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Moxy MT 26 Shop Manual

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Table of Contents

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Shop Manual MT 26/31
Part no 512967
Edition: Dec. 2004
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

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Summary of Contents for Moxy MT 26

  • Page 1 Shop Manual MT 26/31 Part no 512967 Edition: Dec. 2004 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...
  • Page 2 CH 0 CH 0 GENERAL GENERAL PAGE PAGE 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...

  • Page 3: Table Of Contents

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE Chapter 0 General Index 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...

  • Page 4: General

    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.

  • Page 5: 0.2.1 Incidents Are Warning Signals

    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.

  • Page 6: 0.2.2 Vibrations

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.2.2 Vibrations 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.

  • Page 7: 0.2.4 Organic Solvents

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE 0.2.4 Organic Solvents 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 •...

  • Page 8: 0.2.5 Coolant

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.2.5 Coolant 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.

  • Page 9: 0.2.7 Air Pollution

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE 0.2.7 Air Pollution 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) •...

  • Page 10: 0.2.7 Liquid Or Gas Under High Pressure

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.2.7 Liquid Or Gas Under High Pressure Risks There are risks, for instance, when working with: • Fuel system • Hydraulic system • Brake system • Compressed air Dangerous - in what way? •...

  • Page 11: 0.2.8 Fire And Explosion Risks

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE 0.2.8 Fire And Explosion Risks Examples of flammable and explosive substances are: • Oil • Petrol • Diesel fuel • Organic solvents (varnish, plastic, detergents) • Anti-corrosive • Acetylene and other gas for welding and heating Actions causing fire and explosions: •...

  • Page 12: 0.2.9 Asbestos

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.2.9 Asbestos The dust that is emitted by brake and clutch linings partly consists of asbestos fibres. Risks Asbestos dust that is inhaled may cause lung diseases and cancer in various organs. The risk of contracting lung cancer is considerably more acute for people who smoke.

  • Page 13: 0.2.11 Jacked Up Vehicle Or Bodywork

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE 0.2.11 Jacked Up Vehicle Or Bodywork Risks Mechanical or hydraulic lifting equipment may topple and could also be lowered because of incorrect handling or inter- ference. Falling objects may also cause crushing. Protective measures Do not crawl underneath a vehicle that is jacked up without securely supported.

  • Page 14: More Than One Person Working On The Same Vehicle

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.2.13 More than one person working on the same Vehicle If more than one person is working on the same vehicle, involun- tary movements could injure another person. Protect others who work on the same vehicle •...

  • Page 15: Splinters, Flying Object When Using Certain Tools

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE 0.2.16 Splinters, Flying Object When Using Cer- tain Tools Risks Burr loosens from drift or chisel. Hammer head loosens from handle. Flying objects when using grinder, cutting discs etc. Protective measures Use goggles. Gloves are preferred. 0.2.17 Springs Under Load - Balancing springs for bonnets etc.

  • Page 16: Precautions For Disassembly And Assembly Operations

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.2.19 Precautions for Disassembly and Assem- bly Operations Disassembly Before attempting to disassemble, determine the cause of the trouble by systematically checking and analysing the symptoms. Needless disassembly will not only hinder troubleshooting, but will also result in losses through unnecessary replacement of parts and man-hour costs.

  • Page 17: Types Of Sealing-/Locking Compounds And Lubricants Used During Assembly

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE Apply thread locking (see table for sealing/locking compounds) to important bolts. Prior to coating with sealing or locking compound, wash the bolt with light oil/ trichlorethylene or other fluid recommended by the manufacturer. Tighten bolts in the prescribed sequence figures evenly to the specified torque.

  • Page 18: 0.2.19.2 Torque Limits For Screws

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.2.19.2 Torque limits for screws TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF STANDARDS 148 treatment as well as phosphatized Friction value: µ total= 0,12 for screws and nuts without after nuts.

  • Page 19: 0.2.20 Handling Of Oil Seals

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE 0.2.20 Handling of Oil Seals Be careful to install an oil seal with its lips in the right direction as shown below. Before installing an oil seal, coat it with grease to prevent dry-friction, which may occur during the break-in operation of the machine, according to the following procedure: a) In case of a double-lip type, uniformly coat the surface of...

  • Page 20: 0.2.22 Handling Of O-Ring Seals

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.2.22 Handling of O-ring Seals Replace a seal, if rust exists on the circumference of its contact surface. Apply a thin coat of oil to the contact surfaces when installing a seal. Insert the o-ring in the housing groove taking care not to twist the o-ring.

  • Page 21: 0.3 Precaution Before Any Maintenance Operation

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE 0.3 Precaution before any Maintenance Operation Study and carry out Maintenance Precautions according to Operation and Maintenance Manual, Chapter 7. Place dumper in the shop maintenance area, preferably on a clean, level concrete floor and with the facilities to make the necessary heavy lifts involved during the maintenance operation.

  • Page 22: 0.4 Location Of Main Components

    CH 0 CH 0 GENERAL GENERAL PAGE PAGE 0.4 Location of Main Components Tail Gate Dumper Body Roof Hat Fuel tank Bonnet Tilt Cylinder Hydraulic Tank Head/Parking Bonnet Light/ Lock Turn Signal light Fig 8.1 Location of Main Comoponents SHOP MANUAL MT26/31 - 12.2004 SHOP MANUAL MT26/31 - 12.2004...

  • Page 23: 0.5 Location Of Drive Line Main Components

    GENERAL GENERAL CH 0 CH 0 PAGE PAGE 0.5 Location of Drive Line Main Components Tandem ReductionGear Rear Dif- ferential Main Hydraulic Pump Transm- isson Engine Parking Brake Rear Brakes Intermediate Shaft Front Differential Reduction Gear Front Brake Fig 8.1 Drive Line Overview SHOP MANUAL MT26/31 - 12.2004 SHOP MANUAL MT26/31 - 12.2004...
  • Page 24 CH 0 GENERAL PAGE SHOP MANUAL MT26/31 - 12.2004...
  • Page 25 Engine Ch 1 Tier-3 710655- page Chapter 1 Engine SHOP MANUAL MT26-31 - 06.2005...
  • Page 26 Ch 1 Engine Tier-3 710655- page 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...
  • Page 27 Engine Ch 1 Tier-3 710655- page 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 ..................8 Cylinderblock ..................
  • Page 28 Ch 1 Engine Tier-3 710655- page Cooling system .................. 127 View of the cooling system ......................17 Circulation ..........................18 View of the radiator system .......................18 Disassemble the cooling unit ....................19 Thermostat and thermostat housing ..................131 Thermostat ..........................13 Coolant pump ..........................133 External cleaning ........................137 Internal cleaning ........................137 Specifications ..................

  • Page 29: Removal Of Engine Assembly

    Engine Ch 1 Tier-3 710655- page 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 &...
  • Page 30 Ch 1 Engine Tier-3 710655- page Left side: Disassemble the cab pump unit from the air filter stand. Remove the water hose from the pipe socket. Remove the fuel hoses (3 pcs) and Disassemble screws from filter stand bracket Disconnect the brake hose from the magnetic valve. (Left side behind the cab bracket) Right side: Unscrew the hose clamps and remove the pipe bend,...
  • Page 31 Engine Ch 1 Tier-3 710655- page Disasssemble the cable to the Air filter sensor. Disassemble the clamps for the wiring on the filter stand Disconnect the exhaust pipe from the turbo pipe bend. SHOP MANUAL MT26-31 - 06.2005...
  • Page 32 Ch 1 Engine Tier-3 710655- page 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.
  • Page 33 Engine Ch 1 Tier-3 710655- page Disconnect the cables between starter motor and the frame Disconnect the contact on the dynamo. Remove the cover and disconnect the electrical contact from the engine ECU -S6 control unit SHOP MANUAL MT26-31 - 06.2005...
  • Page 34 Ch 1 Engine Tier-3 710655- page Drive shaft Remove safety atcher. Remove driveshaft between transmission and engine coupling, Disassemble screw for the ground cable ( pcs) Left and right hand side, disassemble 3 screws on the engine mounting bracket. Disassemble the hose clamp bracket. Unscrew the engine bracket bolt left and right hand side.

  • Page 35: Lifting The Engine

    Engine Ch 1 Tier-3 710655- page Lifting the engine Note: The engine lifting eyes are designed for lifting the engine only, not the engine together with its ancillary equipment (alternator, gearbox etc.) or fram 8394 8373 Lever block Lifting chain - Fasten the lifting chain 8373 to the rear lifting eyes.

  • Page 36: Engine Identification

    Ch 1 Engine Tier-3 710655- page Engine identification TYPE DESIGNATIONS The engine type designation indicates, in the form of a code, the type of The engine designation indicates, in the form of a code, the type of engine, its size and applications, etc. engine, its size and applications, etc.

  • Page 37: Fuel System

    Engine Ch 1 Tier-3 710655- page Fuel system Schematic diagram of the fuel system 1 Feed pump  Hand pump 3 EMS control unit 4 Fuel filter 5 Cylinders 6 Fuel tank 7 Return line for excess fuel A Check valve B Gear pump (feed pump) C Safety valve D Pressure relief valve...

