Moxy MT 26 Installationsanleitung

Shop Manual MT 26/31

Part no 512967

Moxy articulated dump trucks are manufactured by MOXY ENGENEERING AS, Elnesvågen, Norway.

Tel. +47 71 26 85 00 Fax +47 71 26 85 50

www.moxy.no

Edition: Dec. 2004

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Contents

Shop Manual MT26/MT31

Chapter 0 General

Chapter 1 Engine Group

Chapter 2 Transmission

Chapter 3 Drive Line and Brakes

Chapter 4 Air System

Chapter 5 Hydraulic System

Chapter 6 Electrical System

Chapter 7 Front Wagon

Chapter 8 Rear Wagon

Chapter 9 Optional Equipment

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0 General .................................................................................................................. 4

0.1 Introduction .........................................................................................................................4

0.1.1 Important information on Industrial Safety .......................................................................4

0.2.1 Incidents are warning signals ...........................................................................................5

0.2 Workshop Safety ............................................................................................... 5

0.2.2 Vibrations ........................................................................................................................6

0.2.3 Injurious Noise .................................................................................................................6

0.2.4 Organic Solvents ..............................................................................................................7

0.2.5 Coolant .............................................................................................................................8

0.2.6 Refrigerant .......................................................................................................................8

0.2.7 Air Pollution ......................................................................................................................9

0.2.7 Liquid Or Gas Under High Pressure ..............................................................................10

0.2.8 Fire And Explosion Risks ...............................................................................................11

0.2.9 Asbestos ........................................................................................................................12

0.2.10 Lead .............................................................................................................................12

0.2.11 Jacked Up Vehicle Or Bodywork ..................................................................................13

0.2.12 Heavy Objects ..............................................................................................................13

0.2.13 Protection Against Damage And Injury .......................................................................13

0.2.13 More than one person working on the same Vehicle ...................................................14

0.2.14 Involuntary Start of Electric Equipment ........................................................................14

0.2.15 Rotating Parts ..............................................................................................................14

0.2.16 Splinters, Flying Object When Using Certain Tools ......................................................15

0.2.17 Springs Under Load .....................................................................................................15

0.2.18 Tyres and Wheels .........................................................................................................15

0.2.19 Precautions for Disassembly and Assembly Operations ..............................................16

0.2.19.1 Types of sealing-/locking Compounds and Lubricants used during Assembly ..........17

0.2.19.2 Torque limits for screws ............................................................................................18

0.2.20 Handling of Oil Seals ...................................................................................................19

0.2.21 Handling of Gaskets .....................................................................................................19

0.2.22 Handling of O-ring Seals ..............................................................................................20

0.2.23 Handling of Bearings ....................................................................................................20

0.3 Precaution before any Maintenance Operation .................................................................21

0.4 Location of Main Components ..........................................................................................22

0.5 Location of Drive Line Main Components .........................................................................23

Chapter 0 General

Index

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This Shop Manual is an aid for planning and performing quality repairs of your dumper truck, and giving the

service personnel information to obtain good overall knowledge on the dumper truck.

This manual will also serve as a useful reference for other personnel involved in the service of the dump truck.

Study, and make sure that you understand the manual and use it at every maintenance task you are going to

accomplish.

When using this manual, always have the Operation and Maintenance Manual at hand for references, and be

familiar with both manuals

Generally, the persons maintaining MOXY products are responsible for their own safety.

The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to

persons and to the product during maintenance and repair works.

Persons performing repair works must familiarize themselves with these regulations.

The proper repair of MOXY-products requires the employment of suitably trained and skilled personnel.

The mechanic is obliged to perform the training.

WARNING!_______________________

Symbols like this followed by a written warning serves as an attention to

special working procedures where care must be taken not to cause injury

to people, or damage to equipment !

Caution

Illustrations do not always represent the original equipment, just the working procedure is shown.

The illustrations are not always drawn to scale, and conclusions regarding size and weight must not be drawn

(not even within one representation).

The tasks must be performed according to the description.

0.1 Introduction

0 General

0.1.1 Important information on Industrial Safety

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Purpose

This section is intended as general information about dangers of various types of workshop activities.

Follow the workshop manual

This shop manual provides instructions for work methods and equipment that reduces the risk of

accidents.

Mechanical skill

This is a very important factor. The Moxy-mechanic is skilled and well trained for his job.

Without these qualities, risks are much greater and more difﬁcult to anticipate.

Common sense

This characteristic should form the basis of activities in the workshop.

Negligence and carelessness cannot be allowed.

Work with a safety margin

Always expect that something can go wrong during the work.

Always work with a safety margin where there are risks.

Legislation and local rules

In most countries there are legislation and local practices that apply to safety at work. Follow them at all times.

Warnings (parts or packages)

Always read and follow warnings and instructions.

Do not trust your own knowledge of the risks. The properties of a part or the chemical composition of a product

could have been changed during transit.

You have to know where the risks are

In this way you can avoid them. In many cases, risks are so obvious that you do not have to search for them,

e.g. carbon monoxide - true it is invisible, but you know that it is lethal. Therefore protect yourself.

