Moxy MT 26 Bedienungsanleitung
Engine
SHOP MANUAL MT26-31 - 06.2005
Tier-3 710655- Ch 1 page 1
Chapter 1
Engine
SHOP MANUAL MT26-31 - 06.2005
Engine
Tier-3 710655-
Ch 1 page 2
Chapter 1
Engine
Index
Removal of engine assembly ................................................................ 5
Lifting the engine.........................................................................................................................11
Engine identification............................................................................ 12
Fuel system .......................................................................................... 13
Schematic diagram of the fuel system ........................................................................................13
Overflow valve.............................................................................................................................13
General .......................................................................................................................................14
FUEL...........................................................................................................................................14
Fuel filter .....................................................................................................................................15
Water separating prefilter............................................................................................................15
Feed pump ..................................................................................................................................17
Diagnostic prosedure .......................................................................... 18
Use of diagnostic kit, machine ....................................................................................................18
Measurement ..............................................................................................................................21
Ecom standard settings code......................................................................................................24
Engine control unit, ECU ..................................................................... 27
Wiring and cable duct..................................................................................................................28
Throttle position sensor...............................................................................................................28
Positions of sensors for ECU ......................................................................................................29
Diagnostic lamp and switch.........................................................................................................31
Fault codes..................................................................................................................................32
How to read fault codes from the ECU control unit .....................................................................33
Flash codes tables ......................................................................................................................35
Overview of flash codes for coordinator......................................................................................37
Renewing the control unit............................................................................................................39
Removing the ECU wiring ..........................................................................................................40
Cylinder head ....................................................................................... 44
Special tools................................................................................................................................44
Cylinder head, parts view............................................................................................................45
Valve mechanism ........................................................................................................................46
Dismantling ................................................................................................................................51
Renewing the valve stem seal.....................................................................................................51
Replacement of valve seats ........................................................................................................52
Machining the valve seats insert .................................................................................................53
Renewing the valve guides ........................................................................................................55
Renewing PDE unit injector sleeves ...........................................................................................56
Assembly ....................................................................................................................................57
Fitting ..........................................................................................................................................57
PDE Injectors........................................................................................ 58
Fitting the PDE injector ...............................................................................................................58
Adjusting unit injectors ................................................................................................................62
Adjusting the valve clearance and unit injectors .........................................................................64
Checking, adjusting the PDE32 injector rocker arms (I)..............................................................65
Turbocharger ........................................................................................ 67
General ......................................................................................................................................68
Special tools................................................................................................................................69
Measuring radial clearance and axial clearance ........................................................................70
Renewing the turbocharger.........................................................................................................72
Continuation next page
Engine
SHOP MANUAL MT26-31 - 06.2005
Tier-3 710655- Ch 1 page 3
Pistons and cylinder liners.................................................................. 73
Special tools................................................................................................................................74
Connecting rods..........................................................................................................................75
Removing and dismantling connecting rods and pistons ............................................................76
Renewal of bearing bushing in connecting rod ...........................................................................78
Pistons ........................................................................................................................................80
Assembling piston and connecting rod .......................................................................................82
Cylinderblock........................................................................................ 83
Cylinder liner ...............................................................................................................................83
Removing the cylinder liners .......................................................................................................85
Measuring the cylinder liner height .............................................................................................86
Fitting the cylinder liners .............................................................................................................87
Fitting the piston and connecting rod ..........................................................................................88
Flywheel and flywheel housing........................................................... 90
Special tools................................................................................................................................91
Removing the flywheel................................................................................................................91
Renewing the rear crankshaft seal..............................................................................................93
Removing the flywheel housing ..................................................................................................93
Fitting flywheel housing...............................................................................................................94
Fitting the flywheel ......................................................................................................................96
Timing gears......................................................................................... 97
Gear drive ...................................................................................................................................97
Belt drive collant pump, generator and AC compressor..............................................................98
Renewing the seal in the front cover...........................................................................................99
Crankshaft damper....................................................................................................................100
Timing gear, view exploded.......................................................................................................101
Special tools ....................................................................................... 102
Crankshaft seal .........................................................................................................................103
Timing gear cover......................................................................................................................105
Intermediate gear......................................................................................................................107
Crankshaft gear ........................................................................................................................108
Camshaft gear ..........................................................................................................................109
Camshaft ............................................................................................ 110
Crankshaft .......................................................................................... 112
Lubrication system ............................................................................ 114
Oil pump....................................................................................................................................114
Lubrication oilways ..................................................................................................................115
Oil pressure...............................................................................................................................116
Oil cooler, engine .....................................................................................................................117