  • Page 38: General

    Ch 1 Engine Tier-3 710655- page General Apart from fuel lines and a fuel tank, a PDE (Pumpe-Düse-Einheit) fuel system with unit injectors consists of the following items: • a feed pump • a hand pump • a fuel filter •...

  • Page 39: Fuel Filter

    Engine Ch 1 Tier-3 710655- page Fuel filter Design Fuel filter are of single-mounted type. The filter screw on to a retainer which is bolted to the engine. The filter consists of a metal container with a folded paper ele- ment.
  • Page 40 Ch 1 Engine Tier-3 710655- page Temperature dependence of diesel fuel Warning At temperatures lower than those specified for the diesel fuel, paraffin wax may precipitate from the fuel and block It is not permitted to mix filters and pipes. The engine can then loose power or stop. kerosene with diesel fuel that is The diesel fuel is adapted for use in the specific climate of already adapted for the climate...

  • Page 41: Feed Pump

    Engine Ch 1 Tier-3 710655- page Feed pump The feed pump 1 draws fuel from the fuel tank and forces it through the fuel filter 3 and into the fuel rail 4. On the feed pump there is a hand pump . The hand pump is used to vent air from the fuel system.

  • Page 42: Diagnostic Prosedure

    Diagnostic prosedure Use of diagnostic kit, machine Install the VCI (ECOM programming unit) Moxy No.513376 1. Switch on the laptop. . Connect the cabel end (1) to the CT1 unit 3. Connect the USB plug () to the Laptop 4.
  • Page 43 Engine Ch 1 Tier-3 710655- page Diagnostic Fault Master Codes Slave Measurement Diagnostic Faul Codes ECU Info/ID ECU Identification Data Logs Program EEPROM To read the fault codes in the coordina- tor (EMS COO.) EST 37 Tacho (CANbus conne- ction) The CT1 has following func- tions: Connection point for all CAN-...

  • Page 44: Measurement

    Ch 1 Engine Tier-3 710655- page Diagnostic Fault Codes Read out fault codes Measurement ECU Info/ID Data Logs Measuring of valves Engine Test Adjusting of parameters SHOP MANUAL MT26-31 - 06.2005...
  • Page 45 Engine Ch 1 Tier-3 710655- page Measurement Boost pressure - filtered value Boost pressure - filtered value Boost pressure - filtered value 1. Move text line from the A section to B . Start the logging by the start button 3.
  • Page 46 Ch 1 Engine Tier-3 710655- page Counter Status (YYYY-MM-DD:SS) Description 000 Active -001--1--1-1-1 Engine temp sensor, sensor signal> 4 90 VI< -40°C SHOP MANUAL MT26-31 - 06.2005...
  • Page 47 Engine Ch 1 Tier-3 710655- page Example to change temp alarm and warning: Go to S6 ---> E ---> Program E parameter. Read values. Go to the column for values, find the line for engine temp and change the value. Then go to the "button"...

  • Page 48: Ecom Standard Settings Code

    Ch 1 Engine Tier-3 710655- page Ecom standard settings code From Main Menu, Select: Program E parameters Read values Make changes Write values Typical Description Limits Unit Value Value FE17 Low idle, ref engine speed 0 - 300 Low idle, ref engine speed controller. 0 - 1 0 = use basic low idle, adjustable with CC-buttons FE1...
  • Page 49 Engine Ch 1 Tier-3 710655- page Typical Description Limits Unit Value Value Reaction due to low oil pressure 0, 1, , 6 0 = Alarm only FCB7 1 = Torque limitation  = Stop engine 6 = Stop engine with override option Reaction due to high coolant temperature 0, 1, , 3, 0/1/6...
  • Page 50 Ch 1 Engine Tier-3 710655- page Typical Description Limits Unit Value Value PTO mode 1, accelrator pedal effective 0 - 1 FCA1 0 = Active 1 = Not active FD11 PTO mode 4, max torque 0 - 5100 5100 5100 Low idle to adjust fuel adjustment.

  • Page 51: Engine Control Unit, Ecu

    Engine Ch 1 Tier-3 710655- page Engine control unit, ECU This engine has an electronic management system, ECU Engine Control Unit (also called EMS, Electronic Management System) with unit injectors (PDE) which provide each cylinder with the right amount of fuel at the right time in all operating situations. The ECU system consists of a control unit (S6) and sensors for speed, charge air temperature and pressure, coolant temperature, oil pressure, accelerator pedal/throttle actuation which constantly emit signals to the con- trol unit.

  • Page 52: Wiring And Cable Duct

    Ch 1 Engine Tier-3 710655- page Wiring and cable duct 1 Cylinder 1–6  Coolant temperature sensor 3 Engine speed sensor 1 on flywheel 4 Engine speed sensor  on flywheel 5 Connector to control unit 6 Charge air pressure and temperature sensor 7 Oil pressure sensor Throttle position sensor A throttle position sensor need to be added to the system.
  • Page 53 Engine Ch 1 Tier-3 710655- page Positions of sensors for EMS with S6 on DC9 Positions of sensors for ECU Coolant temperature sensor 1. Oil pressure sensor Oil pressure sensor . Sensor for charge air temperature and pressure Sensor for charge air temperature and 3.
  • Page 54 Ch 1 Engine Tier-3 710655- page SHOP MANUAL MT26-31 - 06.2005...

  • Page 55: Diagnostic Lamp And Switch

    Engine Ch 1 Tier-3 710655- page Diagnostic lamp and switch The diagnostics lamp comes on for one (1) second when the system is started. The diagnostics lamp will be lit continuously while a fault code is active. With the aid of the diagnostics switch, the diagnostics lamps flash out any fault codes.

  • Page 56: Fault Codes

    Ch 1 Engine Tier-3 710655- page Fault codes Troubleshooting using flash codes for the ECU control unit • The diagnostics lamp for the control unit always comes on for a second when the system is powered up. • As soon as a fault is detected by the control unit, a fault code is stored in the EEPROM and the diagnostics lamp for the control unit (the left-hand lamp on the instrument panel) lights up.

  • Page 57: How To Read Fault Codes From The Ecu Control Unit

    Engine Ch 1 Tier-3 710655- page How to read fault codes from the ECU control unit Reading fault codes for the ECU control unit: The instructions below explain how to read fault codes in the form of flashes from the diagnostics switch. You can see how to interpret the flash codes on the next page.
  • Page 58 Ch 1 Engine Tier-3 710655- page How to erase fault codes from the ECU control unit The control unit memory has sufficient space to store 40 fault codes. The fault codes are stored in two different places in the control unit. Erasing with the diagnostic switch erases the fault codes that are flashed on the diagnostic lamp.

  • Page 59: Flash Codes Tables

    Engine Ch 1 Tier-3 710655- page Flash codes tables This is a list of the flash codes which can be read and the fault codes to which they correspond. One flash code in ECU S6 corresponds to several different fault codes. Flashing code list for the EMS control unit Code Code...
  • Page 60 Ch 1 Engine Tier-3 710655- page Troubleshooting using flash codes for the coordinator • As soon as a fault is detected by the coordinator, it is stored in the EEPROM fault code memory. The diagnostics lamp for the coordinator (the right-hand lamp on Scania’s instrument panel) comes on when the diagnostic switch is actuated.

  • Page 61: Overview Of Flash Codes For Coordinator

    The signal from the integrated unit. The signal is Renew the coordinator. pressure sensor. sensor is outside the range. not always required. Check with Moxy service. The signals from the Check the brake pedal See also fault The flash code is registered after 5...
  • Page 62 Ch 1 Engine Tier-3 710655- page Description of Code Cause Action Note fault Certain inputs and outputs become The supply voltage is The supply voltage exceeds 35 Check the alternator. inactive. The too high. volts for more than  seconds. coordinator may suffer damage.

  • Page 63: Renewing The Control Unit

    Engine Ch 1 Tier-3 710655- page Renewing the control unit Tightening torques Control unit, screws  Nm Work description IMPORTANT! The control unit may suffer damage if it is powered when you unplug it. Before removing the control unit you must switch off the power with the starter key and wait for the EMS warning lamp to go out.

  • Page 64: Removing The Ecu Wiring

    Ch 1 Engine Tier-3 710655- page Removing the ECU wiring Drain the coolant from the engine as described in the work de- scriptions for the cooling system. Wash clean the rocker covers and the area around them. Remove the inlet pipe between the turbocharger and the air cleaner.
  • Page 65 Engine Ch 1 Tier-3 710655- page Fitting the wiring Tightening torques: Unit injector solenoid valves, screws: ,0 +/-0, Nm 5156 Torque screwdriver IMPORTANT! If the screws are tightened too tight, there is a risk that they may break. If this happens, the entire unit injector must be replaced.
  • Page 66 Ch 1 Engine Tier-3 710655- page Work description: Make sure that the inlet pipe between the turbocharger and the air cleaner has been removed. Fit the cable ducts. Schematic illustrations of the location of the cable ducts and their components are shown below 1 Cylinder 1–6  Coolant temperature sensor 3 Engine speed sensor 1 on flywheel...
  • Page 67 Engine Ch 1 Tier-3 710655- page Press the cables into the groove in the lower rocker cover. See the illustration about Fitting the wiring. Note: Take care when tightening the cable connection screws on the unit injector. If a screw breaks, the unit injector must be replaced.

