oil contamination to rest.

32c

3. Remove and clean the filling plug 32a, the level plug 32b, and clean the area around them.

4. Remove the drain plug 32c, clean off the magnet of any grime then replace the plug.

32b

Inside tandem housings

5. Fill the tandem housing with oil until oil exits from the level control opening (32b).

6. Replace the level control plug and the filling plug. The tightening moment for both plugs is 70+10Nm. 7. After test driving, check that the oil is at lower edge of the level plug.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-66

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation

4.

Rear differential DA30

4.1. Change oil, at least once a year 31* 1. The oil should be at working temperature prior to draining. Take care, there is a risk of scalding.

2. Clean the areas around the screw plugs 31a, 31b, 31c.

3. Remove oil filler plug 31a, then open the drain plug 31c and drain the oil.

4. Clean the oil drain plug 31c magnet of debris before refitting the plug. Fill with new oil (refer to the lubrication table) until the oil exits from the control opening 31b.

31a

CAUTION 31b

Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

31c

5.

33a

Planetary drive (hubs) DA30

5.1 Oil change 33* Bottom drain position

* Replacement of planetary drive oil shall also be car- ried out after first 500 hours of operation.

1. The oil should be at working temperature prior to draining. Take care, there is a risk of scalding.

2. Turn the hub to bottom drain position (hub outside).

3. First open plug 33a to ventilate the hub then plug 33b to drain the oil. Use an extension tool and a container with minimum filling volume of 11L.

33b

4. Turn the hub and remove plug 33c (hub inside). Use an extention tool and a container with a minimum filling volume of 2L.

Hub inside

5. Replace plug 33c then turn the hub to horizontal fill and control position (hub outside).

33c

6. Fill the hub with oil through position 33a until it reaches the level of 33b. Wait 5 minutes then refill with oil again until it reaches the level of 33b.

33a

33b

Fill and control position

7. Replace plug 33b and 33a. The tightening moment for both plugs is 70+10Nm

6.

Continue with all items in 1000 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-67

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation

1.

Cooling system

1.1 Internal cleaning, every 2 years 5* Removing deposits, oil and grease For internal cleaning use liquid dishwasher detergent designed for household use. Alternative BASF Glycacorr G93 or Texaco Havoline XLI can be used.

Important: The cleaning agent must not foam.

1. If possible, run the engine until it is warm and then drain the cooling system, see changing coolant, item 1.2 2. Remove the thermostat housing (1) and replace it with a hose. Plug the by-pass.

3. Fill the system with clean, hot water mixed with liquid dishwasher designed for household use. Concentration 1% (0.1 L by 10 L water). Alternative BASF Glycacorr G93 or Texaco Havoline XLI can be used.

4. Run the engine for about 20-30 minutes.

NOTE! Do not forget turn to max heat cab heater.

1

5. Drain the cooling system.

6. Fill the system again with hot water and run the engine for about 20 -30 minutes.

7. Drain the water from the cooling system.

8. Refit the thermostat housing and the connections.

9. F ill the system with coolant as described in the specifications in item 1.3 at 2000 hours service.

WARNING Handling cleaning agents for the cooling system: Read the warning label on the container

* Numbers refer to positions on the lubrication schedule, chapter 6 7-68

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation

1.2 Change coolant, every 2 years 5* 1. Remove the filler cap from the expansion tank.

2. Drain the coolant in two places: • the “lowest point” on the engine block, see ill.

• the “lowest point” of the cooling system (1), under the oil cooler on left hand side. Access through the engine bottom guard.

3. Close the cocks.

4. Fill with correct mixture, pre-mixed coolant through the expansion tank filler hole (2). See item 1.3 at 2000 hours service.

5. S et the heating control to maximum heating and startthe engine.Idling speed must not exceed the normal rpm. Leave the engine idling for 15 minutes.

6. S top the engine and top up with coolant to the maximum level through the expansion tank.

7. A small amount of air may still be left in pockets of the cooling system which will disappear when the vehicle is back on the road. This means that it will need some topping up to start with.

1

2

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-69

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation 2.

Hydraulic system

2.1. Change oil 40* 1. Accumulators contain oil under high pressure! Empty the accumulators, before draining the hydraulic oil.

Procedure is described in chapter 2, item 27.

2. The drain plugs both for the main reservoir and the emergency steering reservoir are to be found on the right hand side of the hydraulic tank (on the bottom).

Remove the cover to get into the magnetic plugs.

3. Place a suitable container to catch spillage.

4. Remove the cap from both drain plugs.

5. Install the draining hose with nipple to the first drain plug and drain the oil into the container.

6. Install the draining hose to the second drain plug and drain the oil into the container.

7. Remove the draining hose and reinstall both caps.

8. The oil filler is located on the top of the hydraulic filter unit under the cover on the top of the hydraulic tank.

Magnetic plug

9. Fill new oil through the oil filler, according to the oil specification sheet, chapter 6.

• T he accumulators will be recharged with oil when the engine is re-started.