Oil cooler view...........................................................................................................................118
Renewing seals.........................................................................................................................119
Oil filter......................................................................................................................................120
Centrifugal oil cleaner ....................................................................... 121
Dismantling and assembly ........................................................................................................122
Cooling fan ......................................................................................... 126
Continuation next page
SHOP MANUAL MT26-31 - 06.2005
Engine
Tier-3 710655-
Ch 1 page 4
Cooling system .................................................................................. 127
View of the cooling system........................................................................................................127
Circulation .................................................................................................................................128
View of the radiator system.......................................................................................................128
Disassemble the cooling unit ....................................................................................................129
Thermostat and thermostat housing .........................................................................................131
Thermostat................................................................................................................................132
Coolant pump............................................................................................................................133
External cleaning ......................................................................................................................137
Internal cleaning........................................................................................................................137
Specifications..................................................................................... 138
General information...................................................................................................................138
Cylinder head............................................................................................................................140
Turbocharger ............................................................................................................................142
Pistons and cylinder liners ........................................................................................................142
Connecting rods........................................................................................................................143
Flywheel and flywheel housing .................................................................................................143
Timing gear ...............................................................................................................................144
Lubrication system ...................................................................................................................145
Troubleshooting tables ..................................................................... 146
White smoke .............................................................................................................................146
White smoke, water vapour.......................................................................................................146
Black smoke when running/under load .....................................................................................147
Black smoke on starting ............................................................................................................148
Blue smoke ...............................................................................................................................148
Fuel in the oil.............................................................................................................................148
Oil in coolant ............................................................................................................................149
Coolant/water in oil ...................................................................................................................150
Low oil pressure........................................................................................................................151
High oil pressure (Engine warmed up)......................................................................................153
Abnormal wear (liner, piston rings, etc.)....................................................................................153
Vibration, no driven components engaged................................................................................154
Delivery pipe fractures ..............................................................................................................155
External corrosion on cylinder liner ...........................................................................................155
Engine difficult to start...............................................................................................................155
Fluid stroke................................................................................................................................156
Knocking noise..........................................................................................................................156
High oil consumption.................................................................................................................158
High fuel consumption...............................................................................................................159
Low compression ......................................................................................................................159
Low engine output.....................................................................................................................159
Hot engine.................................................................................................................................161
Cold engine...............................................................................................................................162
Coolant loss ..............................................................................................................................162
Polluted coolant.........................................................................................................................162
Engine heater............................................................................................................................163
High oil temperature..................................................................................................................163
High exhaust temperature.........................................................................................................164
Low charge air pressure............................................................................................................164
Low fuel pressure......................................................................................................................165
Low system voltage...................................................................................................................165
High system voltage..................................................................................................................165
External oil leakage...................................................................................................................166
External fuel leakage ................................................................................................................166
External coolant leakage...........................................................................................................167
Oil pressed out via crankcase ventilation..................................................................................167
Turbocharger breakdown ..........................................................................................................167
Engine
SHOP MANUAL MT26-31 - 06.2005
Tier-3 710655- Ch 1 page 5
Removal of engine assembly
NOTE!
Place the dump truck on level ground and apply parking brake
Apply articulation lock.
Turn off main switch in battery case.
Raise the dump body and lock it with the safety support.
Raise the tiltable cab and lock it with the safety support
Drain engine coolant
Look in OPERATION & MAINTENANCE MANUAL chapter 2 for instructions.
Take away the cab bolt, left and right hand side.
Nv 46 mm
Turn the direction valve on the pump in lifting up
position.
Place wheel chocks to the front wheel
With the handle, pump and raise the cab.
SHOP MANUAL MT26-31 - 06.2005
Engine
Tier-3 710655-
Ch 1 page 6
Left side:
1
Disassemble the cab pump unit from the air filter stand.
2
Remove the water hose from the pipe socket.
3
Remove the fuel hoses (3 pcs) and
4
Disassemble screws from filter stand bracket
Right side:
1
Unscrew the hose clamps and remove the pipe bend,
filter - turbo
2
Disconnect the oil hose from engine brake cylinder and bracket
disassemble the other end at left side on the magnetic valve
3
Hook up the filter stand in lifting device.
4
Screw off the fastening bolt for filter stand,
left and right hand side
2
1
1
4
3
Disconnect the brake hose from the magnetic valve.
(Left side behind the cab bracket)
1
2
34
Engine
SHOP MANUAL MT26-31 - 06.2005
Tier-3 710655- Ch 1 page 7
Disconnect the exhaust pipe from the turbo pipe bend.
Disasssemble the cable to the Air filter sensor.
Disassemble the clamps for the wiring on the filter stand
SHOP MANUAL MT26-31 - 06.2005
Engine
Tier-3 710655-
Ch 1 page 8
Slack the transmission belt.
Disassemble the ground wiring.
Detach the Air Cond. compressor with the hoses on, from the
engine. Check that all of the clamps are undone.
Place the Air condition compressor on the left while the engine is
dismount.
Disconnect the hose from the termostathousing,
the pipe between the air cooler and the engine air inlet.
Disconnect bracket for the air pipe and bracket between engine
and fan rack
Disconnect the outlet pipe bend from turbo, and the inlet water
hose from the transmission cooler.
Disconnect the retur hose. (Engine - ekspantionstank)
(Quick release coupling)
(Front of the engine, view from the right hand side)
Engine
SHOP MANUAL MT26-31 - 06.2005
Tier-3 710655- Ch 1 page 9
Disconnect the contact on the dynamo.
Remove the cover and disconnect the electrical contact from the
engine ECU -S6 control unit
Disconnect the cables between starter motor and the frame
SHOP MANUAL MT26-31 - 06.2005
Engine
Tier-3 710655-
Ch 1 page 10
1
Disassemble screw for the ground cable (2 pcs)
2
Left and right hand side, disassemble 3 screws on the engine
mounting bracket.
2
1
1
2
1
Disassemble the hose clamp bracket.
2
Unscrew the engine bracket bolt left and right hand side.
1
2
Drive shaft
Remove safety atcher.
Remove driveshaft between transmission and engine coupling,
12
2
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1
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