  • Page 68: Cylinder Head

    Ch 1 Engine Tier-3 710655- page Cylinder head Special tools 5156 Slide hammer 8049 Impact drift 8049 8029 809 Extractor for injectors 512256 8019 8019 Compression tester 8386 Sleeve for injectors 8405 Tool for turning flywheel 8387 Socket 8406 Press drift 8386 8387 8406...

  • Page 69: Cylinder Head, Parts View

    Engine Ch 1 Tier-3 710655- page Cylinder head, parts view. 31. Gasket 1. Valve bridge 17. Bearing bracket 3. Exhaust valve . Pin 18. Rocker arm for unit 33. Valve seat insert 3. Bolt injector 34. Intake valve 4. Collet 19.

  • Page 70: Valve Mechanism

    Ch 1 Engine Tier-3 710655- page Valve mechanism The purpose of the valve mechanism is to actuate the valves, causing them to open and close at the right times in relation to the position of the crankshaft and piston. The camshaft is located high up and driven by the timing gears at the rear end of the engine so that it rotates at half the speed of the crankshaft.
  • Page 71 Engine Ch 1 Tier-3 710655- page Open the bleeder nipple and drain the fuel system by undoing the banjo screw on the back of the fuel manifold. WARNING! The fuel system must be empty or fuel may run down into the cylinders, which 1.
  • Page 72 Ch 1 Engine Tier-3 710655- page WARNING! Do not lean over the engine when removing the rocker arm shaft. The unit injector spring is pre-tensioned and can come loose, causing personal injury. Note: If the spring comes loose from the unit injector, the unit injector must be renewed.
  • Page 73 Engine Ch 1 Tier-3 710655- page Remove the fork clamp bolt holding the unit injector in place. 1. Fork clamp . Fork clamp bolt 3. Unit injector Detach the cables on the unit injector. The screws cannot be removed but undo them as far as possible.
  • Page 74 Ch 1 Engine Tier-3 710655- page It is easier to position the slide hammer if one of the lower rocker cover bolts is removed. Withdraw the unit injector. If the unit injector is stuck, tap carefully with a rubber mallet on the solenoid valve housing.

  • Page 75: Dismantling

    Engine Ch 1 Tier-3 710655- page Dismantling Remove collets, valve spring collars, springs and valves. Press the spring down using tool 8406 in a press so that the 8406 collets can be removed. Mark and place the valves in a rack so that they can be refitted in the same position in the cylinder head.

  • Page 76: Replacement Of Valve Seats

    Ch 1 Engine Tier-3 710655- page Replacement of valve seats Remove the valve seat inserts. Use a discarded valve that has been ground so that the diameter of the disc is slightly smaller than the inside diameter of the seat. Fit the valve and weld around it with an electric welder.

  • Page 77: Machining The Valve Seats Insert

    Engine Ch 1 Tier-3 710655- page Machining the valve seats insert Machining values Inlet valve Exhaust valve A = 1,9 - ,6 mm A = 1,8 - ,6 mm B = 0,75 - 1,8 mm B = 0,66 - 1,8 mm C = diameter 39,8 +/- 0,5 mm C = diameter 37,9 +/- 0,5 mm (setting value for machining tool)
  • Page 78 Ch 1 Engine Tier-3 710655- page Select and fit the cutter. Release the quick-action lock and move the pivot plate to the upper position with the adjusting screw. Set up the dial on the cutter adjuster using a valve. Adjust the cutter. Diameter 37.9 mm or 39.8 mm, see Machining values.

  • Page 79: Renewing The Valve Guides

    Engine Ch 1 Tier-3 710655- page Machine the valve seat by cranking clockwise while turning the feed screw. Never crank counterclockwise, as this could damage the cutter. Lubricate with cutting oil during the procedure. When the machining of the valve seat is completed, reduce the cutting pressure by turning the crank 3 turns without feeding.

  • Page 80: Renewing Pde Unit Injector Sleeves

    Ch 1 Engine Tier-3 710655- page Renewing PDE unit injector sleeves The cylinder head must be removed when renewing the injector sleeve. The valves do not need to be removed. The illustration shows the cylinder head with valves removed to demonstrate clearly the 512560 work described.

  • Page 81: Assembly

    Engine Ch 1 Tier-3 710655- page Assembly Lubricate all parts well with engine oil before assembly. 8406 Fit the valves in the their guides and position the cylinder head in a press. Fit the valve springs and the valve spring collars.

  • Page 82: Pde Injectors

    Ch 1 Engine Tier-3 710655- page PDE Injectors Each unit injector consists of a pump element, a solenoid valve and a nozzle. In this way, it is possible to control the fuel injection for each individual cylinder. EMS (Engine Management System) is the electronic system that controls both how much fuel each unit injector should inject into the cylinder and also when the unit injector should inject the fuel.
  • Page 83 Engine Ch 1 Tier-3 710655- page IMPORTANT! Check the unit injector spring diameter before adjusting and ensure that the correct tool is used when adjusting the unit injector. Note: All work that involves opening the fuel system must be completed in the following way: Start the engine and check for leaks.
  • Page 84 Ch 1 Engine Tier-3 710655- page Note: Make sure that the fork clamp and bolt are dry and free of oil. Place the fork clamp with screw in position on the unit injector and insert it into the cylinder head. Press down the unit injector by hand as far as possible.
  • Page 85 Engine Ch 1 Tier-3 710655- page IMPORTANT! Make sure the pushrods are placed in their correct positions. Make sure the pushrod to the unit injector is firmly secured in its lower position by the retaining ring. IMPORTANT! If the rocker arms have been removed on more than one cylinder, the rocker arm lock bolts must be completely unscrewed before adjustment commences.

  • Page 86: Adjusting Unit Injectors

    Ch 1 Engine Tier-3 710655- page IMPORTANT! 5163 Use torque screwdriver 512562 to avoid the risk of shearing off the screws. The entire unit injector must be renewed if the screws shear off. Refit the upper rocker cover and torque tighten the bolts to 18 Nm.
  • Page 87 Engine Ch 1 Tier-3 710655- page WARNING! Take care when carrying out the 5164 adjustment if the dimension is well outside the adjustment dimension. The spring is pre-tensioned and can cause personal injury if it is released. PDE32 Position setting tool 5164 with the metal plate around the injector spring.

  • Page 88: Adjusting The Valve Clearance And Unit Injectors

    Ch 1 Engine Tier-3 710655- page Adjusting the valve clearance and unit injectors Fit the unit injector according to the section Fitting the PDE injector, steps 1-11. Fit the pushrods. Fit the bearing bracket and torque tighten the bolts to 115 Nm. Fit the valve bridges.
  • Page 89 Engine Ch 1 Tier-3 710655- page Checking, adjusting the PDE32 injector rocker arms (I) - Turn the flywheel with tool 8405 to valve overlap on cylinder 1 (which corresponds to TDC Up (0°) in the opening). Then turn the flywheel anti-clockwise 144° at a time and observe UP TDC the valve overlap.
  • Page 90 Ch 1 Engine Tier-3 710655- page Dimension A= PDE3: 69.9±0.1 mm Dimension B= PDE3: 38.5 mm Placing of the tool 5164 Check the clearanse, using a finger to sense that the small piston is level with the flat upper surface of the tool. It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what has already been adjusted.

  • Page 91: Turbocharger

    Engine Ch 1 Tier-3 710655- page Turbocharger The purpose of the turbocharger is to increase the volume of air entering the engine’s cylinders. With more air the engine can burn more fuel and so de- velop more power and achieve cleaner combustion than a corresponding engine without supercharg- ing.

  • Page 92: General

    - Fit the compressor housing and measure charge pressure again. The valve is designed for genuine Moxy filters and only these should be used. NOTE! The compressor wheel must not be removed from the shaft.

  • Page 93: Special Tools

    Engine Ch 1 Tier-3 710655- page Special tools 8014 8388 8389 8391 8014 Dial gauge 8388 Filter wrench 8389 Deflection gauge 8391 Stand 1. Lubrication oil pipe . Ferrule 3. Union nut 4. Straight union 5. Seal 6. Straight union 7.

  • Page 94: Measuring Radial Clearance And Axial Clearance

    Ch 1 Engine Tier-3 710655- page Measuring radial clearance and axial clearance Measuring radial clearance and axial clearance does no usually give any indication of the remaining service life of the turbocharger. When the turbocharger is not working correctly or sounds abnormal, measuring charge pressure or measuring radial clearance or axial clearance can show that the turbocharger is defective.
  • Page 95 Engine Ch 1 Tier-3 710655- page Axial clearance Place the tip of the dial gauge 8014 against the end of the shaft. Press the shaft forwards and backwards and read the dial at the end positions. The difference between readings is axial clearance.

  • Page 96: Renewing The Turbocharger

    Ch 1 Engine Tier-3 710655- page Renewing the turbocharger Note: When renewing the turbocharger, all gaskets and the oil filter must be changed and the centrifugal cleaner must be cleaned. Removal Detach the delivery and return oil lines from the turbocharger. Detach the exhaust pipe, induction pipe and charge air cooler pipe from the turbocharger.