Oil filler

* Numbers refer to positions on the lubrication schedule, chapter 6 7-70

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation 3.Tandem housing DA40 3.1. Change oil 32* 1. T he dump truck and tandem housings must be horizontal.

2. Unscrew drain plugs (1) on the inside of the hous-ings.

3. Drain the oil into a suitable container.

4. Clean plugs, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the filler plugs (2) to correct level.

2

6. Clean plugs, replace seals if necessary and reinstall.

• Tightening torque: 80 Nm. 7. After test driving, check that level is at lower edge of the level plug.

1

CAUTION

Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

4.

Cab ventilation

4.1. Air conditioner system 1. Clean evaporator coils.

2. Clean drain pane and valve.

3. Recover the refrigerant and replace the filter - receiver - dryer.

4. Check the thermostat.

5.

Continue with all items in 2000 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-71

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be preformed yearly

1.

Transmission

1.1. General condition check 1. Check tightness of lubrication system when engine is running.

• Tighten or change defective connections.

2. C heck transmission rubber mountings and replace if necessary.

Inspect the mounting bolts.

2.

Drive line

2.1. General condition check Check the general condition and mountings, joints, bearings, etc. for general deterioration, wear, damages and leakages.

• Replace or recondition if necessary.

1. Rear axle and tandem housing.

2. Articulation hinge and turning ring.

3. Suspension:

• shock absorbers • rubber dampers • arms and rods

4. All prop. shafts, universal joints included.

3.

Tanks

3.1. General condition check Check the hydraulic and the diesel tank bolts/ mountings.

* Numbers refer to positions on the lubrication schedule, chapter 6 7-72

Operating & Maintenance Manual

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be preformed yearly

4.

Hydraulic system

4.1. Inspect the hydraulic hoses Replace hoses which are deteriorated, leaking or otherwise damaged.

5.

Exhaust system

5.1. Safety check • C heck fastening brackets, muffler, pipes and joints for leaks, damages and insecurity.

• I f body is exhaust heated, check also that the channels in the body not are clogged by any means.

CAUTION

Be aware of hot parts when engine has been running!

6.

Bearings

6.1. Check clearance Contact your local Doosan Dealer for checking of the bearing clearance: • Tandem bearing • Tip bearings • Turning ring and articulation bearings • Wheel bearings

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

7-73

8. Technical Data

Technical Data

Operating & Maintenance Manual

8-1

8. Technical Data

Technical Data................................................................................................................................8-1 Measurements..................................................................................................................................8-3 Engine..............................................................................................................................................8-4 Transmission.....................................................................................................................................8-4 Hydraulic system..............................................................................................................................8-5 Tyre pressures..................................................................................................................................8-5 Electrical system..............................................................................................................................8-6 Bulbs ...............................................................................................................................................8-7 Metering conversion table................................................................................................................8-7 Tool kit content (standard)................................................................................................................8-7 Tool kit content (optional)..................................................................................................................8-7 Rimpull Performance .......................................................................................................................8-8 Graph of altitude power reduction DA30 T2/T4/Stage 3B.................................................................8-10 Graph of altitude power reduction DA40 T2/T4/Stage 3B.................................................................8-11 Engine and retarder brake capacity chart........................................................................................8-12 Torque limits for bolts........................................................................................................................8-13 Reference information......................................................................................................................8-13 Consumeable parts..........................................................................................................................8-13 Product signs....................................................................................................................................8-14 Periodic service................................................................................................................................8-16

8-2

Operating & Maintenance Manual

8. Technical Data

Measurements Machine dimension (mm)

DA30

DA40

Total length

9534

10590

Total width (with standard tyres)

2990

3475

Total width (with optional tyres)

3220

3630

Total height

3560

3850

Overhang, front

2625

2775

Overhang, rear

1024

1410

Wheelbase

1771

1960

Body upper height (rear edge)

2946

3355

Body floor height (rear edge)

2100

2390

Total height, raised body

5885

6680

Ground clearance, raised body

625

763

Ground clearance

571

652

Min. ground clearance, loaded

566

588

Turning radius (ISO 7457)

7680

8420

70°

70°

Body tipping angle Steering angle, both sides

45°

45°

23.5 R25

29.5 R25

185B (2 stars)

202B (2 stars)

Empty weight

23400

30300

Gross weight

51400

70300

Maximum payload

28000

40000

Front axle empty

11900

14500

Rear axle empty

11500

15800

Struck (with / without tailgate)

14,2/13,6

20.4/19,6

Heaped, SAE 2:1 (with / without tailgate)

