Doosan DA40 Manuals

Doosan DA40 Manuals

Manuals and User Guides for Doosan DA40. We have 1 Doosan DA40 manual available for free PDF download: Shop Manual

Doosan DA40 Shop Manual

Doosan DA40 Shop Manual (945 pages)

Brand: Doosan | Category: Trucks | Size: 60 MB

Table of Contents

Chapter 0 General Instructions Index

4
- Table of Contents
  4
- Foreword
  5
- Torque Limit Table
  6
- Types of Sealing-/Locking Compounds and Lubricants
  7
- Safety in Workshop
  8
- Working on Machine
  9
- Personal Protective Equipment (PPE)
  12
- Vibration
  13
- Injurious Noise
  14
- Organic Solvent
  15
- Fueling
  16
- Fire and Explosion Prevention
  16
- Fire and Explosion Risks
  18
- In Case of Fire
  19
- Coolant
  20
- Refrigerant
  21
- Air Pollution
  22
- Operation in Extreme Conditions
  23
- Liquid or Gas under High Pressure
  27
- Asbestos
  28
- Lead
  28
- Battery Hazard Prevention
  29
- Disposal of Hazardous Materials
  31
- Jacked up Vehicle or Bodywork
  32
- Crushing and Cutting Danger
  32
- Heavy Units
  33
- More than One Person Working with the same Object
  34
- Involuntary Start of Electric Motors Etc
  34
- Rotating Parts
  35
- Splinters, Flying Object When Using Certain Tools
  36
- Springs under Load
  37
- Precautions for Disassembly and Assembly
  38
Chapter 1 Engine Index