  • Page 97: Pistons And Cylinder Liners

    Engine Ch 1 Tier-3 710655- page Pistons and cylinder liners 1. O-ring 3. Cylinder liner for steel piston 5. O-ring 6. Compression ring 7. Compression ring 8. Oil scraper ring 9. Circlip 10. Steel piston 1. Gudgeon pin 13. Circlip 14.

  • Page 98: Special Tools

    Ch 1 Engine Tier-3 710655- page Special tools 8004 8005 8014 8224 8215 8036 8409 8390 8395 8004 Rule for dial gauge 8005 Drift 8014 Dial gauge 84 Piston ring compressor 808 Pressing tool 8036 Hydraulic cylinder 815 Puller for cylinder liner 8049 Impact drift 8401...

  • Page 99: Connecting Rods

    Engine Ch 1 Tier-3 710655- page Connecting rods The connecting rod and big-end cap consist of a single casting which is split during the machining operation. To prevent the big-end cap from being displaced in relation to the connecting rod, the contact surfaces are provided with grooves and guide pins.

  • Page 100: Removing And Dismantling Connecting Rods And Pistons

    Ch 1 Engine Tier-3 710655- page Removing and dismantling connecting rods and pistons Remove the cylinder head and oil sump. Remove the piston cooling nozzle in the cylinder block. Note: The piston cooling nozzle must not be damaged. The oil jet must hit the piston precisely.
  • Page 101 Engine Ch 1 Tier-3 710655- page Checking connecting rods Check the connecting rods using tool 587 110. Proceed as follows: When the gudgeon pin bushing has been checked, insert the bearing cap as marked and tighten the bolts to full torque. Mount the connecting rod in the tool using the expander and place the gudgeon pin in its bushing.

  • Page 102: Renewal Of Bearing Bushing In Connecting Rod

    Ch 1 Engine Tier-3 710655- page Renewal of bearing bushing in connecting rod Use tool 51564 when renewing the bearing bushing. The tool comprises three parts: 1. Pressplate with guide pin . Press drift 3. Supports There are different supports, depending on the engine type.
  • Page 103 Engine Ch 1 Tier-3 710655- page After pressing in a new bearing bushing, it must be finish-turned. This requires special equipment. Refer to illustration for the dimensions required. Diameter, d = 54.030 - 54.043 mm Surface quality = 0.6 Ra SHOP MANUAL MT26-31 - 06.2005...

  • Page 104: Pistons

    Pistons The pistons which are used in Moxy MT41 engine is of type; articulated pistons. Articulated pistons are split and have an aluminium skirt and a steel crown. (For the aluminium piston to resist the high pressure and high temperature prevailing in the com- bustion chamber, the material is thicker at the piston crown and piston ring grooves than in the remainder of the piston.)
  • Page 105 Engine Ch 1 Tier-3 710655- page The bowl-shaped combustion chamber in the piston crown has a protuberance in the centre. The design of this pro- tuberance ensures that the fuel injected at the end of the compression stroke is quickly mixed with the air in the com- bustion chamber.

  • Page 106: Assembling Piston And Connecting Rod

    Ch 1 Engine Tier-3 710655- page Assembling piston and connecting rod Clean the piston and its rings thoroughly without scratching the sides of the ring grooves. The oil holes in the piston should be cleaned using a suitable drill. Make sure the piston ring gaps do not exceed the permitted limit.

  • Page 107: Cylinderblock

    Engine Ch 1 Tier-3 710655- page Cylinderblock The cylinder block is a one-piece casting. It has 5 cylinder bores. There is a separate cylinder head for each cylinder. The seal between cylinder block and cylinder head consists of a steel/elastomer gasket. Seals are bonded in place at the oil and coolant passages.
  • Page 108 Ch 1 Engine Tier-3 710655- page The inside of the cylinder liner is machined by what is known as plateau honing. This type of machining leaves a fine pattern of grooves which ensures that the oil needed for lubrication between piston rings and liner remains on the wall of the liner.

  • Page 109: Removing The Cylinder Liners

    Engine Ch 1 Tier-3 710655- page Removing the cylinder liners Mark the liners with the numbers 1-6. The mark is necessary so that the liners can be refitted in the same place and position as previously. Note: The mark must be made only on the surface indicated in the illustration.

  • Page 110: Measuring The Cylinder Liner Height

    Ch 1 Engine Tier-3 710655- page Measuring the cylinder liner height Thoroughly clean the cylinder block liner shelf, the face around the cylinder, the cylinder liner shelf and the upper face of the cylinder liner. Fit the cylinder liner without O-rings and twist down by hand into position.

  • Page 111: Fitting The Cylinder Liners

    Engine Ch 1 Tier-3 710655- page Fitting the cylinder liners Check cylinder liner height as described in Check cylinder liner height as described in the section entitled Measuring the cylinder the section entitled Measuring the cylinder liner height. liner height. Make sure the interior of the cylinder block Make sure the interior of the cylinder block is clean.

  • Page 112: Fitting The Piston And Connecting Rod

    Ch 1 Engine Tier-3 710655- page Fitting the piston and connecting rod Lubricate the piston, piston rings, cylinder liner and piston ring compressor with engine oil. . Remove the protection on the connecting rod journal and lubricate the journal. Turn the piston rings so that the ring gaps are evenly distributed round the piston.
  • Page 113 Engine Ch 1 Tier-3 710655- page Fit the lower connecting rod bearing shell into the cap and lubricate the bearing surface. Fit the cap. Check that the connecting rod and cap have the same marking and that they are opposite each other. Lubricate the bolts, fit them and tighten to 0 Nm + 90°.

  • Page 114: Flywheel And Flywheel Housing

    Ch 1 Engine Tier-3 710655- page Flywheel and flywheel housing NOTE: Timing gear plate, to the engines with PDE unit injectors. 1. Flywheel housing 15. Stud 7. Cover . Seal 16. Rotation speed sensor 8. O-ring 3. Bolt 17. Contact housing 9.

  • Page 115: Special Tools

    Engine Ch 1 Tier-3 710655- page Special tools 8006 8410 8412 8432 8006 Puller bolts 843 Assembly tool Not illustrated: 8410 Drift 51556 Assembly tool 841 Guide pins 51555 Assembly tool 51559 Air powered sprayer 51557 Cartridge adapter 51558 Nozzle Removing the flywheel 8006 Remove the engine speed sensor(s) in the...
  • Page 116 Ch 1 Engine Tier-3 710655- page Renewing support bearing 8410 Remove the retaining rings on both sides of the support bearing. Knock out the support bearing from the flywheel using drift 8410. Fit the inner retaining ring and fit the new support bearing with drift 8410.

  • Page 117: Renewing The Rear Crankshaft Seal

    Engine Ch 1 Tier-3 710655- page Renewing the rear crankshaft seal Remove the crankshaft seal using a screwdriver. Take care not to scratch the sealing surfaces on the crankshaft and the flywheel housing. Note: The crankshaft seal must be fitted dry and must not be lubricated.

  • Page 118: Fitting Flywheel Housing

    Ch 1 Engine Tier-3 710655- page Fitting flywheel housing Remove all old sealing compound on the sealing surfaces of the timing gear casing and timing gear plate. Clean off any oil and grease using an alcohol based cleaning agent. Note: The sealing surfaces must be absolutely clean and free from grease.
  • Page 119 Engine Ch 1 Tier-3 710655- page SHOP MANUAL MT26-31 - 06.2005...

  • Page 120: Fitting The Flywheel

    Ch 1 Engine Tier-3 710655- page Fitting the flywheel Fit two guide pins 8412 in the crankshaft flange. Fit the flywheel on the crankshaft. NOTE! Always use new bolts and washer . 512563 99 411 Lock the flywheel using tool: - 51563 for engines with unit injector.

  • Page 121: Timing Gears

    Engine Ch 1 Tier-3 710655- page Timing gears Gear drive On the engine, the gear drive is located at the rear end of the engine. Important components like the injection pump and valve mech- anism require precise operation and are therefore attached to the rear end of the crankshaft, close to the flywheel, where crankshaft rotation is smoothest.

  • Page 122: Belt Drive Collant Pump, Generator And Ac Compressor

    Ch 1 Engine Tier-3 710655- page Belt drive collant pump, generator and AC com- pressor The coolant pump and alternator are driven by the belt drive, as also is the A/C compressor. (The fan is mounted on a special bracket and is driven by the hydraulic system.

  • Page 123: Renewing The Seal In The Front Cover

    Engine Ch 1 Tier-3 710655- page Renewing the seal in the front cover Remove the fan ring and the fan. Thermostatic fan: Store it upright (vertical). Remove the belt(s), crankshaft damper and belt pulley. Remove the driver bolts and withdraw the driver.

  • Page 124: Crankshaft Damper

    Ch 1 Engine Tier-3 710655- page onnecting rods Crankshaft damper he crankshaft. at certain engine ign of the engine, erised as follows: 1.Oscillation damper of the crankshaft) eed throughout aft. In relation to eel, the rotational ankshaft will imes during each oscillation, a o the front end of ver.

  • Page 125: Timing Gear, View Exploded

    Engine Ch 1 Tier-3 710655- page Timing gear, view exploded 1. Timing gear housing 14. Flange bolt 27. Thrust bearing 2. Gasket 15. Flange bolt 28. Intermediate gear 3. Pin 16. Crankshaft seal 29. Thrust bearing 4. Flange bolt 17. Cover 30.