17,8/16,8

26/24,4

5/8/11/15/22/30/42/55

5/8/11/16/23/32/45/55

5/8/11/16

5/8/11/16

Front

100 (each)

100 (each)

Rear

200

200

108

107

72

71/72

Min. (-)

- 25

- 25

Max. (+)

+45

+45

Standard tyre dimension Tyre load/speed index

Machine weights (kg)

Weight distribution (kg)

Body capacity (m³)

Machine speed (km/h) Forward speeds (1/2/3/4/5/6/7/8) Reverse speeds (1/2/3/4)

Towing load on hooks (k/N)

Sound power level, dB (A) According to ISO 6396 (external)

Sound pressure level, dB (A) According to ISO 6394 (in cab)

Ambient operating temperature (°C)

The measurements are valid for a standard, unloaded machine if nothing else is given.

Operating & Maintenance Manual

8-3

8. Technical Data

Engine Water cooled, unit injected (T2) and extra high pressure injection (T4) diesel engine with turbo charger and air to air intercooler Engine Type Cylinder volume Bore x stroke No. of cylinders

DA30 T2/T4/Stage3B

DA40 T2/T4/Stage 3B

Scania DC9 070A / DC9 074A / DC9 077A

Scania DC13 070A / DC13 074A / DC13 077A

9.3 Litres

12.7 litres

130 x 140 mm

130 x 160 mm

5 (in line)

6 (in line)

Power rating (ISO 3046)

276 kW (375hp)

368 kW (500hp)

Power rating (ISO 9249)

268 kW (364hp)

360 kW (489hp)

1873

2373

Max. torque (Nm) Engine speed, low idle

Set to 720 rpm ±20

Engine speed, high idle

Set to 2280 rpm ±20

Max. allowed engine speed Oil capacity

2400 rpm 32 litres

45 litres

Oil pressure Normal with the warm engine, operating speed Oil pressure Normal with the warm engine, minimum permitted at idling speed

3-6 bar

Min. 0,7

Min. 1.0 bar

Specific oil consumption Coolant volume Normal temperature Thermostat

<0.3 g/kWh 45 litres (approx.)

50 litres (approx.)

70-90°C

70-93°C

83°C

83°C

Max. system pressure Compression ratio Firing order

1 kW = hp 1,36

0.5 bar 16:1

17,3:1

1-2-4-5-3

1-5-3-6-2-4

Engine rotation, seen from rear

Counterclockwise 0.45 mm, inlet valves 0.70 mm, inlet valves

Valve clearance (cold engine)

Transmission Automatic transmission. Integrated in the gearbox: torque converter, automatic lock-up clutch, retarder brake and lockable inter axle differential.

Transmission Type No. of forward gears No. of reverse gears Oil capacity Normal temperature Max. permitted temp. when using retarder brake Lock -up clutch Lock-up in/out Inter axle diff. distribution

8-4

DA30

DA40

ZF 8EP-320

ZF 8EP-420 8 4 75 litres 50-105°C 150°C (short period only) In all gears

Depending on the engaged mode 1/3 to front axle, 2/3 to rear axle, lockable

Operating & Maintenance Manual

8. Technical Data

Hydraulic system DA30 - DA40 (One pump solution) The system have one variable displacement piston pump. Pump supplies steering, tilting, fan and brakes system, where the steering circuit has priority.

The main and emergency steering pumps are fitted on the transmission.

DA40 (Two pumps solution) The system have two variable displacement piston pumps. One pump for the steering, accumulator charging and tilting. Where the steering circuit has priority.

One pump for the cooling fan and tilting.

The main and emergency steering pumps are fitted on the transmission.

Hydraulic system

DA30

Tank capacity

DA40 (Two pumps solution)

DA40

205 litres

275 litres

Normal oil temperature

40-90°C

Filter

One return flow filter

Pumps

1 variable displacement piston pumps

2 variable displacement piston pumps

Capacity per pump Steering/tipping

320 l/min at 2200 rpm

Emergency steering pump

450 l/min at 2200 rpm

Pistom pump, ground driven, speed dependent

Pump delivery

Max. 50 l/min Pressure settings - main safety valves

Tipping circuit- up (pump setting)

280 bar

Tipping circuit- down (pump setting) Shock valves in the tip circuit

300 bar (up), 80 bar (down)

Steering circuit

210 bar

Tipping cylinders

2x Single stage, double acting

Steering cylinders

2 x Single stage, double acting

Steering wheel turns

Approx. 5

Tyre pressures

Basic pressure for cold tyres (based on max. load and max. speed): Model

DA30(23.5)

DA30(750/65)

DA40(29.5)

DA40(875/65)

Type

Front (bar {psi})

