Daewoo Novus M2SEF, Manual

Page 1: ...re the most enjoyable safe and trouble free operation of your vehicle When it comes to service remember that your TATA DAEWOO dealer knows your vehicle best and is interested in your full satisfaction...

Page 2: ...F CONTENTS 1 HOW TO HANDLE THE VEHICLE 2 DRIVING 3 INSPECTION AND MAINTENANCE 4 TROUBLE SHOOTING AND CORRECTIONS 5 MISCELLANEOUS CONTROLS AND OPTIONS 6 SPECIFICATIONS AND SERVICE https www truck manua...

Page 3: ...OF CAB TILT 3 OPENING OR CLOSING OF FRONT LID 4 INSTRUMENTS AND CONTROLS 1 Attachments of steering column 2 Peripheral devices of steering column 3 Instruments and indicator lamps 4 Controls of center...

Page 4: ...5 000km Every 15 000km Lubricants When this vehicle was released engine oil added with abrasive material was used for its diesel engine DE DV So make sure to change the engine oil after the first 1 00...

Page 5: ...d be performed ac cording to CONTROLS AND INSTRU MENTS and BEFORE DRIVING OFF MTA0050 4 In order to operate your vehicle safely and dependably it is imperative to perform ne cessary inspection and adj...

Page 6: ...d damage electrical fuel injection system ECU 3 minutes of engine warming up is enough in winter time 2 Cautions for engine abnormalities during driv ing 1 Check Engine indicator indicates engine s ma...

Page 7: ...Seat belts should be adjusted as firmly as possible 5 Do not wear seat belts low under your shoul der 6 If you replace your seat belts incorrectly you may be injured by hardwares of the belts at sudd...

Page 8: ...ide of the cab before manipulating it Recommended cab tilt oil Specifications EQUIVIS ZS15 manufactured by ISU MTA1191 Caution Be sure to use recommended cab tilt oil replenish ment 2 How to lift the...

Page 9: ...ption 1 Pull forward lock lever located at the lower right hand side of the rear of the cab while lifting the hook and then the lock will be released Hook Lock lever MTA1240 tilting position MTS0190 M...

Page 10: ...lower the cab Hydraulic cab latch option 1 Position the direction change lever in D posi tion 2 Press the switch as shown and then the pump works and the cab starts to descend 3 Once the cab descended...

Page 11: ...of the front part and then the front lid becomes unlocked 3 Pull the front lid to open 5 3 4 2 1 MTA1160 MTA1140 MTA1171 4 Opening the front lid enables you to easily check top up or clean the followi...

Page 12: ...or inside knob 11 Power window switch 12 Instrument panel 13 Controls of center console 14 Radio and cassette tape holder 16 Side mirror adjusting switch option 17 Front lid opening lever 18 Combinati...

Page 13: ...K The key can be inserted or removed only when the switch is in this position 2 ACC This position turns on the radio digi tal clock cigarette lighter and consent 3 ON This position turns on the electr...

Page 14: ...that the corresponding turn signal lamp operates and causes the turn signal indicator lamp on the instrument panel to flash The switch lever returns automatically to the neutral position when the stee...

Page 15: ...he windshield wipers are simultaneously operated for 2 3 cycles Exhaust brake switch The exhaust brake system is designed to shut off exhaust pipe when the engine brake is ap plied resulting in assist...

Page 16: ...0733 2 Differential lock switch L R If it is difficult to get your vehicle out of the mire even by using the differential lock switch which distributes power to both front and rear axles operate the d...

Page 17: ...alve knob releases the brake Make sure that the indicator lamp is off KPAR before driving off K E R A G B RK I N P A BW HPUS MTA0290 ascending position MTA0300 6 Idle control knob For DE DV engine Tur...

Page 18: ...Side mirror adjusting switch MTA0320 8 Side mirror adjusting switch option Side mirrors can be adjusted by using this switch from inside your vehicle Press the angle adjust button with arrow marks to...

Page 19: ...gauge 8 Bulb check switch warning lamps 1 Temperature gauge The gauge indicates the engine coolant temperature If the gauge needle stands below the red colored zone it means that engine coolant temper...

Page 20: ...ge needle indicates the normal condition Caution If the gauge needle stands in the red zone warn ing lamp comes on and alarm buzzer sounds Im mediately stop the vehicle check for unusual con ditions r...

Page 21: ...pressed warning lamp on instrument panel comes on And also the warning buzzer sounds Before driving use this switch to check that all warning lamps and their circuits are operating normally MTA0420 8...

Page 22: ...Exhaust Working lock lever high Trailer brake lamp P T O FRT RR range ABS ASR ASR ENG ASR TRAILER CRUISE ABS SPEED LOCK T M BRAKE PTO LIMIT BRAKE SPLIT Trailer hand Cruise ABS Differential Speed Lock...

Page 23: ...e seat belt warning lamp comes on when the ignition switch is placed in the ON position unless the driver s seat belt is se curely fastened MTA0561 Parking brake indicator lamp The parking brake indic...

Page 24: ...oblem occurs Such problems are to be displayed Caution Inactive codes These codes will be flashed on the Check Engine light CEL When code flashing is initiated it means that your vehicle can be operat...