47
- Engine Identification
  52
- Removal of Engine Assembly
  56
- Lifting the Engine
  62
- XPI Fuel System DA30/40
  63
- Route of the Fuel on 9 and 13 Litre Engines
  64
- Fuel Filter and Water Separation
  65
- Overflow Valve
  66
- Fuel System Components
  67
- Schematic Diagram of the Fuel System
  67
- Important Information about the Fuel
  68
- Exhaust System XPI
  69
- Introduction System Overview
  69
- Control System for Exhaust Gas Aftertreatment
  70
- Control Unit EEC3
  78
- System Overview for Mechanics
  79
- System Overview for Electrics
  80
- Ad Blue Filter Change
  81
- Reductant Doser
  82
- Reductant Pump, Function
  84
- Start-Up Instruction for New SCR Pump
  85
- Fuel System Tier2 (PDE)
  87
- Overflow Valve
  87
- Schematic Diagram of the Fuel System Tier2
  87
- Fuel
  88
- General
  88
- Temperature Dependency of the Fuel
  89
- Changing the Fuel Filter
  90
- Fuel Filter
  90
- Changing the Water Separating Fuel Filter
  91
- Water Separating Prefilter XPI
  91
- Bleeding the Fuel System
  92
- Feed Pump
  94
- Can Bus Overview
  95
- Connection Point Can Pc VCU + Testman
  95
- Diagnostic Prosedure
  95
- Use of Diagnostic Kit, Tier 2
  95
- Connection Point SDP3 Scania Dagnostic
  96
- Renewing the Control Unit
  97
- Removing the ECU Wiring Tier2
  98
- Cylinder Head - PDE System Tier2
  102
- Cylinder Head, Parts View. PDE Tier2
  102
- Special Tools
  103
- Valve Mechanism
  104
- Dismantling
  109
- Renewing the Valve Stem Seal
  109
- Replacement of Valve Seats
  110
- Machining the Valve Seats Insert
  111
- Renewing the Valve Guides
  113
- Renewing PDE Unit Injector Sleeves
  114
- Assembly
  115
- Fitting
  115
- Common Rail Injectors Tier4/Xpi
  116
- Cylinder Head - XPI System Tier4
  117
- Cylinder Head, Parts View. XPI System Tier4
  117
- Injector Scania XPI
  118
- Order of Adjustment for 13 Litre Engines
  120
- Valve Adjustment DC13 with XPI
  120
- Cylinder Configuration, 6 Cylinder Engines
  121
- Valve Adjustment DC9 with XPI
  122
- Cylinder Configuration, 5 Cylinder Engines
  123
- Adjusting Unit Injectors
  124
- Valve Adjustment DC13 with PDE
  124
- Adjusting the Valve Clearance and Unit Injectors
  126
- Checking, Adjusting the PDE Injector and Rocker Arms
  127
- Checking, Adjusting the PDE32 Injector and Rocker Arms (I)
  128
- Valve Adjustment DC9 with PDE
  128
- Turbocharger
  129
- General
  130
- Changing Oil Filter
  131
- Checking Oil Level
  132
- Oil Analysis
  132
- Changing the Oil
  133
- Special Tools
  134
- Measuring Radial Clearance and Axial Clearance
  135
- Renewing the Turbocharger
  137
- Pistons and Cylinder Liners
  138
- Special Tools
  139
- Connecting Rods
  140
- Removing and Dismantling Connecting Rods and Pistons
  141
- Renewal of Bearing Bushing in Connecting Rod
  143
- Pistons
  145
- Assembling Piston and Connecting Rod
  147
- Cylinder Liner
  148
- Cylinderblock
  148
- Removing the Cylinder Liners
  150
- Measuring the Cylinder Liner Height
  151
- Measuring the Cylinder Wear Ridge and Cylinder Bore
  151
- Fitting the Cylinder Liners
  152
- Fitting the Piston and Connecting Rod
  153
- Flywheel and Flywheel Housing
  155
- Removing the Flywheel
  156
- Special Tools
  156
- Removing the Flywheel Housing
  158
- Renewing the Rear Crankshaft Seal
  158
- Fitting Flywheel Housing
  159
- Fitting the Flywheel
  161
- Gear Drive
  162
- Timing Gear, 13 Litre with Unit Injector
  162
- Belt Drive Collant Pump, Generator and AC Compressor
  163
- Checking the Drive Belt
  164
- Check for Leaks
  165
- Renewing the Seal in the Front Cover
  166
- Crankshaft Damper
  167
- Timing Gear, View Exploded
  168
- Special Tools
  169
- Intermediate Gear
  170
- Camshaft Gear
  173
- Crankshaft Gear
  174
- Camshaft
  175
- Replacement of Camshaft Bearing
  176
- Crankshaft
  183
- Removal
  184
- Fitting
  187
- Adjust - Machining the Crankshaft
  188
- Lubrication System
  189
- Oil Pump
  189
- Lubrication Oilways
  190
- Oil Pressure
  191
- Oil Cooler, Engine
  192
- Oil Cooler View Se 010009
  193
- Renewing Seals and Leakage Testing
  194
- Oil Filter
  195
- Centrifugal Oil Cleaner
  196
- Dismantling and Assembly
  197
- General
  201
- High Levels of Oil Carryover
  201
- Oil Mist Separator
  201
- Crankcase Pressure Measurement
  203
- Oil Mist Separator Exploded View
  204
- Oil Mist Separator Disassemble
  205
- Check - Rotational Speed on Oil Mist Separator
  207
- Alternator 100 a
  208
- Check
  208
- Output Test
  209
- Renewal - Bearing and Carbon Brushes
  212
- Exploded View
  216
- Oil Pump, Brake Cooling Circulate (DA40)
  216
- Disassemble and Overhaul the Oil Pump
  217
- Checking and Renewing Parts
  219
- Oil Circulate Pump Assemble
  220
- Renewing the Gasket
  223
- Cooling Fan
  224
- View of the Radiator System DA40
  224
- Cooling System
  225
- Principal View of the Cooling System
  225
- Circulation
  226
- Coolant
  227
- Checking Coolant Level
  228
- Changing Coolant
  229
- Checking the Antifreeze Level
  229
- Cleaning the Cooling System
  231
- Disassemble the Cooling Unit
  232
- Thermostat and Thermostat Housing
  234
- Thermostat
  235
- Coolant Pump
  236
- External Cleaning
  240
- Internal Cleaning
  240
- General Data
  241
- Technical Data DC13 with XPI
  241
- General Data
  243
- Technical Data DC9 with XPI
  243
- Technical Data DC13 with PDE
  245
- General Data
  247
- Technical Data DC9 with PDE
  247
- To Do
  250
- Troubleshooting ECOM / Canbus
  250
- Troubleshooting, -Basic Info
  250
- Troubleshooting Fuel System
  251
- Troubleshooting Guide
  251
- Troubleshooting Manual
  269
- Troubleshooting T4I Engines with High Nox Values
  270
- Work Description
  271
- The SCR System Is Unable to Build Pressure
  272
- Blocked Filter in the Bottom of the Tank Pick-Up Unit
  273
- Blocked Prefilter in the Doser
  273
- Leaking Tank Pick-Up Unit
  273
- White Smoke
  274
- White Smoke, Water Vapour
  274
- Black Smoke on Starting
  275
- Blue Smoke
  276
- Fuel in the Oil
  276
- Coolant/Water in Oil
  277
- Oil in Coolant
  277
- Low Oil Pressure
  278
- Abnormal Wear (Liner, Piston Rings, Etc.)
  280
- High Oil Pressure (Engine Warmed Up)
  280
- Vibration, no Driven Components Engaged
  281
- Vibration When Alternator Is in Operation
  282
- Vibration When the Clutch or Reverse Gear Is Engaged
  282
- Engine Speed Hunting - Single-Speed Engines with RQ Governor
  283
- Engine Speed Hunting - Single-Speed Engines with RSV Governor
  283
- Delivery Pipe Fractures
  284
- External Corrosion on Cylinder Liner
  284
- Engine Difficult to Start
  285
- Fluid Stroke
  286
- Knocking/Noise
  287
- High Oil Consumption
  288
- High Fuel Consumption
  289
- Low Compression
  289
- Low Engine Output
  290
- Hot Engine
  291
- Cold Engine
  292
- Coolant Loss
  292
- Polluted Coolant
  292
- High Exhaust Temperature
  293
- High Oil Temperature
  293
- Low Charge Air Pressure
  294
- Low Fuel Pressure
  294
- Low System Voltage
  294
- External Fuel Leakage
  295
- External Oil Leakage
  295
- High System Voltage
  295
- External Coolant Leakage
  296
- Oil Pressed out Via Crankcase Ventilation
  296
- Turbocharger Breakdown
  296
- Compressed Air System
  297
Chapter 2 Transmission Index