Rear (bar {psi})

max. 50 km/h

max. 50 km/h

Bridgestone VLT/VLTS

4.75 {68.8}

5.00 {72.5}

Goodyear E3/E4

4.00 {58}

4.50 {65.2}

Michelin E4T

4.00 {58}

4.25 {61.6}

Michelin E3

4.50 {65.2}

4.75 {68.8}

Techking

3.50 {50.7}

4.50 {65.2}

Magna E3T (E4)

4.50 {65.2}

4.50 {65.2}

Bridgestone VLT/VLTS

3.75 {54.3}

4.00 {58}

Goodyear E3/E4

3.25 {47.1}

3.50 {50.7}

Techking

3.60 {52.2}

4.40 {63.8}

Bridgestone VLT/VLTS

3.75 {54.3}

4.50 {65.2}

Goodyear E3/E4

3.75 {54.3}

4.75 {68.8}

Michelin E4T

3.75 {54.3}

4.40 {63.8}

Michelin E3

3.75 {54.3}

4.40 {63.8}

Techking

3.50 {50.7}

4.70 {68.1}

Magna E3T (E4)

5.00 {72.5}

5.00 {72.5}

Bridgestone VLT/VLTS

3.00 {43.5}

3.75 {54.3}

Goodyear E3/E4

2.75 {39.8}

3.25 {47.1}

Techking

3.60 {52.2}

4.40 {63.8}

Regarding tyre pressure: Contact your Doosan Dealer or tyre supplier to get further information.

Operating & Maintenance Manual

8-5

8-6 F28 / 7,5A F29 / 7,5A

LCD + ign U30

Aux U30 Extra #8 Extra #7 Radio / CD CB

Extra #5 Seat

HVAC system HVAC fan T/M + other T/M U30

F32 / 10A F33 / 10A

F34 / 15A F35 / 15A F36 / 10A F37 / 15A F38 / 15A F39 / 15A

F40 / 7,5A F41 / 10A F42 / 15A F43 / 10A

F44 / 10A F45 / 10A F46 / 10A F47 / 15A F48 / 5A F49 / 10A

Solenoid 1-4

Solenoid 5-8

Engine U30A

Engine U30B

Engine other

Mirror heat

Mirror work light

Mirror low beam

Front parking + direction light

Front low beam

Front high beam

Horn

Extra #2

Extra #3

Lubrication

Rear work light

A/C Clutch

Rear light +other

Wiper + washer

Operating & Maintenance Manual F27 / 15A

F26 / 7,5A

F25 / 15A

F24 / 15A

F23 / 15A

• Engine heater • Engine fuel

F22 / 10A

28 V, 100 A

Extra #6

Alternator

F21 / 15A

Negative earth cable

Roof work light

2x 12 V, 140 Ah

F20 / 15A

Grounding

Beacon + mark

DA30

F19 / 10A

System voltage

F18 / 10A

Starter motor

F17 / 10A

K1

F16 / 10A

Battery

F15 / 10A

F14 / 5A

F13 / 5A

LCD + other

F31 / 7,5A

PWM 5-8

Joystick + instr.

F12 / 5A

Sat + diag U30

F30 / 15A F11 / 5A

F10 / 5A

PWM 1-4

VCU internal

8. Technical Data

Electrical system 24 V DA40

2x 12 V, 225 Ah

5.5 Kw

Fuses and relays:

The fuses are located behind the cover on the backwall. Be sure to use fuses of correct size. Never install larger fuses than specified! If a certain fuse blows several times, the circuit must be checked and failure corrected.

Relays 88

• Webasto

Fuses:

8. Technical Data

Bulbs DA30/DA40 Light Head lights (H7)

Watts

Socket

70

PX 26 d

Side lights in head light

LED

Direction indicator front

21

BAU 15 s

Direction indicators rear Stop lights

Diode Light

Rear lights Licence plate lights

5

S 8.5

Work light Reverse light

Pk 22s

65

Rotating beacon (H1)

P14.5s

Cab lights

LED

Parking brake switch

1,2

W2x4.6d

Metering conversion table Length:

1 m 1 km

= =

1.094 yd 1000 m

= =

3.281 ft 0.621 mile

=

39.37 in

Volume:

1 dm3 1 dm3 1 m3

= = =

1 litre 0.0353 ft3 35.32 ft3

= =

0.264 gal (US) 61.02 in3

=

0.220 gal (UK)

Weight:

1 kg = 1000 kg =

2.20 lb 1 ton (metric)

= =

35.27 oz 0.984 ton (UK)

=

0.902 ton (US)

Power:

1 kW

= =

1.34 hp (British) 1.36 hk (Metric)

Torque:

10 Nm

=

1.02 kpm

=

7.38 lbf ft (pound-force foot)

Pressure:

1 bar

=

1.02 kp/cm2

=

14.5 p.s.i.