Page 25: ...rear fog lamp indicator and external fog lamps are turned on when the rear fog lamp switch is pressed ON MTA0651 Front fog lamp indicator lamp The fog lamp indicator and external fog lamps are turned...

Page 26: ...sitioned ON while it goes out when the preheating is completed MTA0621 High beam indicator lamp The high beam indicator lamp comes on when head lamps with high beam are in use MTA0661 Exhaust brake in...

Page 27: ...or lamp comes on MTS0461 ABS indicator lamp This is a device designed to shorten brak ing distance and to prevent slippage on a rain wet road ice covered road or road of abnormal condition It is lit w...

Page 28: ...N position the corresponding in dicator lamp comes on and the warning buzzer goes off which indicates that both left and right axles are in differential opera tion Caution Before operating your vehicl...

Page 29: ...f abnormal condition It is lit when there is an irregularity within TRAILER ABS MTS0593 ASR indicator lamp When the vehicle is accelerated on the slip pery road or uphill ASR optimize the adhe sion be...

Page 30: ...Active codes These codes will be flashed on the Stop Engine light SEL When code flashing is initiated it means severe engine problem In this case take a proper measure for the engine before continuin...

Page 31: ...oster switch 4 Cab tilt enable switch The vehicle that the hydraulic cab lock option system is applied 5 Power take off switch 6 Heating and air conditioning control 7 Radio and cassette tape player 1...

Page 32: ...8 9 seconds 2 When the lift descend 30 40 seconds Caution 1 for 25ton cargo truck actuating the reversing gear with the self steer lowered will raise the selfsteer 2 When laden a cargo refer to the fi...

Page 33: ...m occurs SEL Stop Engine light for ac tive codes andCEL Check Engine light for inactive codes will be flashing in the order of most recent to least recent occurrence based on engine hours so as to ind...

Page 34: ...high Turbo boost sensor input voltage low Oil pressure sensor input voltage high Oil pressure sensor input voltage low Fuel pressure sensor input voltage high Fuel pressure sensor input voltage low T...

Page 35: ...ons are not to be effective in this case 1 How to read engine diagnostic codes Code 21 CEL Inactivecodes CEL CEL CEL 2 Flashes 1 Flash The process of flashing all the inactive codes will repeat until...

Page 36: ...switch RES INC SET DEC MTA0716 is activated results in increase of vehicle speed Vehicle speed will be maintained constantly when de pressing the switch Pressing brake or clutch pedal will disengage...

Page 37: ...ctuates 4 Jake Brake cylinders while turning the switch on console box to ON actuates 2 Jake Brake cylinders The operator is required to elect the Jake Brake correctly according to the road condition...

Page 38: ...fan control switch can control the speed of air flow in 4 steps 1 OFF MTA0760 MTA0770 B Air direction control switch This switch allows you to change the direction of air flow Airflowsinthroughthecent...

Page 39: ...the vehicle Recirculation switch position ON Circulation switch position OFF Ventilation Air conditioning switch OFF Recirculation switch OFF Temperature switch As required Fan control switch As requ...

Page 40: ...due to traffic jam or for any other reasons a long time use of this operation may cause battery discharge Normal cooling Air conditioning switch ON Recirculation switch OFF Temperature switch As requi...

Page 41: ...T U N E A ME F C BND LUD f e n m l k j i h g MTA0860 a Liquid crystal display LCD b EJECT button c Tape insertion d Program switching button Fast forward rewind button e Seek Preset A ME button f Band...

Page 42: ...k Preset button Use buttons No 1 6 to store the desired broadcasting stations or select the stored Press FF button for last winding of the tape in the tape advancing drection For fast winding in reve...

Page 43: ...Selecting a station using the preset button Press the button to which the desired frequency is stored Channel number and frequency appear on the press 1 FM1 CH LCD panel press 2 FM1 CH MTA0870 Storin...

Page 44: ...right side to turn on the power 2 Use the VOLUME and TONE control knob to select the desired sound 3 Insert the tape into the tape deck while pointing the tapehead to the right hand side Radio functio...

Page 45: ...T M LO LO HI HI MEA0292 MTA0920 After manipulating the HI LO adjusting switch attached to knob without changing the position of gearshift lever depress the clutch and then release it to change gears...

Page 46: ...Use this brake lever when preparing to reduce only trailer speed on a downhill MTA0930 Accelerator pedal To avoid unnecessary increase in fuel con sumption the accelerator pedal should be operated smo...

Page 47: ...UP NEUTRAL MEA0300 DOWN Dump control lever for 19 24ton dump truck If the dump control lever is placed into the UP or DOWN position after the PTO lever is pulled up at this time the dump control lever...

Page 48: ...overheated it may cause a fire MTA1000 Consent 12V option Use this consent for other convenience electric appliances Caution Be sure to switch off these convenience electric appliances when leaving y...

Page 49: ...ON OFF 3 Center lamp ON OFF The light is turned on when a door remains open MTA1030 Reading lamp The reading lamp switch is located at the rear upper side of the cab It is used to illuminate the cab w...