  • Page 126: Special Tools

    Ch 1 Engine Tier-3 710655- page Special tools Special tools, gear 87 509 Drift 98 721 Assembly tool 87 596 Slide hammer 99 059 Slogging wrench 87 663 Support drift 99 088 Puller 87 665 Puller 99 093 Support drift 87 932 Drift 587 315 Puller 98 133 Washer...

  • Page 127: Crankshaft Seal

    Engine Ch 1 Tier-3 710655- page Crankshaft seal Removing 1. R emove components that are in the way: radiator, fan ring, fan or belt guard. 2. Undo the crankshaft damper bolts and those for the belt pulley, if fitted. R emove the crankshaft damper and belt pulley, if fitted.

  • Page 128: Timing Gear Cover

    Ch 1 Engine Tier-3 710655- page Fitting 1. W ipe clean the seal seat in the housing. Note The crankshaft seal should be fitted dry and must not be lubricated. The sleeve inside the seal must not be removed until immediately before the seal is fitted in the engine.
  • Page 129 Engine Ch 1 Tier-3 710655- page Timing gear cover Timing gear cover Removing 1. R emove components that are in the way: radiator, fan ring, fan, belt guard, alternator, V -belt, belt tensioner, tensioning rollers, fan drive, alternator bracket. 2. T urn the engine over to the ignition position. 3.
  • Page 130 Ch 1 Engine Tier-3 710655- page 11. Check that the engine is in the ignition posi- tion. 12. R emove the oil sump. 13. R emove the timing gear housing. Fitting 1. Clean the mating surfaces and fit a new gasket. 2.

  • Page 131: Intermediate Gear

    Engine Ch 1 Tier-3 710655- page Intermediate gear Intermediate gear Removing 1. R emove the timing gear cover. See Timing gear cover: Removing. 2. R emove oil catcher from end of crankshaft. 3. T urn the crankshaft so that the marks on the camshaft gear and crankshaft gear point towards the centre of the intermediate gear.

  • Page 132: Crankshaft Gear

    Ch 1 Engine Tier-3 710655- page Crankshaft gear Crankshaft gear Removing 1. R emove the timing gear cover. See Timing gear cover: Removing. 2. R emove oil catcher from the end of the crankshaft. R emove oil pump. 3. T urn the crankshaft so that the marks on the camshaft gear and crankshaft gear point towards the centre of the intermediate gear.

  • Page 133: Camshaft Gear

    Engine Ch 1 Tier-3 710655- page Camshaft gear Camshaft gear Removing 1. R emove the timing gear cover. See Timing gear cover: Removing. 2. R emove oil catcher from end of crankshaft. 3. T urn the crankshaft so that the marks on the camshaft gear and crankshaft gear point towards the centre of the intermediate gear.

  • Page 134: Camshaft

    Ch 1 Engine Tier-3 710655- page Camshaft Camshaft Removing - I t is assumed that the timing gear housing has already been removed. 1. R emove rocker arms and pushrods. 2. T urn crankshaft around until the tooth marked ”O” on the crankshaft gear and camshaft gear point towards the centre of the intermediate gear.
  • Page 135 Engine Ch 1 Tier-3 710655- page Changing valve tappets 1. Clamp the side cover in a vice. R emove the retaining ring and valve tappet. 2. Fit a new valve tappet. Fit the retaining ring, using a screwdriver. Camshaft bearings - T here is very little wear on the camshaft and camshaft bearings and these components rarely need any work to be done on them.

  • Page 136: Crankshaft

    Ch 1 Engine Tier-3 710655- page Crankshaft Crankshaft Removing 1. R emove the cylidner heads and pushrods. 2. R emove the flywheel and flywheel housing. 3. R emove the fan, fan bearing, oil sump, tim- ing gear housing and intermediate gear. 4.
  • Page 137 Engine Ch 1 Tier-3 710655- page Fitting 1. B e particularly careful to clean all oilways in the crankshaft, pivot pins and contact sur- faces for bearings and caps. 2. Check that the dimensions of bearings and thrust washers are correct. Fit the bearing halves in block and cap.

  • Page 138: Lubrication System

    Ch 1 Engine Tier-3 710655- page Lubrication system Oil pump An oil pump, driven by the crankshaft gear, generates the circulation required to provide lubrication oil to all lubrication points so that it flows through the oil cleaner and oil cooler. The lubricating oil is sucked from the sump through a strainer in the oil pump.

  • Page 139: Lubrication Oilways

    Engine Ch 1 Tier-3 710655- page Lubrication oilways The lubrication oil passes through channels in the cylinder block to reach the camshaft bearings and the crankshaft main bearing. Channels in the crankshaft feed the oil on to the connecting rod bearings. Lubrication oil for the rocker arms is led via a direct channel from the main oilway.

  • Page 140: Oil Pressure

    Ch 1 Engine Tier-3 710655- page Oil pressure Max. oil pressure: High lubricating oil pressure (above 6 bar) is normal when Warm engine running at a speed above 800 rpm 6 bar starting a cold engine. Normal oil pressure: Warm engine running at an operating speed of 3 - 6 bar Min.

  • Page 141: Oil Cooler, Engine

    Engine Ch 1 Tier-3 710655- page Oil cooler, engine From the oil pump, the lubricating oil flows via passages in the block to the oil cooler located inside the front side cover on the right-hand side of the block. The oil cooler is a plate heat exchanger. All the oil flows through the cooler where it is cooled by the cool- ant from the cooling system.

  • Page 142: Oil Cooler View

    Ch 1 Engine Tier-3 710655- page Oil cooler view 1. Gasket 9. Gasket . Flange bolt 10. Cover 3. O-ring 11. Bolt 4. O-ring 1. Piston 5. Oil cooler 13. Spring 6. Oil cooler cover 14. Gasket 7. Flange bolt 15.

  • Page 143: Renewing Seals

    Engine Ch 1 Tier-3 710655- page Renewing seals Remove the side cover and oil cooler from the block. Remove the 4 bolts securing the oil cooler to the side cover. Remove the oil cooler. Renew the 4 O-rings. Fit the oil cooler insert and bolt securely to the side cover using 6 Nm torque.

  • Page 144: Oil Filter

    Ch 1 Engine Tier-3 710655- page Oil filter From the oil cooler, the oil passes through a large-capacity full- flow filter of paper. This filter also cleans the oil to the turbocharger. The oil filter has an overflow valve which opens if the filter be- comes clogged.

  • Page 145: Centrifugal Oil Cleaner

    Engine Ch 1 Tier-3 710655- page Centrifugal oil cleaner Some of the oil passes from the main passage in the oil cooler cover to the centrifugal cleaner and then, after cleaning, flows back to the sump. Surplus oil is drained back to the sump via an overflow valve.

  • Page 146: Dismantling And Assembly

    Ch 1 Engine Tier-3 710655- page Dismantling and assembly - During routine cleaning of the oil cleaner, there should be a certain amount of dirt deposits in the rotor bowl. - If this is not the case, it indicates that the rotor is not spinning.
  • Page 147 Engine Ch 1 Tier-3 710655- page Grasp the rotor bowl and tap lightly with your hand or carefully use a screwdriver between the rotor bowl and the strainer so that the rotor bowl comes loose from the rotor. Note: Never strike on the rotor directly as this may damage its bearings.
  • Page 148 Ch 1 Engine Tier-3 710655- page Position the O-ring in the lid. Renew the O-ring if it is at all damaged. Assemble the parts and tighten the rotor nut by hand. When tighten the rotor axle (point 15) its neccesarry to modified the Socket spanner 803 with to weld nut M0 without threads, on the square end.
  • Page 149 Engine Ch 1 Tier-3 710655- page Make sure the shaft is not loose. If it is, it can be locked using screw locking compound. First clean thoroughly using a suitable solvent. Tighten the rotor shaft using socket 803. Tightening torque 34 Nm. Refit the rotor and spin it by hand to make sure it rotates easily.

  • Page 150: Cooling Fan

    Ch 1 Engine Tier-3 710655- page Cooling fan The fan is driven by the hydraulic system and is moved to the hydraulic chapter. Look in the chapter 5. SHOP MANUAL MT26-31 - 06.2005...

  • Page 151: Cooling System

    Engine Ch 1 Tier-3 710655- page Cooling system View of the cooling system Cooling water sirculates in Charge air the engine cooling system cooler Thermostat Expansion tank Pump SHOP MANUAL MT26-31 - 06.2005...

  • Page 152: Circulation

    Ch 1 Engine Tier-3 710655- page Circulation From the pump, the coolant is carried into the cylinder block’s longitudinal distribution ducting and then through holes in the cylinder block, washes round the cylinder liners and flows up to the cylinder heads. The coolant is also forced directly up into the cylinder heads from the distribution ducting via passages which leads to the injectors and exhaust valves.