Temperature:

o

= =

5/9 x ( F- 32) (9/5 x oC)+32

=

0.62 mph

o

Speed:

C F

1 km/h

=

100 kPa

o

Tool kit content (standard) • Operation manual • Basic driving instruction • Safety support (tiltable body) • Parts catalogue DVD • Draining hose • Lever for lifting cab

Tool kit content (optional) • Hex. sockets 10,12,17,22 mm • Socket 30 mm • Long socket 32 mm • Socket 46 mm • Toggle joint

• Extention arm 200 mm • Extention arm 470 mm • Handle 510 mm • Grease gun

Operating & Maintenance Manual

8-7

8. Technical Data

Rimpull Performance

8-8

Operating & Maintenance Manual

8. Technical Data

Rimpull Performance

Operating & Maintenance Manual

8-9

8. Technical Data

Graph of altitude power reduction DA30 T2/T4/Stage 3B

Power output (kW)

DA30 T2 DA30 T2

Altitude (m)

Power output (kW)

DA30 T4i DA30 T4i and Stage 3B

Altitude (m)

8-10

Operating & Maintenance Manual

8. Technical Data

Graph of altitude power reduction DA40 T2/T4/Stage 3B

Power output (kW)

DA40 T2 DA40 T2

Altitude (m)

Power output (kW)

DA40 T4i DA40 T4i and Stage 3B

Altitude (m)

Operating & Maintenance Manual

8-11

8. Technical Data

Engine and retarder brake capacity chart Below diagram gives guidelines for calculation of the dump truck engine and retarder brake performance related to rolling grade. The traction capabilities depend on the ground conditions and surroundings, i.e. available wheel grip (friction), tyre pattern, weight on the wheels, etc. If the driving conditions (f.ex curves) requires hard decel lerating by using the main brake, driving in a lower gear is advised.

Bremskraftdiagramm Vorwärts Brake force Diagram Forward

Bremskraft / Retardation [kN]

Engine / Rotor Speed (rpm)

DA30

Geschwindigkeit / Velocity [km/h]

Engine / Rotor Speed (rpm)

Bremskraftdiagramm Vorwärts Brake force Diagram Forward iA = 23,506

Bremskraft / Retardation [kN]

DA40

Geschwindigkeit / Velocity [km/h]

8-12

Operating & Maintenance Manual

8. Technical Data

Torque limits for bolts 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.

Metric Threads Dim./Class

8.8

Fine Metric Threads 10.9

12.9

Dim./Class

8.8

UNF - Threads

10.9

12.9

Dim./Class

8.8

10.9

12.9

M8

24

33

40

M8 x 1

25

35

42

3/8" UNF

41

59

73

M10

47

65

79

M10 x 1.25

48

68

81

7/16" UNF

66

93

115

M12

81

114

136

M10 x 1

49

70

84

1/2" UNF

99

141

175

M14

128

181

217

M12 x 1.5

83

117

140

9/16" UNF

142

201

250

M16

197

277

333

M12 x 1.25

85

120

144

5/8" UNF

197

279

347

M18

275

386

463

M14 x 1.5

135

190

228

3/4" UNF

344

486

606

M20

385

541

649

M16 x 1.5

204

287

344

7/8" UNF

547

772

963

M22

518

728

874

M18 x 1.5

294

413

496

1" UNF

814

1150

1430

M24

665

935

1120

M20 x 1.5

408

574

688

1 1/8" UNF

1170

1660

2060

M27

961

1350

1620

M22 x 1.5

546

768

921

1 1/4" UNF

1620

2290

2850

M30

1310

1840

2210

M24 x 2

696

979

1170

1 3/8" UNF

2170

3070

3820

M33

1770

2480

2980

M27 x 2

1000

1410

1690

1 1/2" UNF

2840

4000

5000

M36

2280

3210

3850

M30 x 2

1390

1950

2340

M33 x 2

1860

2610

3130

M36 x 3

2350

3310

3970

Reference information Machine model:

Serial no.:

Prod. year:

In operation:

Engine s/no.:

Transm. s/no.:

Dealer:

Consumeable parts

Part No.

Quantity

Description

Operating & Maintenance Manual

8-13

8. Technical Data

Product signs

Punched serial number

DA30

F

ZF Passau GmbH Made in Germany Type Serial-No.

8 EP 320 Parts List No. Total Ratio / Version

Oil ltr. List of lubricants TE-ML

03

TE-ML TE-ML Customer’s Code No.

DA40

F

ZF Passau GmbH Made in Germany Type Serial-No.

8 EP 420 Parts List No. Total Ratio / Version

Oil ltr. List of lubricants TE-ML TE-ML TE-ML Customer’s Code No.