303
- General
  305
- Structure of the Repair Manual
  306
- Conversion Table
  307
- Denomination of Standard Dimensions
  307
- Table
  308
- Torque Limits for Screws
  308
- Information on Spare Parts Ordering
  309
- Labeling of Type Plate
  309
- Configuration of Transmission
  310
- Transmission Schematics and Gear Schematics
  310
- Measuring Points and Connections
  311
- Table
  311
- Clutch Calibration
  312
- Installation Sheet
  314
- Specjal Tools for Disassembly and Reassembly
  316
- Commercial Tools for Disassembly and Reassembly
  319
- Removal of Transmission, Disass'y
  323
- Disassemble the Hydraulic Hoses
  330
- Disassemble the Structure Bar
  330
- Positioning for Disassembly and Reassembly
  334
- LKV Axle Insert
  335
- Removal and Refitting Various Components
  335
- Transmission
  335
- Removal
  336
- Removal and Refitting of Speed Sensor N4-Output
  336
- Retting
  336
- Removal
  338
- Removal and Refitting of Solenoid Valves of Shifting Block II and Temperature Sensors
  338
- Retting
  339
- Disassembly
  341
- Disassembly and Reassembly of Shifting Block I and Speed Sensors
  341
- Reassembly
  345
- Removal and Refitting of LKV Axle Insert
  350
- Separation of LKV Axle Insert from Transmission
  350
- Attachment of LKV Axle Insert to Transmission
  351
- Exchange of Shaft Seal Ring Towards LKV Axle Insert
  353
- Fitting of Shaft Seal Ring
  353
- Removal of Shaft Seal Ring
  353
- Sealing of Outputs Towards Rear Axle and LKV Axle Insert
  353
- Fitting of Shaft Seal Ring
  354
- Transmission Assembly
  356
Drive Line