  • Page 153: Disassemble The Cooling Unit

    Engine Ch 1 Tier-3 710655- page Disassemble the cooling unit Drain the coolant and transmission oil. First, remove both cover on the underside front frame left and right side. On left side of the transmission cooler unscrew the plug (Nv 13 mm) and drain the coolant from the engine and radiator.
  • Page 154 Ch 1 Engine Tier-3 710655- page Disassemble the Air Condition condenser and the fastening clamps from the fastening brackets. Place the condenser on the left side of the engine. NOTE ! Do not disassemble the Air Condition hoses from the condenser filter or the compressor. Fastening the lifting device to the radiator unit.

  • Page 155: Thermostat And Thermostat Housing

    Engine Ch 1 Tier-3 710655- page Thermostat and thermostat housing The engine have a double thermostat. When a double thermostat are used they have the same opening temperature as standard. The thermostats use wax as the temperature-sensitive me- dium. At coolant temperatures below the opening temperature of the thermostats, nearly all the coolant circulates between the engine’s coolant passages and the coolant pump without passing through the radiator.

  • Page 156: Thermostat

    Ch 1 Engine Tier-3 710655- page Thermostat Removing Remove the expansion tank filler cap. Drain a sufficient amount of coolant from the system. Remove the hose from the thermostat housing cover. Detach the thermostat housing cover and remove the thermostat (double thermostat). Fitting Clean the thermostat housing and check that nothing obstructs the function of the...

  • Page 157: Coolant Pump

    Engine Ch 1 Tier-3 710655- page Coolant pump The coolant pump is located at the front side of the front cover on the right-hand side of the engine. The coolant pump is driven by a multigroove belt directly from the crankshaft damper. The pump is of centrifugal type and consists of a spiral shaped pump housing with an impeller directly mounted on the driveshaft.
  • Page 158 Ch 1 Engine Tier-3 710655- page Removing Drain the cooling system through the drain taps in the block and in the pipe from the outlet on the radiator. Remove any protection meshes and fan ring with sealing ring to gain access to the fan. Remove the fan.
  • Page 159 Engine Ch 1 Tier-3 710655- page Changing the pulley 501348 Remove the pulley using puller 501348 and drift 501349. Press the pulley on until it is flush with the shaft end face. 501349 The pulley is removed The pulley is pressed on Changing the sealing ring If coolant has leaked out inside the housing behind the pulley, the sealing ring can be changed.
  • Page 160 Ch 1 Engine Tier-3 710655- page Prise off the seal using two screwdrivers and separator plates. Note: Do not damage the pump housing gasket surface. 5. Apply sealing agent (501350) to the inside and outside (brass sleeve) of the sealing ring. Make sure that no sealing agent gets onto The seal ring is removed other sealing surfaces.

  • Page 161: External Cleaning

    Engine Ch 1 Tier-3 710655- page External cleaning Radiator Check that the radiator is not clogged on the air side and that the cooling fins are not damaged. Carefully scrape the deposit off the radiator’s cooling fins. If necessary, a paraffin-based engine cleaner can be used. Bent fins can be straightened using a wire brush, for example, and exercising care.

  • Page 162: Specifications

    Ch 1 Engine Tier-3 710655- page Specifications TECHNICAL DATA General information GENERAL DC9 EMS Number of cylinders 5 in line Cylinder diameter Stroke Displacement (litres) 8.87 No. of main bearings Firing order 1 - 2 - 4 - 5 - 3 Compression ratio 18:1 Engine direction of rotation viewed from rear...
  • Page 163 Engine Ch 1 Tier-3 710655- page FUEL SYSTEM DC9 EMS Low idle speed 700 (adjustable 500-800) Maximum full load speed See engine card Fuel Diesel fuel oil see page 55 COOLING SYSTEM Number of thermostats 1 (dual thermostat) ° Thermostat, opening temperature Coolant temperature: °...

  • Page 164: Cylinder Head

    Ch 1 Engine Tier-3 710655- page Cylinder head Intake valve Valve head angle ..........19.5 Minimum dimension A for ground valve .
  • Page 165 Engine Ch 1 Tier-3 710655- page Exhaust valve seat Seat angle ........... . . 45.0°-45.5° Width of contact surface A .

  • Page 166: Turbocharger

    Ch 1 Engine Tier-3 710655- page Turbocharger Wear limits Shaft radial clearance......... . . 0.198-0.564 mm Shaft axial clearance (after running in) .

  • Page 167: Connecting Rods

    Engine Ch 1 Tier-3 710655- page Connecting rods Connecting rod and bearing cap marked 1 to 6. Fitted with marking in. Tightening torques Oil sump bolts..........30 Nm Connecting rod bolts.

  • Page 168: Timing Gear

    Ch 1 Engine Tier-3 710655- page Timing gear Camshaft gear Backlash against intermediate gear ......0.03 - 0.15 mm Injection pump gear Backlash against intermediate gear .

  • Page 169: Lubrication System

    Free spring length ..........61.4 mm Oil filter Only use original MOXY filters. Tightening torques: Oil pump: Bolts for oil pump cover .

  • Page 170: Troubleshooting Tables

    Ch 1 Engine Tier-3 710655- page Troubleshooting tables White smoke Effect Cause Troubleshooting Action If possible: reduce en- gine speed or put the engine under load The white smoke starts Install a white smoke to turn blue and disap- Incompletely burnt fuel Cold engine limiting device (exhaust pears when the engine...

  • Page 171: Black Smoke When Running/Under Load

    Engine Ch 1 Tier-3 710655- page Black smoke when running/under load Effect Cause Troubleshooting Action “Adjusted” injection Check the lead seal Test in test bench pump, attempt to boost Injection timing too late Inlet valve does not open properly. Valve adjustment disturbed Disconnect one delivery pipe at a time and listen for changes in the engine sound.

  • Page 172: Black Smoke On Starting

    Ch 1 Engine Tier-3 710655- page Black smoke on starting Effect Cause Troubleshooting Action Open the cover on the actuator solenoid and Take the pump to a check with a finger on Engine difficult to start Binding control rack Bosch workshop for the control rod that it repair goes to the maximum...

  • Page 173: Oil In Coolant

    Engine Ch 1 Tier-3 710655- page Oil in coolant Effect Cause Troubleshooting Action Test pressurize the oil cooler Note: classed oil cooler, test pressurized: 10 bar oil Oil cooler leaks when on the oil side, 0.5 bar air on the water side, im- engine is running mersed in water 5 - 7 °C Defective cylinder head...

  • Page 174: Coolant/Water In Oil

    Ch 1 Engine Tier-3 710655- page Coolant/water in oil Effect Cause Troubleshooting Action Oil cooler leaks when Test pressurize the oil engine is not running cooler, see above Leaky O-rings at cylinder Leakage in telltale hole? Change liner seals liner Dilution of oil in sump Water is condensed in crankcase ventilation and...

  • Page 175: Low Oil Pressure

    Engine Ch 1 Tier-3 710655- page Low oil pressure Effect Cause Troubleshooting Action Crankshaft bearing/ Max. oil pressure  bar Change to bearings of main bearing of wrong also when engine cold the correct size. Check size has been fitted on the bearing seats be- reground crankshaft fore assembly...
  • Page 176 Ch 1 Engine Tier-3 710655- page Effect Cause Troubleshooting Action Loosened guide plates in the oil cooler prevent passage of the oil Worn/damaged oil pump Gauge shows low pres- Clogged oil cooler sure Loose screws in timing gear’s intermediate gear Oil pressure at idling/ Gauge indicates low The main oil duct (to...

  • Page 177: High Oil Pressure (Engine Warmed Up)

    Engine Ch 1 Tier-3 710655- page High oil pressure (Engine warmed up) Effect Cause Troubleshooting Action Take a reading of the oil pressure on the warmed- up engine using a mechanical pressure gauge Defective sensor/ directly on the engine: instrument Gauge indicates high Minimum 1 bar at 800 r/min.

  • Page 178: Vibration, No Driven Components Engaged

    Ch 1 Engine Tier-3 710655- page Vibration, no driven components engaged Effect Cause Troubleshooting Action Wrong injection timing Disconnect one delivery pipe at a time and listen for Broken delivery valve changes in the engine sound. spring WARNING! Be careful when disconnecting the delivery Individual injectors not pipes as the pressure is extremely high and operating...

  • Page 179: Delivery Pipe Fractures

    Engine Ch 1 Tier-3 710655- page Delivery pipe fractures Effect Cause Troubleshooting Action No clamping Carelessly handled delivery pipe External corrosion on cylinder liner Effect Cause Troubleshooting Action Clean the cooling system and fill up with Unsuitable corrosion coolant as described protection agent, glycol in the maintenance or water in coolant...

  • Page 180: Fluid Stroke

    Ch 1 Engine Tier-3 710655- page Fluid stroke Effect Cause Troubleshooting Action Leaky charge air Test pressure (air cooler 0.5 bar, liquid 4 bar) Leaky cylinder head gasket If the fault is hard to trace: Change all cylinder heads for exchange cylinder heads.
  • Page 181 Engine Ch 1 Tier-3 710655- page Effect Cause Troubleshooting Action Piston seizure (may be caused by clogged pis- ton cooling nozzles) Wrong injection timing Worn collets on ex- haust valves Disconnect one delivery pipe at a time and listen for Incorrectly adjusted changes in the engine sound.