8-14

Operating & Maintenance Manual

03

8. Technical Data

IMPORTANT INFORMATION THIS ENGINE IS SOLELY FOR EXPORT AND IS THEREFORE EXEMPT UNDER 40 CFR 1068.230 FROM U.S. EMISSION STANDARDS AND RELATED REQUIREMENTS. THIS ENGINE DOES NOT COMPLY WITH ANY EMISSION REGULATIONS IN THE UNITED STATES. IMPORTATION, SELLING, INSTALLATION OR USAGE IN THE UNITED STATES, OTHER THAN THE EXEMPT UNDER 40 CFR 1068.230. CAN BE A VIOLATION OF FEDERAL LAW SUBJECT TO CIVIL PENALTY.

5

7

4

8

3

6

5

LH side LH side

RH side side

Operating & Maintenance Manual

8-15

8. Technical Data

Periodic service DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

Fill in the boxes according to the maintenance performed on the dump truck serial no.:

SERVICE Hrs:_ ________ Date:_______________ Stamp / Sign.:

SERVICE Hrs:_ ________ Date:_______________ Stamp / Sign.:

SERVICE Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

8-16

Operating & Maintenance Manual

8. Technical Data

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

DELIVERY Hrs:_ ________ Date:_______________ Stamp / Sign.:

Operating & Maintenance Manual

8-17

9. Index

Index

Operating & Maintenance Manual

9-1

9. Index

Index Symbols 8 Hours / Daily Service .............................................. 7-17 40 Hours / Weekly Service ........................................ 7-25 500 Hours Service ..................................................... 7-28 1000 Hours Service ................................................... 7-43 2000 Hours Service ................................................... 7-57 A A/C ............................................................................. 3-21 Accumulators .................................................... 2-24, 7-23 AEB-Tester ....................................................... 7-10, 7-51 AEM Safety manual ................................................... 1-13 Air conditioner system ............................. 7-25, 7-39, 7-68 Air conditioning system hazard prevention ................ 2-12 Air filter ...................................................................... 7-47 Air filter warning,......................................................... 3-10 Articulation lock ......................................................... 2-23 Ashtray ...................................................................... 3-34 Automatic central lubrication ................... 7-26, 7-27, 7-41 Automatic/Manual transmision status ........................ 3-14 Axles oil list ................................................................ 6-14 B Battery charge warning ............................................. 3-12 Battery power assistance .......................................... 5-29 Bearings .................................................................... 7-70 Bleed fuel system ...................................................... 7-44 Body down indicator, green ....................................... 3-13 Body support ............................................................. 2-21 Brake pedal ............................................................... 3-26 Brakes ................................................................ 1-7, 5-14 Brake system .................................................... 7-22, 7-62 Brake system warning ............................................... 3-11 Braking/stopping ........................................................ 5-16 Breather element ....................................................... 7-51 C Cab light .................................................................... 3-34 Cab rear hinges ......................................................... 7-42 Cab ventilation ................................3-21, 7-25, 7-39, 7-68 CE Marking .................................................................. 1-9 Centrifugal cleaner .................................................... 7-29 Change coolant ......................................................... 7-66 Change oil 7-28, 7-49, 7-53, 7-54, 7-55, 7-64, 7-67, 7-68 Check/adjust valve clearance .................. 7-57, 7-58, 7-59 Check battery ............................................................ 7-45 Check coolant level .................................................... 7-19 Check driver’s seat .................................................... 7-17 Check fuel injectors ................................................... 7-16 Check fuel level ......................................................... 7-20 Check function, main brake ....................................... 7-23 Check function, steering ............................................ 7-24 Check lining thickness ............................................... 7-36 Check multi-groove belt ............................................. 7-46 Check of the centrifugal cleaner ................................ 7-20 Check oil level, hydraulic system ............................... 7-22 Check oil levels .......................................................... 7-34 Checks after stopping the engine .............................. 5-23 Check the coolant ...................................................... 7-60 Check tyre pressures ................................................. 7-26 9-2