Page 50: ...rning a door knob open and close the ap propriate door window Caution When closing a door window exercise care so that your hand or head is not caught in it MTA1041 Power window switches one touch opt...

Page 51: ...amp 3 Trun signal lamp 4 Parking lmap 5 Clearancel lamp and conering lamp 6 Sub trun signal lamp 1 5 2 MTA1071 6 5 Rear lamp tractor 1 Turn signal lamp 2 Parking lamp clearance lamp and stop lamp 3 Ba...

Page 52: ...0km h 2 right Yellow green above 81km h 3 middle Red MTA1090 Auto door lock switch deluxe This switch locks or opens both the driver s door and co driver s door simultaneously MTA1110 MTA1100 Remote s...

Page 53: ...ll not be used for the purpose of parking 2 Activate air parking brake valve before operating this lever 3 Air pressure is subject to drop by leakage after long hours when engine is off Activated when...

Page 54: ...2 STARTING AND STOPPING THE ENGINE 3 BEFORE DRIVING OFF 4 WHEN DRIVING OFF 5 DRIVING FOR ECONOMY 6 WHILE TRAVELING 7 TRAVEL ON HIGHWAY 8 OPERATION AND CARE IN HOT WEATHER 9 OPERATION AND CARE IN COLD...

Page 55: ...MMENDED LUBRI CANTS and wait a while to check the level again Also check for purity and viscosity of the oil before replenishing it 3 Always check the oil level with the vehicle parked on level ground...

Page 56: ...to be overheated and consequently exploded 3 Check also the wheel pin nuts on the wheel for looseness Caution Tighten to specified torque 60 65kg m as exces sive tightening torque may cause damage to...

Page 57: ...st indicator installed on the face of the battery Test indicator State of charge Correction Green Normal Use Black Low charge level Recharge Transparent Low electrolyte level Replace MTS0100 3 If the...

Page 58: ...ight can cause premature damage to the bearings of its periph eral devices Follow these procedures to adjust the fan belt tension 1 1 DE Engine First loosen the air con com pressor bolt then adjust th...

Page 59: ...dle the engine at the normal speed rpm until the normal operat ing temperature is reached Caution 1 Avoid unnecessary idling as prolonged idling may accelerate wear of valves pistons and pis ton rings...

Page 60: ...ansmission lever is in neutral polsition with parking brake applied before stat ing the engine 2 ECM automatically controls idling RPM consid ering ambient air oil coolant temperature Manual adjustmen...

Page 61: ...operation 5 Avoid unnecessary idling of the engine when it reaches normal temperature Caution Abrupt start during warming up operation may shorten the engine life 6 After warming up the engine bring...

Page 62: ...MTB0240 more then 10 seconds have passed under turning the streeing wheel fully to the right or left on en gine idle 2 Parking brake Before travel manipulate the parking brake valve to check for its m...

Page 63: ...35mm Pedal free play should be 15mm Make brake pedal adjustment by using the adjusting bolt fitted to the pedal Also check the brake warning lamp switch for its electrical contact 15mm MTB0290 7 Door...

Page 64: ...could be reduced when keeping it in a partially engaged condition 2 Don t start the vehicle when the level of collant engine oil and powersteering oil lowers beyond the MIN marked level MTB0330 5 DRIV...

Page 65: ...f trouble was not located check at your nearest Daewoo dealer MTB0350 4 If the air pressure falls below 5 3kg cm2 stop the engine and check to locate the cause of trouble MTS0380 MTB0441 5 The engine...

Page 66: ...d condi tion causing premature wear of clutch facing TMB0390 8 Stop your vehicle completely when attempting to STOP R 1 2 3 4 5 6 7 8 shift into reverse Note When change to 1st or reverse gear would b...

Page 67: ...angerous to drive your vehicle with tires whose treads have been worn out excessively because the vehicle may lose traction Limit of use The depth of the tread grooves should be more than 3 2mm Note Y...

Page 68: ...your vehicle s speed by at least 10km h greater than the speed of the vehicle ahead Before preparing to pass be sure to check the traffic behind you and then pull out into the left lane promptly with...

Page 69: ...spect and clean each part and check for leakage and oil levels 8 OPERATION AND CARE IN HOT WEATHER 1 Cooling system How to wash off cooling system Open the drain cock of radiator to drain off the rema...

Page 70: ...e Fill up the coolant circulation system with a 50 MTB0460 50 mixture of specified antifreeze and water in all seasons 3 Precautions when using antifreeze 1 Wash off the inside of the cooling system i...

Page 71: ...nt temperature between the atmosphere and inside of fuel tnak Drain the wa ter in the fuel tank and the fuel filter more than two times a month as sedimetal water can make engine end fuel lines damage...

Page 72: ...INSPECTIONANDMAINTENANCE 1 DAILY CHECK BEFORE DRIVING 2 PERIODIC INSPECTION AND MAINTE NANCE 3 PERIODIC INSPECTION CHART 4 IN CASE OF EMERGENCY 5 VEHICLE REPAIR https www truck manuals net...

Page 73: ...ressure 3 Running Wheels and tires 1 Damage or looseness of bolts and nuts 2 Damage or severe wear of wheels and tires and tire inflation pressure 4 Suspension Chassis spring Damage of spring and tigh...