366
- Introduction
  368
- General
  369
- Structure of the Repair Manual
  370
- Conversion Table
  371
- Denomination of Standard Dimensions
  371
- Table
  372
- Torque Limits for Screws
  372
- Main Drive Line Components
  373
- Front Hub
  374
- Outer View and Section Drawing
  374
- Tools for WDB
  376
- Disassembly: Front Wheel Hub
  378
- Disassemble the WDB-Brake Housing
  383
- Reassemble
  388
- Adjust the Rolling Resistance of the Wheel Bearing
  391
- Installation of the Wet Multi-Disc Brake
  393
- Pre-Assemble the Return Mecanism
  394
- Installation of the Wheel Head
  399
- Check the Brake Chamber/Wheel Head for Leak Tightness
  407
- Leakage Test of Brake Hydraulics
  408
- WDB Cirquit Front Brake
  409
- Drive Shafts
  410
- Front Frame
  410
- Rear Frame
  411
- Mounting the Bearings on the Intermediate Shaft (B)
  412
- Front Differential and Transmission
  421
- Brakes
  422
- Service Brake Description
  423
- Testing of Parking Brake
  424
- Remove the Linings
  425
- Disassembly the Park Brake Unit
  427
- Assembly the Park Brake Unit
  428
- Adjust the Initial Caliper Clearance
  429
- Park Brake Maintenance
  430
- Troubleshooting Park Brake
  431
- Rear Differential
  435
- General Function
  436
- Illustrated Tables - Special Tools
  439
- Disassemble the TK-Differential
  440
- Safety Precautions
  440
- Disassemble the Differentilal from the Axle Housing
  441
- Disassemble the Boggi Unit from Frame
  444
- Dismantle Differential
  448
- Disassemble Drive Pinion
  449
- Assembly
  452
- Adjust Backlash
  466
- Examples of Gear-Tooth-Contact
  467
- Assemble the TK-Diff in the Axle Housing
  469
- Disassemble the Tandem Unit from the Rear Frame
  473
- Disassembling the Axle Housing from the Tandemhousing
  475
- DISASSEMBLY New Differential (Mod No. 8X0660)
  481
- Contact Pattern Examples of Gleason Tooth System
  503
- EXAMPLE 1: Dedendum Tooth Position
  504
- EXAMPLE 2: Dedendum Tooth Position
  504
- Example 3: „Line"Contact Pattern
  505
- Assemble the Tandem Housing Unit to the Rear
  508
- Outer View and Section Drawing
  511
- Rear Wheel Hub
  511
- Disassembly the Rear Wheel Hub
  513
- Assemble the WDB Rear Hub
  519
- Cooling Cirquit Rear Brake
  537
- Axle and Tandem Housing Bearing
  539
- Cross Section
  539
- Checking Clearance in the Tandem Bearing
  540
- View of the Tandem Bearing
  541
- Calculation of the Tandem Bearing
  543
- Disassemble Tandem Housing Unit
  544
- Safety Precautions
  544
- Disassemble the Tandem Unit from the Rear Frame
  545
- Disassembly the Axle Housing from the Tandemhousing
  547
- Disassemble the Tandem Bearings
  548
- Assemble the Tandem Housing to the Axle
  549
- Housing
  549
- Disassemble the Tandem Housing's Inside Parts
  552
- Assembly Piniong in the Tandem House
  561
- Tyres
  563

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