Check urea ............................................................7-21 Check wheel nuts torque .......................................7-38 Check wiring ..........................................................7-55 Cigarette lighter .....................................................3-28 Clean centrifugal cleaner .......................................7-29 Clothing and personal protection items ...................2-4 Cold weather .........................................................5-27 Column switch .......................................................3-24 Consumeable parts ...............................................8-13 Controls .................................................................3-24 Coolant ..................................................................7-60 Cooling system ......................................................7-65 D Dangerous loads ...................................................2-16 Declaration of Conformity ........................................1-9 Differentials .................................................. 5-18, 5-19 Direction light indicator ..........................................3-13 Direction switch .....................................................3-24 Display screen .........................................................3-5 Drain the water separating fuel filter ......................7-18 Drive line ...................................................... 7-34, 7-69 Driver’s seat ................................................. 3-30, 7-43 Dump truck knowledge ............................................2-3 Dump truck transportation .....................................2-24 Dusty areas .............................................................5-3 E Electrical system ........................................... 7-55, 8-6 Electrical System .....................................................1-7 Emergency braking ................................................5-16 Emergency exit .............................................. 2-7, 3-29 Emergency steering ..............................................2-14 Emergency steering warning .................................3-12 Engine .........................1-6, 7-18, 7-28, 7-43, 7-57, 8-4 Engine and retarder brake .....................................7-24 Engine and retarder brake operation .....................5-15 Engine bonnet .......................................................2-19 Engine brake .........................................................7-24 Engine brake indicator ...........................................3-14 Engine coolant .........................................................3-5 Engine failure warning ...........................................3-10 engine oil pressure warning ..................................3-10 Engine overspeed ..................................................2-15 Engine revolution counter ........................................3-5 Environmental requirements ....................................1-6 Exhaust heating .....................................................2-16 Exhaust system .....................................................7-70 External cleaning of the radiator ............................7-33 External door opener/lock .....................................3-31 Extremely cold areas ...............................................5-5 Extremely hot areas .................................................5-5 F Fender hatches ......................................................7-42 Filling capacities ............................................ 6-6, 6-10 Filling fuel or oil ......................................................2-13 Fire extinguisher ......................................................2-5 Fire prevention .........................................................2-8 Fire prevention for fuel and oil .................................2-5 First 8 hours .............................................................4-4 First 100 hours .........................................................4-4 First 500 hours .........................................................4-5 First aid kit ...............................................................2-5 FOPS .......................................................................2-6

Operating & Maintenance Manual

9. Index

Foreword ......................................................................1-5 Front differential ................................................7-12, 7-53 Front reduction gears .......................................7-15, 7-55 Fuel filter ....................................................................7-18 Fuel gauge ...................................................................3-6 Fuses ...........................................................................8-6 G Gear selector .............................................................3-27 Gear shift restriction ..................................................3-15 Gear sifting ................................................................5-10 General ......................................................................7-17 General condition check ............................................7-69 General condition check, engine ...............................7-18 General description .....................................................1-6 General failure warning .............................................3-12 General precautions ....................................................2-3 Getting on and off the dump truck ...............................2-4 Groeneveld pump test ...............................................3-16 H High altitude .................................................................5-4 High beam indicator ...................................................3-13 High pressure ............................................................2-24 High temperatures .......................................................2-5 High-voltage cables ...................................................2-10 Hoisting ......................................................................2-23 Horn ...........................................................................3-24 How to adjust the parking brake ................................7-37 Hydraulic return filter element ...................................7-11 Hydraulic system .............1-8, 7-22, 7-51, 7-67, 7-70, 8-5 Hydraulic system failure ............................................3-12 I Important operating instructions ................................5-21 indicator symbols and lights ........................................3-9 Information about errors ..............................................3-7 Information about transmission ...................................3-6 Initial 100 Hours Service .............................................7-8 Initial 500 Hours Service ...........................................7-14 Inspect brake lines .....................................................7-62 Inspect the hydraulic hoses .......................................7-70 Instructor seat ............................................................3-31 Instruments ..................................................................3-5 Intended use ................................................................1-6 Inter axle differential .........................................5-18, 5-19 Internal cleaning ........................................................7-65 Internal door opener ..................................................3-31 Introduction ..................................................................1-6 K Keypad .......................................................................3-18 L Lamp fault ..................................................................3-14 Lifting .........................................................................2-23 Loading and tipping ...................................................5-23 Load wight indicator .....................................................3-7 Long term storage .....................................................5-28 Low coolant level warning ..........................................3-10 Lubricants ....................................................................6-1 Lubrication .................................................................7-42 Lubrication schedule ............................................6-3, 6-7 Lubrication system warning .......................................3-15 M Machine turning .........................................................2-13