Page 74: ...oil capacity standard level when changing to gether with oil filters 2 Engine oil filter Engine oil filter element should be changed together with engine oil at the same time DE engine is of cartridg...

Page 75: ...ution Overtightenting may distort or crack the filter adaptor Model DE DV DDC Changeintervals At end of first 1 000km Short distance travel in city every 10 000km Long distance travel at high speed ev...

Page 76: ...13L 5 Rear axle oil 1 Oil level check Check oil level at end of first 1 000km and there after every 4 000km for new vehicle and re Filler level plug Oil level plenish if the oil remains below the lev...

Page 77: ...rn the steering wheel slowly in both direction 2 Tighten the joint bolts securely and fill the oil tank to the specified level with the specifed fluid 3 After 2 3 minutes lower the front wheels to gro...

Page 78: ...ystem for fluid leakage Before running check the steering wheel works smoothly and unusual sound is not heard 5 Change of oil filter element Oil filter element of paper type shall be changed at the sa...

Page 79: ...out the element Handle the element carefully so as not to cause damage to it 2 Blow the dust particle away by directing compressed air to the inner face of element MTC0150 Caution Caution For the dump...

Page 80: ...ement intervals for air cleaner depend on the conditions of working area dust earth or sand and contamination or deformation of the element Replace in a timely manner Be sure to replace it every 48 00...

Page 81: ...e over tightening can damage the threads 3 Replacement 1 Clean the area around fuel filter head It is strongly advisable to use genuine Daewoo fuel filter element 2 Remove the fuel filter 3 Remove the...

Page 82: ...h clean fuel oil 4 Thread the new filters onto the adaptors until they make full contact with the gasket and no side movement is evident Then rotate an additional one half turn by hand Caution Overtin...

Page 83: ...tighten the air bleeder screw of fuel filter 5 Hold down and then pull up the fuel pump cap repeatedly to check fuel supply resis tance To close the cap press it firmly down and turn it clockwise 6 Af...

Page 84: ...2 10 Fuel return pipe 11 Fuel suction pipe 9 12 Fuel feed pump 13 Injection pump MDC0071 Fuel system diagram DV engine 4 3 6 6 572 9 1 8 MDC0072 1 2 3 4 5 6 7 8 9 Fuel tank Strainer Fuel filter Air bl...

Page 85: ...mm Intake 0 25mm Exhaust 0 35mm Intake 0 203mm Exhaust 0 660mm 3 Adjustment of valve clearance Loosen the lock nut of rocker arm adjusting screw insert a rated clearance gauge in between the rocker ar...

Page 86: ...CYL 2 VALVES CYL 5 INJ HEIGHT CYL 5 VALVES CYL 2 INJ HEIGHT CYL 3 VALVES CYL 4 INJ HEIGHT Caution Never set the valves and injector of the same cylin der at the same time Doing this will result in en...

Page 87: ...ry 24 000km MTC0260 MTB0470 13 Change of coolants Drain the coolant by opening the radiator drain cock engine water drain cock and oil cooler cover plug After completely draining off close the drain c...

Page 88: ...aced with new ones every 24 000km operation How to replace elements 1 Close the coolant filter inlet and outlet shut off valves 2 Remove and discard the element 3 Clean the filter adapter with a clean...

Page 89: ...TC0300 MEC0050 tance between the initial position of the pedal and the point where a strong resistance is felt 2 Adjustment of free play 1 Master cylinder a Disconnect the clutch pedal return spring b...

Page 90: ...requently check and re place them and contact your nearest Daewoo dealer if necessary 2 Adjustment of brake lining clearance Full air type Insert a 0 3mm feeler gauge into the lining clearance through...

Page 91: ...edal depressed loosen the bleeder half a turn to discharge air mixed clutch fluid and tighten it immediately 5 Repeat the above steps of operation until air bubbles disappear completely from the fluid...

Page 92: ...130 PSI Overinflation 5 7 3 1 8 6 5 7 3 MTC0370 1 10 8 6 2 Tire rotation Tire wear depends on tire position road con ditions or a habit of applying brakes To avoid unbalanced wear of your tires and to...

Page 93: ...ack as shown MEC0060 6x4 series 1 Front wheel 2 Rear front wheel 3 Rear rear wheel 4 1 2 3 4 Spare tire MTC0420 19ton cargo 19ton dump vehicle 1 Front front wheel 1st shaft 2 Front rear wheel 2nd shaf...

Page 94: ...ear wheel 2nd shaft 3 Rear front wheel 3rd shaft 4 Rear rear wheel 4th shaft 5 Spare tire 1 2 3 4 5 1 2 3 MTD0430 4 MTC0431 10x4 series 1 Front front wheel 1st shaft 2 Front rear wheel 2nd shaft 3 Sel...

Page 95: ...ort cap sus upper left 2 Bracket support cap sus upper right 3 Change lever 4 1st relay 5 2nd relay 6 Drag link front 7 Drag link rear 8 King pin left upper 9 King pin right upper 10 King pin left low...