The hidden dangers

Dangers are found in all work environments and the most serious danger is in not being aware of them.

The three demands of safety

* Knowledge: You have to know your job and also where the risks are.

* Apprehension: You must be aware that you are exposed to risks.

* Caution: You have to protect yourself, do not take chances.

0.2.1 Incidents are warning signals

An incident is an unforeseen event without injury or damage.

The next time the consequence of the same event may be worse.

An incident demonstrates that there is a risk. Every incident must be taken as a warning signal - exactly as if

there had been an accident or someone had been taken ill.

Look out

Do not trust others to point out the hazards. It is difﬁcult to remember all pointers and exhortations. New and

unexpected risks may also occur.

Therefore; look out!

As a guide, a number of examples follow. They are not to be regarded as a comprehensive listing.

0.2 Workshop Safety

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When using vibrating tools e.g. chisel hammer, impact drill,

impact nut runner, grinder injuries may be sustained by transition

of tool vibrations to the hands.

Risks

Vibrations may cause vascular spasms (prickling and pain) in the

surface veins. The ﬁngers turn white, cold and senseless. Also

nerves, muscles, bones, sinews and joints may be injured.

The risk of injury is believed to increase by smoking and also

by low temperatures e.g. if the tools are cold or if the hands are

exposed to chilling air.

The injuries become apparent especially when the ﬁngers are

cold, often when not working.

Vibration injuries are curable if taken care of in time.

Protective measures

Use heavy gloves. Gloves provide some protection

against vibrations and low temperatures.

Alternate between vibration-free and vibrating jobs to provide the

body with a possibility to rest from vibrations. By varying the work

posture and grips, the body is not one-sidedly exposed to vibra-

tions.

Avoid smoking before and during the work to help the blood cir-

culation as much as possible. If you notice any signs of vibration

injury consult a doctor.

Protection against vibration

• Heavy gloves

• Alternate jobs

• Do not smoke before and during the work

Rule of thumb: Noise that is louder than 85 dB (A) and that

prevails for more than 8 hours is classed as injurious. (Some

countries have other limits.) High frequency noise (high-pitched)

is more injurious than low frequency noise (low-pitched) of the

same amplitude.

Risks

Partial deafness, in difﬁcult cases impaired hearing beyond cure.

It is impossible to train your tolerance to noise. You may believe

that you are doing that if you notice less of the noise after some

time.

IN THAT CASE YOU ARE REALLY IN DANGER.

Probably your sense of hearing is already impaired.

Protective measures

With noise absorbers on roof and walls and screens between

work places it is easier to limit the propagation of noise. Against

injurious noise you have to protect yourself with ear muffs. Ear

muffs must be tested and approved.

Protection against noise:

• Use ear muff

0.2.2 Vibrations

0.2.3 Injurious Noise

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Organic solvents are mixtures of organic liquids (different from

e.g. water) that dissolve grease, paint, varnish, wax, oil, glue,

rubber etc.

Examples:

• Petroleum spirit

• Toluene

• Trichlore ethylene

• Thinner

• Petrol

• Alcohols

• Xylen

• Plastics and appertaining glues

Risks

Solvents release fumes. Fumes may cause dizziness, loss of

balance, headache and nausea. Fumes may also irritate the

windpipe.

Solvent exposure may also lead to injury to the central nervous

system. This may result in insomnia, depressions, nervousness,

poor memory and a general sense of feeling tired.

When solvents come in direct contact with the skin, it will

become dry and cracked. The risk of skin allergies increases

and, additionally, there is a risk of a solvent causing dermatitis.

Many solvents are ﬂammable.

Protective measures

As a ﬁrst measure, arrange for ventilation that prevents fumes

from mixing with the air you breath. Note that the ventilation has

to be ﬁre-proof if a solvent is ﬂammable.

If a problem cannot be resolved with ventilation it is necessary to

wear either a face mask or breathing protector with ﬁlter against

dust and organic fumes.

Never leave tins with paint or solvent uncovered.

Use solvent with low content of aromatics. This reduces the risk.

Ensure that solvents do not come into contact with the skin and

do not use them as detergent.

Use gloves when working. Gloves of certain materials can be

penetrated by the solvent or even dissolved by such solvents.

Make certain that the gloves give sufﬁcient protection.

Protection against organic solvents:

• Fireproof ventilation

• Face mask or breathing protection with ﬁlter

• Replace caps/lids

• Use as harmless solvents as possible

• Avoid contact with the skin

• Do not wash the skin with solvent

• Use gloves

0.2.4 Organic Solvents

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Coolant is used in the engine cooling system.

Risks

The cooling system is pressurized when hot.

Coolant that leaks or bursts out may cause scalding. Coolant

consists of water and corrosion inhibitor, and if necessary, anti-

freeze. The anti-freeze may consist of ethylene glycol.