Main driving statistic ................................................3-7 Main lights indicator ...............................................3-13 Maintenance ............................................................7-1 Maintenance precautions ........................................7-3 Maintenance table ...................................................7-5 Manual release of parking brake ...........................5-30 Manual release of the ball valve on tilting circuit .... 5-31 Measurements .........................................................8-3 Menu button ...........................................................3-14 Monitor warning .......................................................3-9 N Neutral gear position .............................................5-10 Normal operation ...................................................5-13 O Oil specification sheet ...................................... 6-5, 6-9 Operating Controls ..................................................3-1 Operating hints ......................................................5-12 Operating Instructions .............................................5-1 Operating the dump truck ........................................5-9 Operation of brakes ...............................................2-14 Operator’s cab .........................................................2-9 Optional accessories ....................................... 2-6, 2-7 Other buttons .........................................................3-15 Other cab equipment .............................................3-30 P Parking brake ...................................... 5-14, 7-22, 7-36 Parking brake activated indicator ...........................3-11 Parking brake switch ..............................................3-20 Parking the dump truck ..........................................5-22 Periodic service .....................................................8-16 Planetary drive ......................................................7-64 Poduct plates .........................................................1-11 Precautions before starting the engine ....................2-8 Precautions for mirrors, windows and lights ..........2-10 Precautions for optional accessories .......................2-6 Precautions on work sites ........................................5-3 Precautions when handling at high temperatures ...2-5 Product signs .........................................................8-14 Protection against falling objects .............................2-6 R Radio/Cassette player ...........................................3-35 Rear camera view button .......................................3-14 Rear differential .................................. 7-16, 7-54, 7-64 Rear working lights indicator .................................3-13 Reference information ...........................................8-13 Refrigerant .............................................................2-12 Relays ......................................................................8-6 Replace breather element .....................................7-51 Replace filter element ............................................7-49 Replace fuel filter ...................................................7-43 Replace hydraulic return filter element ........ 7-11, 7-52 Replace oil filter .....................................................7-32 Replace transmission filter element .........................7-8 Retarder brake ............................................. 5-14, 7-24 Retarder brake indicator ........................................3-14 Retarder oil temperature ..........................................3-6 Retractable roller sunblind on front window ...........3-34 Reversing (back-up) operations .............................5-13 Rocky areas .............................................................5-3 Roll-over protection .................................................2-6 ROPS ......................................................................2-6 Rotating beacon indicator ......................................3-13

Operating & Maintenance Manual

9-3

9. Index

Running-in operation ................................................... 4-3 Running-in period ........................................................ 4-1 Running-in services ..................................................... 4-4 Run the AEB-Tester ................................................... 7-51 S Safety at the worksite .................................................. 2-8 Safety equipment ....................................................... 3-33 Safety information ...................................................... 1-12 Safety Instructions ....................................................... 2-1 Safety labels .............................................................. 2-25 Safety rules .................................................................. 2-3 SCR failure warning ................................................... 3-10 Seashore or salty areas ............................................... 5-4 Seat belt warning ....................................................... 3-14 Service brake .................................................... 5-14, 7-22 Service position ......................................................... 2-22 Side window .............................................................. 3-32 Side window, left rear ................................................ 3-32 Side window, right front ............................................. 3-32 Specified loading ....................................................... 5-26 Speedometer ............................................................... 3-5 Starter switch ............................................................. 3-28 Starting in cold weather ............................................... 5-8 Starting the engine ...................................................... 5-7 Steep driving ............................................................... 5-5 Steering ............................................................ 5-17, 7-24 Steering column ........................................................ 3-25 Stopping the engine ................................................... 5-22

Warming up period ................................................5-10 Warning triangle ......................................................2-5 Welding ..................................................................2-17 Wet, swampy or muddy areas .................................5-4 Wheel chocks ........................................................2-22 Wheel nuts .............................................................7-42 Wheels ...................................................................7-38 When starting the engine ......................................2-10 Windscreen wiper ..................................................3-25 Worker protection rules, refrigerant .......................2-12 Working and extra high beam lights idicator ..........3-13

T Tandem housing ............................................... 7-63, 7-68 Tanks ......................................................................... 7-69 Technical Data ............................................................. 8-1 Throttle pedal ............................................................. 3-26 Tip- and steering cylinders ........................................ 7-38 Tip control lever ......................................................... 3-28 Tipping ....................................................................... 5-24 Tool kit content ............................................................. 8-7 Top tailgate ................................................................ 2-18 Torque limits for bolts ................................................. 8-13 Towing the dump truck ............................................... 5-30 Transit, long distance drive-away on road ................. 5-26 Transmission ...................... 1-7, 7-8, 7-21, 7-49, 7-69, 8-4 Transmission failure warning ..................................... 3-11 Transmission lock-up indicator .................................. 3-14 Transmission oil list .................................................... 6-12 Transmission oil temperature ....................................... 3-6 Transportation ............................................................ 2-24 Travelling on slopes ................................................... 2-14 Troubleshooting ......................................................... 5-32 Tyre handling ............................................................. 5-25 Tyres .......................................................................... 7-26 U Unauthorised modification ........................................... 2-4 Up, down and crossgradient travel ............................ 5-20 Urea (AdBlue) level ...................................................... 3-7 Urea filter ................................................................... 7-56 V Valve clearance ................................................ 7-57, 7-58 Ventilation for enclosed areas ...................................... 2-9 W Wading ...................................................................... 2-15 9-4

Operating & Maintenance Manual

9. Index

Operating & Maintenance Manual

9-5