  • Page 182: High Oil Consumption

    Ch 1 Engine Tier-3 710655- page High oil consumption Effect Cause Troubleshooting Action Piston ring seizure Combustion tempera- ture too high? Cylinder seizure Liner wear Unclean intake air? Carbon polishing (in patches) Piston ring wear Poor grade of oil? Piston rings stuck Tapered piston rings fitted wrong way Individual piston rings broken = incorrectly fitted...

  • Page 183: High Fuel Consumption

    Engine Ch 1 Tier-3 710655- page High fuel consumption Effect Cause Troubleshooting Action Faulty injector Low charge air pres- sure Check in a pump test Adjusted injection bench that the amount pump (Q-mm /stroke) corre- sponds to specification Manner of driving, oper- ating/load conditions Low compression Effect...
  • Page 184 Ch 1 Engine Tier-3 710655- page Effect Cause Troubleshooting Action Fuel too hot Check density and vis- Incorrect fuel specifica- cosity tion Check charge air pres- Low charge air pres- sure sure Abnormal pressure Check the vacuum before the turbocharger, max. drop in intake piping 500 mm wc.

  • Page 185: Hot Engine

    Engine Ch 1 Tier-3 710655- page Hot engine Effect Cause Troubleshooting Action Check that sensor and instrument suit each other Defective sensor/instru- (10 and 150 °C) ment Check with a separate instrument Low coolant level Clean the cooling Clogged cooling sys- system internally and externally Pressure cap not...

  • Page 186: Cold Engine

    Ch 1 Engine Tier-3 710655- page Cold engine Effect Cause Troubleshooting Action Check that sensor and instrument match each other Defective sensor/instru- (10 and 150 °C) ment Check with a separate instrument Instrument indicates low temperature Thermostat jammed in Check operation of open position thermostat Coolant loss...

  • Page 187: Engine Heater

    Engine Ch 1 Tier-3 710655- page Engine heater Effect Cause Troubleshooting Action Incorrect mixture or Clean the cooling type of glycol and/or Boiler scale on engine system and fill it with corrosion inhibitor heater coolant as described Anti-freeze with phos- in the maintenance phate-based inhibitor instructions...

  • Page 188: High Exhaust Temperature

    Ch 1 Engine Tier-3 710655- page High exhaust temperature Effect Cause Troubleshooting Action Adjusted injection Check the lead seal, pump check CRO if neces- Test in test bench sary Check the injection Wrong injection timing timing Check type, opening pressure and general Nozzle drips condition Take a reading, recommended counterpressure:...

  • Page 189: Low Fuel Pressure

    Engine Ch 1 Tier-3 710655- page Low fuel pressure Effect Cause Troubleshooting Action Clogged fuel filter Defective overflow valve Defective feed pump Air leakage in suction pipe High pressure drop in suction pipe Low system voltage Effect Cause Troubleshooting Action Broken alternator drive belt Slipping alternator...

  • Page 190: External Oil Leakage

    Ch 1 Engine Tier-3 710655- page External oil leakage Effect Cause Troubleshooting Action Check “blow-by” in crankcase Correct value for new engine: 0 - +10 mm wc Crankcase pressure (flow rate 60 - 100 l/min.) too high Closed crankcase ventilation: -50 - +0 mm wc Leaky crankshaft seal Leakage at liner seal via overflow hole in...

  • Page 191: External Coolant Leakage

    Engine Ch 1 Tier-3 710655- page External coolant leakage Effect Cause Troubleshooting Action Leakage in cylinder liner seal Change to original Cold leakage hoses Defective cylinder head gasket Check at the water pump housing’s telltale Water pump leakage hole Leakage at charge air cooler connection Oil pressed out via crankcase ventilation Effect...
  • Page 192 Ch 1 Engine Tier-3 710655- page SHOP MANUAL MT26-31 - 06.2005...
  • Page 193 Engine Ch 1 Tier-3 710655- page Note SHOP MANUAL MT26-31 - 06.2005...
  • Page 194 Ch 1 Engine Tier-3 710655- page Note SHOP MANUAL MT26-31 - 06.2005...
  • Page 198 Ch 2 TRANSMISSION page Chapter 2 Transmission SHOP MANUAL MT26/31 - 08.2006...
  • Page 199 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Chapter 2 Transmission Index GENERAL ........................ 6 Structure of the Repair Manual ....................7 Denomination of standard dimensions..................8 Conversion table ........................8 Torque limits for screws..................9 Table............................9 Technical data ....................... 10 Description: ..........................10 Transmission cross section.................
  • Page 200 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil circuit diagram ....................53 Valve block controll circuit .......................53 Measuring points and connections..............54 Troubleshooting ....................55 Prerequisites for the troubleshooting ..................55 Lay out 6WG-260 ........................56 Introduction ..........................57 ZF - Display:..........................57 Display during operation ......................58 Display during AEB-Mode .......................59 Definition of operating modes ....................60...
  • Page 201 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clutches, Powershift transmission ..............168 Multi-disk clutch ........................169 Clutch chart...........................170 Plate clearanse in the single Multi-disc clutches..............171 Oil circuit diagram .........................172 Disassemble Multi-disc clutches ...................173 Dismantle multi-disc clutch KR/K2 ..................180 Manual transmission assembly .....................189 Multi-disc clutch-K3.......................197 Multi-disc clutch-KR ......................204 Multi-disc clutch-K2.......................209...
  • Page 202 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 203: General

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page GENERAL The Service Manual covers all works required for dismantling and the pertaining installation. When repairing the transmission, ensure utmost cleanliness and that the works are carried out in an expert-like manner. The transmission should only be disassembled for renewing damaged parts.

  • Page 204: Structure Of The Repair Manual

    See this chapter, 2.0 Important information on industrial safety Generally, the persons repairing MOXY product-sets are responsible on their own for the industrial 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.

  • Page 205: Denomination Of Standard Dimensions

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Denomination of standard dimensions Note: linear density in kg/m; areal density in t/m2 Unit Conversion Note Mass kg (Kilogramm) Force N (Newton) 1 kp = 9,81 N Work J (Joule) 0,102 kpm = 1J = 1 Nm 1 PS = 0,7355 KW Power KW (Kilowatt)

  • Page 206: Torque Limits For Screws

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Torque limits for screws. Table TORQUE LIMITS FOR SCREWS (IN Nm) ACCORDING TO ZF STANDARDS 148 Friction value: µ total= 0,12 for screws and nuts without after treatment as well as phosphatized nuts.

  • Page 207: Technical Data

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Technical data Description: Engine speed: max. min ............750 - 2600 Starting torque multiplication: ..............2 to 3,0 Mass (without oil): kg about ............900 The Transmissions 6 WG-310 are composed of a hydrodynamic torque converter and a rear-mounted multi- speed powershift transmission with integrated transfer case (See: Transmission cross section next page) The torque converter is a wear-free starting device which is infinitely variable adapting itself to the required situ-...

  • Page 208: Transmission Cross Section

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Transmission cross section = Input flange - Drive via universal shaft = Retarder = WK = Converter = Breather = Electrohydraulic controll unit = 2nd Power take- off = Transmission pump = 1st Power take- off = Clutch axle “KV/K1”...

  • Page 209: Oil Temperatures

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil temperatures: Normal operation: Minimum temperature behind the heat exchanger is 50° C Operating temperature behind the converter at least 65° C, and the maximally permitted permanent temperature is 105° C. In case of exceptions, 120° C are short-time (max. 5 minutes) permitted. Retarder operation: Maximally permitted permanent temperature behind Retarder is 145°...

  • Page 210: Oil Grade

    Oil grade The List of lubricants will be updated every two years and can be requested, resp. inspected as follows: Moxy Engineering as 6440 Elnesvågen Norway Oil level check: At the oil level check, the prescribed safety directions according to § 6 of the rules for accident prevention for power plants in Germany, and in all other countries the respective national regulations have to be absolutely respected.

  • Page 211: List Of Lubricants

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page List of lubricants Converter transmissions for off-road equipment List of lubricantsTE-ML 03 Product groups Lubricants authorized for service fills (1) Ergopower WG 310 Lubricant class 03D (I) Transmissions adapted to suit to ATF Lubricant class 03A / 03B (II) Transmission to suit to ENGINE OIL Note: TCU is set to meet classes (I) and (II).
  • Page 212 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Lubricant class 03A M ineral oil-b ased engin e oil in accordance w ith G roup standard ZFN 13030 (A P I C D /C E /C F-4/C F/C G -4/S F/S G /S H /S J or A C E A , categ ories A , B , E ) V iscosity class: S A E 20W -20 / 30 / 10W -30 / 10W -40 / 15W -30 / 15W -40 / 20W -40 N ote: A ll m in eral oil-ba sed trade products w hich satisfy th e a bo ve specificatio ns m a y be use d.
  • Page 213 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Lubricant class 03D Automatic Transmission Fluids (ATF) in accordance with Group standard ZFN 13030 Manufacturer Product designation Manufacturer Product designation AGIP PETROLI SPA, ROM/I AGIP ATF D 309 KÄPPLER KARL, STUTTGART/D SELECTOL FLUID GETR.ÖL IID 23 AGIP PETROLI SPA, ROM/I AGIP ATF IIE KUWAIT PETROLEUM, EUROPOORT/NL...