Page 96: ...2 Bracket support cap sus upper right 3 Change lever 4 1st relay 5 2nd relay 6 Drag link front 7 Drag link rear 8 King pin left upper 9 King pin right upper 10 King pin left lower 11 King pin right lo...

Page 97: ...22 Spring pin inter left 23 Spring pin inter right 24 Spring pin rear left 25 Spring pin rear right 26 Shackle front left 27 Shackle front right 28 Shackle rear left 29 Shackle rear right 30 Transmis...

Page 98: ...C0601 1 Brake cam shaft right 2 Brake cam shaft left 3 Slack adjuster right 4 Slack adjuster left 5 King pin right upper 6 King pin right lower 7 King pin right upper 8 King pin right lower 9 Tie rod...

Page 99: ...MAINTENANCE 5 Greasing points nipples Use a greasing pump to inject every 15 000km of grease to each nipple King pin MTC0440 Drag link MTC0450 Inside spline shaft of steering column MTC0460 https www...

Page 100: ...N AND MAINTENANCE Gearshift control rod to gearshift lever MTC0480 Gearshift control rod to cab lower MTC0490 Gearshift control rod to frame MTC0500 Spring pins and shackle pins MTC0510 https www truc...

Page 101: ...INSPECTION AND MAINTENANCE Spring pads MTC0520 Trunnion shaft MTC0530 Front wheel brake chamber and slack adjuster MTC0540 Rear wheel brake chamber and slack adjuster MTC0550 https www truck manuals...

Page 102: ...3 97 INSPECTION AND MAINTENANCE Propeller shaft universal joints and slid ing sleeve MTC560 Tie rod ends MTC570 Front and rear hubs MTC0580 P T O Drive shaft MTC0581 https www truck manuals net...

Page 103: ...equipment Therefore it is essential to remove moisture from compressed air in or der to extend the service lives of devices to enhance reliability and to prevent possible dam age or breaks 2 Features...

Page 104: ...ir dryer and change dessicant oil filter cloth filter and whole rubber parts Check air tubing and wiring connec tions 5 Operation of air dryer Season Spring Summer Autumn warm or hot weather Winter co...

Page 105: ...with compressor in unload cycle air can be leaked through the main tank drain Correction Check and drain the main tank until the des iccant is dried up Increase pressure for governor to 6 45 DR 5 7 2...

Page 106: ...lamps or headlamps never touch the surface of MTC0630 the new halogen bulb by hand Bulbs Description Wattage Model Number Remarks Fog lamp 55W Halogen 2 Front combination lamp Rear combination lamp H...

Page 107: ...d on the external part of the cab Pre heater unit chime bell unit DE12TIS ECU unit 2 Fuses corresponding starter key Fuse to F Relay and unit R each position of the power relay unit and Keyless entry...

Page 108: ...iper system E C U power Meter power E C U power Fuel heat Headlamp with high beam Headlamp with F10 10A Foglamp F21 10A Reciver clock F32 15A low beam Taillampsand F11 20A Power window F22 10A Bed hea...

Page 109: ...key OFF Constant power source ACC ON MTS0111 Fuse No F2 F3 F4 F5 F8 F7 F9 3 Designations of fuses No Capa Use No Capa Use F1 F2 F3 F4 F5 30A 20A 50A 50A Headlamp with high beam Headlamp with low beam...

Page 110: ...rear part of alternater 2 After check the contact state of fuse Test indicator Green Black State of charge Normal Low charge level Correction Use Recharge blink should be review whether re charging o...

Page 111: ...not permit any metal tools to make contact between the positive battery terminal and other metal on the vehicle 5 When installing the battery do not incline it above 45 Caution Be sure to remove batt...

Page 112: ...d in the glove box near the assistant driver s seat 2 Then the solenoid valve is energized to allow ether pressurized within the ether cylinder to spray through valve metering orifice tubing and nozzl...

Page 113: ...e valve or the cylinder 7 Tighten an additional 11 2 turns 540 Retighten the cylinder clamp 8 Reset the LCI by passing a magnet over the designated reset area 3 or 4 times The lamp should flash indica...

Page 114: ...k Inside wash Coolant change Include artifreeze Inside wash CLUTCH Functions Pedal free play stroke Booster mini pack exhaust cover clean Clutch fluid Change TRANSMISSION Oil leakage Oil change Except...

Page 115: ...Brake function Check Brake pedal free play Check Air leakage from brake system Wear of linings Wear and damage of brake drum Leakage and damage of hoses and pipings Wheel cylinder Check Brake fluid Ch...

Page 116: ...ts Air compressor Lubricating oil filter Replace Fuel filter Replace Coolant filter inhibitor level Replace Air system Exhaust system Engine steam clean Radiator air to air intercooler Oil pressure Ba...

Page 117: ...arking brake and turn on the emer gency warning lamp to prevent possible safety hazard MTC0751 2 Emergency starting 1 Avoid starting the engine while your vehicle is being towed as it may collide with...

Page 118: ...propel ler shaft from rear axle flange to tightly fix the propeller shaft to the frame 3 When damage is found at the differential gear or rear axle gear remove the rear axle shaft before your vehicle...