Ethylene glycol and corrosion inhibitor are injurious and danger-

ous to consume. Splashes in the eyes are dangerous and, in

contact with the skin, such substances can penetrate and cause

dermatitis. Coolant may also consist of other mixtures that may

imply other risks.

Protective measures

If possible, avoid working with coolant lines and containers when

coolant is still hot. Remove the ﬁller cap carefully to release the

pressure. Hot steam and coolant may burst out.If there is a risk

of splashing you must use rubber gloves and protective goggles.

Change clothes if coolant has splashed on them. Contact with

the skin may be dangerous.

Use special equipment for draining and ﬁlling e.g.a. cart with

container and pump. It is not permitted to dump coolant in sewer

systems or on the ground.

Protection against coolant

• Preferably wait until coolant has become cold

• Remove ﬁller cap carefully

• Use rubber gloves and protective goggles

• Use special equipment for draining and ﬁlling

Refrigerants are used in various thermal equipment e.g. the air

conditioning.

Risks

Refrigeration equipment operates under pressure. A refrigerant

that is leaking may cause frost-bite.

A refrigerant that is leaking and exposed to heat e.g. by a weld-

ing ﬂame or cigarette, evaporates and is very dangerous to

breath.

Protective measures

Always use special equipment when draining or ﬁlling refrigera-

tion equipment. This reduces the risk of leakage. Do not loosen

connections on refrigeration equipment without ﬁrst draining the

system or reducing the pressure. Avoid welding and smoking

when carrying out work that implies a risk of leakage.

Leaking refrigerant is not noticed as the gas is practically odour-

less. The gas is heavier than air and therefore a portable air

evacuator at ﬂoor level is suitable.

Protection against refrigerant

• Use special equipment for draining and ﬁlling

• Drain system before loosening connections

• Avoid smoking and naked ﬂame

• Use portable air ventilator

0.2.5 Coolant

0.2.6 Refrigerant

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Examples:

• Carbon monoxide present in exhaust fumes

• Nitric oxide - present in exhaust fumes

• Welding fumes, especially from galvanized or

painted metals.

• Oil mist (e.g. in anti-corrosion treatment)

• Sulphuric acid mist

(e.g. when charging batteries)

• Grinding dust and fumes formed when grinding

and heating plastic, varnish, anti-corrosive,

lubricants, paint etc.

Risks

Carbon monoxide reduces the ability of the blood to supply the

brain and other parts of the body with oxygen.

Carbon monoxide poisoning = “Internal asphyxiation”.

Nitric oxides and gases and the fumes from

plastic, varnish, anti-corrosive, lubricants, paint etc. may damage

the lungs.

Oil mist from certain oils may cause skin problems such as

blemishes, boils and eczema.

Sulphuric acid mist is erosive and may damage the windpipe.

Protective measures

Avoid running engine indoors. Immediately attach evacuation

equipment to the exhaust pipe if an engine has to be kept run-

ning indoors.

Also parking heaters admit exhaust fumes when

in operation (portable air evacuator is suitable).

Use plastic gloves and breathing protection if there is a risk of

oil mist (e.g. anti-corrosion treatment). Before start of work, treat

unprotected skin with protective cream that does not dissolve in

oil.

Ensure that the ventilation is satisfactory where you weld,

charge batteries or apply anti-corrosives.

If necessary, also complemented with portable air evacuator.

When working with eroding substances (e.g. when charging bat-

teries) there must be a possibility for rinsing the eyes.

Protection against air pollution

• Ventilate properly. Use portable air evacuator

when welding.

• Preferably avoid running engines indoors.

• Use evacuation equipment if engines have to be

run indoors.

• Use protective gloves and breathing protection if

there is a risk of oil mist.

• Avoid contact with the skin.

• Ensure that there are facilities to rinse the eyes

when working with eroding substances.

0.2.7 Air Pollution

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Risks

There are risks, for instance, when working with:

• Fuel system

• Hydraulic system

• Brake system

• Compressed air

Dangerous - in what way?

• Spray can penetrate the skin and cause serious

tissue injury

• Eyes may sustain serious injury

• Many substances may cause poisoning

• Air and other gases blown into the rectum may

cause serious, sometimes fatal injuries

• Leak testing or test pressurizing with

compressed air or other gas may cause

explosion

Protective measure

Do not work with pressure in the system unnecessarily. First

stop the pump and release remaining pressure carefully.

Use goggles. Gloves are preferred.

Never use compressed air or other gas to blow dirt from the

clothes.

Use liquid for testing leaks (of e.g. oil cooler).

Protection against gas and liquid under pressure

• Use goggles and gloves.

• Do not work with pressure in the system if not

absolutely necessary.

• Be careful when handling compressed air.

Pipes etc. may become damaged when working and liquid

or gas may burst out. Liquid or gas may also burst out when

loosening a connection.

High pressure may remain in the system even if a pump has

stopped.

Gas containers for e.g. welding gases may explode if

exposed to rough handling e.g. when dropped on a hard

surface.

Valves may be damaged and gas leak out if a gas tube is

dropped.

0.2.7 Liquid Or Gas Under High Pressure

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