Page 119: ...ater to electrical devices connectors air hose etc 2 Wash off water on the door to prevent it from being frozen making it unable to open in the cold area 3 Do not apply thinner or gasoline for the cle...

Page 120: ...4 TROUBLESHOOTING AND CORRECTIONS 1 ENGINE AND RELATED PARTS 2 CHASSIS AND RELATED PARTS 3 ELECTRICAL 4 DUMP https www truck manuals net...

Page 121: ...ed cleaner element Insufficient pre heating Pre heat again Tire underinflated Correct Air in fuel injection lines Bleed Engine overcooling Cover radiator with curtain Air cleaner element Clean or chan...

Page 122: ...connections Steering wheel shimmy Cause Correction 4 DUMP Loose hub nuts Left and right hand tires are different in inflation pressure Irregular tire wear Poor brake action Cause Tire overinflation T...

Page 123: ...SEAT 3 AUTO GREASER 4 TURBO CHARGER 5 ZF TRANSMISSION 6 OPERATION OF DUMP SYSTEM 7 OPERATION OF TRACTOR TRAILER 8 BULK CEMENT TRACTOR 9 SELF STEER 10 HYDRAULIC DEVICE FOR CAR CARRIER 11 TOOL LIST 12...

Page 124: ...5 9 11 12 10 14 1 Key hole 2 Speed indicator lamp 3 Hour hand 4 Speedometer needle 5 Odometer 6 Clock check window 7 Clock graduations 8 Minute hand 9 Speed recording needle 10 Vibration recording me...

Page 125: ...during cargo delivery It is shown that the vehicle was frequently driven at high speeds to travel a short distance This will result in uneconomical operation e The vehicle was put to stop for 20 minu...

Page 126: ...er MTF0040 3 Remove the recording chart paper set by depressing and turing the retaining ring anti clockwise Fig 1 2 If the paper is handled roughly at the time of removal the chart paper cutter will...

Page 127: ...urning it clockwise while depress ing it Fig1 2 Open the lid and then put the recording chart paper after alignment the hole of recording chart paper with the hole of tachograph Fig3 MTF0141 7 Replace...

Page 128: ...ad To release it depress the brake pedal to release air from the air tank then manipulate the seat lock lever 3 4 Lumbar support adjustment buttons These buttons are used for properly adjusting the se...

Page 129: ...te to contact your nearest workshop or service center of the manufacturer Vogel This is an electronic device designed to de tect the internal part of the system for its func tions and troubles and to...

Page 130: ...tt brand DE DV DDC 1 2 1 Caution Be sure to follow the instructions on 1 Starting after oil and oil filter are changed or in winter where oil viscosity becomes higher or the engine is left unattended...

Page 131: ...engine is idled at low speed of 600 650 rpm for prolonged time a sufficient amount of oil cannot be distributed to the turbo charger resulting in premature wear of the rotating part due to lack of lub...

Page 132: ...re is needed for it 1 Care of air cleaner Clean or change the air cleaner element as required to prevent premature wear and damage to the compressor blades and drive portion of the turbo charger due t...

Page 133: ...ir leak from some point between compressor housing and intake manifold Air leak from some point between intake manifold and engine cylinder Obstructions in intake manifold Obstructions in muffler or e...

Page 134: ...t Selector fork Planetary gears for range change group Input shaft Output shaft Lay shaft P T O Splitter 4 speed section with Range group reverse gear change group H 1st gear L H 2nd gear L H 3rd gear...

Page 135: ...or valve 2 Hi Low switch 9 Indicator switch for neutral position 3 Clutch pedal 10 Indicator switch of range change group 4 Master cylinder for hydraulic clutch actuation 11 Intergrated shift cylinder...

Page 136: ...11 14 13 2 Air tank 3 15 10 6 7 8 9 1 Knob 2 Splitter group relay valve 3 4 2 way valve 4 Cut off valve 5 Shift housing 6 Intergated shift cylinder for range change group 7 Speed L joint 8 Speed limi...

Page 137: ...e gear do so after the vehicle is stopped completely Otherwise gears may be damaged If gears are abruptly changed to low range at high engine rpm or especially when gears are changed abruptly from hig...

Page 138: ...ously At this time do not apply unnecessary force to change gears MTF0311 4 How to change ranges ZF 16S 221 T M a In low range 1st 4th gears change ranges in the same manner as for typical transmis si...

Page 139: ...an be prevented Optimum operation economy can be obtained Examples of the use of splitter To produce sufficient engine output when passing a vehicle ahead or driving on an uphill or it is difficult to...

Page 140: ...clutch is not engaged or disengaged com pletely or if the clutch discs have been exces sively worn gearshift problems will occur In ad dition wear on the synchronizers and at the gear teeth and dogs...

Page 141: ...and d as shown Namely it should be operated at the position e a How to identify the point where the clutch is completely disengaged With the engine on and the vehicle being sta tionary apply the reve...

Page 142: ...o drain the tank quickly or you cannot unscrew the plug located on the 4 speed section open the plugs located on range change section and splitter section to drain oil 3 Breather The breather installe...

Page 143: ...ugh it has been de pressed a Check the oil tank for the clutch master cylinder for clutch oil level b Bleed air through the air bleeder installed on the clutch booster c In the event of no effect obta...

Page 144: ...he P T O lever and con trol lever which are installed at the left hand side of the driver s seat Telescopic cylinder Oil tank Stabilizer MTF0580 NEUTRAL UP Dump control lever DOWN P T O lever MTF0590...

Page 145: ...pressed and the PTO lever is pushed up with the engine at idle and gearshift lever in the neutral position the dump control lever is turned to Neutral position simulta neously and the PTO indicator is...

Page 146: ...he NEUTRAL position The control lever and deck operate irrespectively of gear pump rotation P T O lever MTF0640 2 When attempting to stop the deck for a long in terval in the middle of ascending or de...

Page 147: ...to the vehicle with the deck raised or stopping suddenly the deck in the middle of descending may cause damage to dump system and in the worst case even to the deck frame or main frame of the vehicle...

Page 148: ...deck raised be sure to support it with safety posts and chock the wheels for your safety MTF0700 5 Avoid raising the deck on a downward slope MTF0710 6 Avoid raising the deck on a unpaved road or in...

Page 149: ...e hydraulic oil level reaches the high level of the sight glass with the dump control lever placed in the DOWN position and the deck lowered completely it is normal 3 Changing of hydraulic oil with th...

Page 150: ...7 Air bleeding of dump system The dump system has no specific screw for air bleeding When a slight amount of air has entered the hoist cylinder perform the deck ascending and descending operation sev...

Page 151: ...t In the same manner slightly loosen and then retighten the hose on the hoist cylinder side Caution Check each joint on the dump system then perform bleeding operation If the dump system has abnormali...

Page 152: ...ollows 1 6 2 7 8 3 45 MTF0770 No 1 2 3 4 5 6 7 8 Greasing points Lifting bracket right and left Chassis bracket right and left Rear gate locking device right and left Deck hinge right and left Rear ga...

Page 153: ...rs the inside of the turning direction in a large way Watch out behind you through the rear view mirror while turn ing your tractor trailer 2 Jack knife phenomenon Jack knife phenomenon will occur if...

Page 154: ...ing pin is fitted 30 50 mm lower than the upper face of coupler MTF0420 Caution If the king pin plate is fitted higher than the upper face of the coupler and there is clearance between them unsatisfac...

Page 155: ...per cable Harness If air leaks is found from the connecting a b c MTF0460 sections after connecting the air hoses do again the connecting operation a 5 Jumper cable Harness a White Earth b Black Spare...

Page 156: ...he tractor and trailer have been connected MTF0490 satisfactorily with each other 2 Make sure that all the lamps on the trailer operate properly 3 Operate the engine to check if the oil pres sure is n...

Page 157: ...port leg on ground surface in the case that the trailer is not of a mechanical type Sequence MTF0520 2 When disconnecting the air hoses first sepa rate the emergency line red Separating the emergency...

Page 158: ...e trailer will be disconnected from each other MTF0560 5 Checking after connecting the tractor and 3 trailer After completing the connection of the tractor and 1 2 4 Coupler lock 5 6 MTF0570 trailer c...

Page 159: ...0575 the base and jaws Also the end of yoke shaft protrusion from base should be en gaged into the base and adjust nut and base should contact together via cushion rubber At the same time the lever A...

Page 160: ...oupler MTF0572 Section 1 MTF0573 Section 2 MTF0574 2 At 3 of rolling angle Pull back the rolling angle adjust lever to section 1 then turn it 90 in any direction Caution Be sure to match both right an...

Page 161: ...5 154 MISCELLANEOUS CONTROLS AND OPTIONS 8 BULK CEMENT TRACTOR External view of BCT MTF0780 https www truck manuals net...

Page 162: ...very pipe 4 Intake cover 8 Air cleaner MTF0780 Specifications of compressor Descriptions Specifications Items Model VS 715 Type Delivery capacity Working pressure RPM Flow rate Overall height Weight O...

Page 163: ...pulley to the compressor as shown in the following diagram The rotor which draws in and discharges air recip rocates at 90 degrees Engine Trans mission PTO Rotor Drive shaft Connecting rod Pulley low...

Page 164: ...causing various damage to the compressor 5 If water enters the air breather on the crankcase when cleaning the compressor lubricating func tionality is disabled 6 Intake filter element If the filter...

Page 165: ...lied will not damage the connecting rod Therefore causes for damage are as follows Restricted oil filter obstructing oil flow Restricted tube for the oil injection port Air existing in the tube for th...

Page 166: ...valve and or exhaust valve Replace 2 Cause Detached carbon Adhere the carbon 3 Cause Carbon sticked 4 Cause Load applied to suction filter Replace Lubricating oil change Oil injection port 1 Check for...

Page 167: ...ths months year years years Unusual sound Abnormal vibration Compressor RPM Operation of safety valve Oil level in Compressor oil case Suction filter element Oil change Strainer cleaning Loose mountin...

Page 168: ...not getting the correct lift Pusher steering opposite direction than truck Possible cause Not having the proper air pressure to load bags Air control system not properly installed Mounted too high De...

Page 169: ...and enlarged nylon tube 2 Increased Air tank volume 8x4 with lifting axle 811 221x4EA 10x4 Cargo 961 3 Securing parking brake ability 8x4 with lifting axle Secured parking brake ability with lock bra...

Page 170: ...sure is then trans ferred to the unit of the car carrier and its pressure is maintained below 4 solenoid relief valve preset pressure 100kg cm2 Operation of solenoid valve is activated by a switch on...

Page 171: ...for Replacement Every 1 year after initial change at 3 months Replace it with the oil MTF1030 Hydraulic hose for connection 1 This is connecting to the plug and socket coupler on the car carrier unit...

Page 172: ...MTF0890 Name Handle S Tire Carrier 100x200x610 Oil jack asm w lever Plier Wrench monkey Spanner 7x8 Spanner 10x12 Spanner 14x17 Spanner 19x22 Q ty 1 1 1 1 1 1 1 1 Vehicle model All vehicles other tha...

Page 173: ...el nut 41x 24 1 All vehicles 11 MTF0950 Handle wrench wheel nut 1 All vehicles 12 MTF0960 Cab tilt lever 1 19ton 19 5ton 20 5ton 21ton 22 5ton 25ton cargo 19ton 24ton dump All vehicles except above ve...

Page 174: ...se F30 15A 2 Special harness available for working lamp switch is located at the inside pannel of black Working lamp MTF1070 MTF1080 out lamp switch 3 Special harness available for working lamp is loc...

Page 175: ...ed at the inside glove box MTF1110 Caution In the case that customer will use electric equipments mounted to other position beside harness for custom ers Ask service center autorized by Daewoo because...

Page 176: ...SPECIFICATIONS AND SERVICEDATA 1 LOCATION OF CHASSIS NUMBER AND ENGINE NUMBER 2 MAIN DATA 3 RECOMMENDED LUBRICANTS https www truck manuals net...

Page 177: ...DAEWOO parts or servicing MDA0031 Chassis number The chassis number is stamped on the front face of the right hand chassis frame DE Engine DV Engine MTA0100 Engine number MDC0080 DDC Engine Engine num...

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Page 222: ...Deck inside Length Width Height Volume m 3 Min ground clearance 7 745 2 495 3 060 2 050 1 855 4 605 1 080 2 930 1 100 3 170 290 4 900 2 300 900 10 270 WEIGHTS kg Chassis weight Front Rear Total Curb w...

Page 223: ...mm 11 051cc Mechanical Dry paper elements CLUTCH Type Plate diameter Hydraulic control with air assisted Dry single plate with diaphragm Outside diameter 430mm 17 TRANSMISSION Model Speed Gear ratio...

Page 224: ...PENSION Type Size L W Semi elliptical leaf spring 1 300mm 90mm BRAKE Service brake Drum diameter Lining Front Rear Material Parking brake Auxiliary brake Air dryer Full air brake with dual circuit 410...

Page 225: ...g reclining Equipped with head rest Rigid type semi folding reclining Equipped one bed Tricot WIPER Type Two blade 3 speed wiper with electrical washer HEATING Heater Defroster GLASS MIRROR Windshield...

Page 226: ...Deck inside Length Width Height Volume m 3 Min ground clearance 7 745 2 495 3 080 2 050 1 855 4 605 1 080 2 930 1 070 3 205 290 4 900 2 300 900 10 275 WEIGHTS kg Chassis weight Front Rear Total Curb w...

Page 227: ...142 mm 14 618cc Mechanical Dry paper elements CLUTCH Type Plate diameter Hydraulic control with air assisted Dry single plate with diaphragm diameter 430mm 17 TRANSMISSION Model Speed Gear ratio T16S...

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Page 238: ...pler height CH Min ground clearance Swing radius Forward Rearward 6 190 2 495 2 915 2 050 1 855 3 700 960 2 915 1 065 2 710 500 1 270 Opt 1 328 260 1 875 1 635 WEIGHTS kg Curb Weight Front Rear Total...

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Page 242: ...pler height CH Min ground clearance Swing radius Forward Rearward 6 925 2 495 2 915 2 050 1 850 4 540 710 2 915 1 075 3 100 270 1 295 Opt 1 355 275 2 480 2 070 WEIGHTS kg Curb Weight Front Rear Total...

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Page 246: ...pler height CH Min ground clearance Swing radius Forward Rearward 6 925 2 495 2 915 2 050 1 850 4 540 710 2 915 1 075 3 100 270 1 305 Opt 1 365 275 2 480 2 070 WEIGHTS kg Curb Weight Front Rear Total...

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Page 250: ...BTDC 12 1 5 3 6 2 4 5 0 33 Gear Water cooled Full flow Wax pallet 20L 39 6L 24V 6 0kw 24V 45A SERVICE DAT DE12TIS ke 6 16 8 m pm 145kg m 1 260r BTDC 1 8 1 22 d Felt filter TA DV15T V type 90 4 str di...

Page 251: ...5 22L 19ton dump 80L 24ton dump 120L 4x2 6x4seriestruck 6L SSK201 API GL 5 SAE 80W90 Tropical region specifications API GL 5 SAE 85W 140 thermostat open 71oC ISOVG32 Power steering Power steering oil...