  • Page 214: Oil Change And Filter Replacement Interval

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil dipstick Legende: 1 = Oil filler tube with oil dipstick 2 = Oil drain plug M38x1,5 3 = Coarse filter Oil change and Filter replacement interval: First oil change after 100 operating hours in application. Every further oil change after 1000 operating hours in application, however at least once a year ! At every oil change, the Fine filter (pressure filter) has to be replaced.

  • Page 215: Oil Level Check

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil level check. In the cold start phase, the engine must be running about 2 – 3 minutes at idling speed and the marking on the oil dipstick must then be above the cold start mark. Zone Zone "COLD"...

  • Page 216: Oil Change And Oil Filling Capacity

    filled in is greater than at the later oil fillings in the course of the usual Maintenance service. Moxy recommends, to start the AEB at every oil change. If the oil quality are changed it is strongly necessery to run AEB !

  • Page 217: Fine Filter

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Fine filter: Filtration ratio according to ISO 4572: ß > 75 ß = 25 ß = 5,0 Filter surface at least: 2 x 6700 cm = 13 400 cm Dust capacity according to ISO 4572 at least: 17 g MAIN OIL CIRCUIT Converter From the filter...

  • Page 218: Axle Insert „Lk

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Axle insert „LK“: Oil specification: Oils according to List of Lubricants TE-ML 05 are allowed to be used. Oil level check: - With the vehicle standing in a horizontal plane open the screw plug (2) on the transmission, the oil level must reach the upper edge of the check hole (2) .
  • Page 219 Ch 2 TRANSMISSION page SHOP MANUAL MT26/31 - 08.2006...

  • Page 220: Controller

    TRANSMISSION Ch 2 page Controller General: Due to the great number of the available Controllers, the precise Technical Data must be taken from the respective installation drawing. Controller VTS-3 See: Clutch chart next page. At the Console selector VTS-3 (preselection pushbutton switch), the driving direction will be preselected by horizontal tilting of the Controller lever.

  • Page 221: Clutch Chart

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clutch chart PRESSURE REGULATOR UNDER VOLTAGE ENGAGED CLUTCHES DRIVING DIRECTION Y1 Y2 Y3 Y4 Y5 Y6 Speed FORWARD REVERSE NEUTRAL KR K4 K1 K3 KV K2 ENGAGED CLUTCH POSTITIONS ON VALVE BLOCK CONSEC.

  • Page 222: Circuit Diagram Controller

    TRANSMISSION TRANSMISSION Ch 2 Ch 2 page page Circuit diagram controller Coding controller Position KD/E FUNK- TION SWI- AS/N KD/E SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 223: Display

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Display Possible Indications on the Display Preselected Driving range: The number of the lines indicates the driving range, (Special characters b, c, d, e) resp. the gear preselection: 1 Bar b: Driving range 1 2 Barc b,c: Driving range 2 3 Bars b,c,d:...
  • Page 224 TRANSMISSION TRANSMISSION Ch 2 Ch 2 page page Display of the Cold-start phase: Transmission remains in Neutral Bars are flashing: WK open Error display: If the system is recognizing an error, the spanner (Spe-cial symbol „g“) is flashing. If Neutral is preselected on the Controller, a two-digit error number appears on the two alphanumeric display points (central and right Side).
  • Page 225 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Display EE Indication on the Display: EE . In this state, the Display has a timeout, i. e. it receives no Data from the EST-37. Main reasons: − EST-37 is in TOTAL RESETTING MODE (e.g.

  • Page 226: Operation

    TRANSMISSION TRANSMISSION Ch 2 Ch 2 page page OPERATION Driving preparation and Maintenance Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in with the correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filter as well as the pipes must get filled with oil.

  • Page 227: Driving And Shifting

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Driving and Shifting − Neutral position: Neutral position will be selected via the Controller. After the ignition is switched on, the electronics remains in the waiting state. By the position NEUTRAL of the Controller, resp. by pressing the pushbutton NEUTRAL, the EST-37 becomes ready for operation.
  • Page 228 TRANSMISSION TRANSMISSION Ch 2 Ch 2 page page − Shifting of the various outputs. − Axle disconnection/Interaxle differential. Both interlocks can be preselected during the drive via a switch. At exceeding the driving speed below 5 km/h and unloaded transmission, the interlocks engage of automatically. Attention: The engagement is only then permitted, if no speed difference between the axles is prevailing.

  • Page 229: Transmission Control In The Driving Mode Automatic

    Ch 2 TRANSMISSION page Transmission control in the Driving mode Auto- matic: A manual intervention into the automatic shifting sequence is only then practical if the road condition or the shape of the terrain is suitable. Stopping and Parking: Since due to the converter there is no rigid connection existing from the engine to the axle, it is recommended to secure the vehicle on upgrades, resp.

  • Page 230: Testing System, Zf

    Ch 2 TRANSMISSION page Testing system, ZF SERVICE Installation Manual and Summary for the Diagnostic Software SHOP MANUAL MT26/31 - 08.2006...

  • Page 231: Safety Notice

    Ch 2 TRANSMISSION page Safety notice Companies who repair ZF units are responsible for their own work safety. To avoid injury to personnel and damage to products, all safety regulations and legal requirements which apply to repair and maintenance work must be adhered to. Before starting work, mechanics must familiarize themselves with these regulations.

  • Page 232: Diagnostic - Set

    Ch 2 TRANSMISSION page Diagnostic - set Needed hardvare and softvare Pentium Laptop min. > 90 MHz and Windows 95/98 Basic - Software Testman 504672 Diagnostic – Set Programming STANDARD Adapter DPA – 03 504671 504673 Adapter cabel EST - 37 504674 EST - 37 Diagnosis...

  • Page 233: Installation Of Diagnostic Software --> Testman

    Ch 2 TRANSMISSION page Installation of Diagnostic Software --> Testman Mount floppy disk “1” of “Testman” into drive “A” Go under “START” to “Execute” ! (See figure) There, enter “A:\Setup.exe” ! (See figure) Nov, follow the next installation steps and mount upon request the floppy disks 2,3 and 4, one after the other Now, you should have in the directory “C”\ “a subdirectory with the name “GDS3000”.
  • Page 234 Ch 2 TRANSMISSION page Now, you must copy the actual applications (e.g,,; Appl. WG 260 - 310) into the directory “C:\GDS 3000\ apps” copy. (See figure) Now, you must have a Directory “C\GDS 3000\apps\WG 260 - 310.apps (See figure!) Now, “Testman” and the actually desired Application of WG 130-->...

  • Page 235: Start Of Testman

    Ch 2 TRANSMISSION page Start of Testman Prosedure Switch off the ignition ! Connect the Laptop via the programming adapter “DPA-03” (Order -No.: 504673) and the standard adapter cable (order No.:504674 with the diagnostic connector of the vehicle. Switch on the ignition! Now, start the “Testman”...
  • Page 236 Ch 2 TRANSMISSION page Now, select the desired Application, which you start with a double-click, or you are using the command „Open“! Now, start the application (e.g.:WG 260 - 310) by the command „Run“. SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 237 Ch 2 TRANSMISSION page Now, appears the Company logo „ZF-Service“, which you acknowledge which „Enter“ or by mouse click on the Arrow down on the right („Forward-Button“). (As the next step, the Version of „Testman“ and some Instructions will be illustrated to you, which you acknowledge by „Enter“.) Now, you are in the main menu of „Testman”, where you have the selection between the single menu items.

  • Page 238: Produkt Menue Ergopower

    Ch 2 TRANSMISSION page Produkt menue Ergopower Produkt menue ERGOPOW ER Repair assistanse Maintenace To Subprograms Torque limits Torque limits To Subprograms Adjustments values Adjustments values To Subprograms Special tool tester Special tool tester To Subprograms Repair Repair To Subprograms Viring and connections diagrams To Subprograms Pressures...

  • Page 239: Aeb Starter

    Due to the operation of the transmission, the paper friction linings, installed in the Er-gopower transmissions are settling, i.e. the plate clearance becomes greater. Because these settling appearances can interfere the shifting quality, Moxy trucks recommends to repeat the AEB-Cycle at the Maintenance intervals (see 4.3.1) The ZF recommends likewise at a reduced shifting quality as first measure to repeat the...

  • Page 240: Procedure To Start Aeb

    Ch 2 TRANSMISSION page Procedure to start AEB Engine Coordinator Transmission Control unit EST37A Disassemble 2 screws for the seat back. Push (knock) down the seat back. Take up the covering plate SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 241 Ch 2 TRANSMISSION page Find the diagnostic contact (607) between the controller units NOTE ! Before starting the AEB, the transmission-oil must have a temperature at 70 - 80°C Connect the plug from AEB starter to the diagnostic contact without the ignition on. Turn on the ignition.
  • Page 242 Ch 2 TRANSMISSION page Step to do Display message Remark warm up transmission normal operating messages turn off ignition nothing plug in AEB - starter move shift lever to N position engage parkbrake start engine ‘PL’ TCU must recognize PL for at least 2s before you can press the button set engine speed to low idle ‘PL’...

  • Page 243: Aeb Code List

    Ch 2 TRANSMISSION page AEB code list Symbol Meaning Remarks AEB - Starter is plugged at the diagnostic plug AEB-Starter-button is pressed K1..K4,KV,KR calibrating clutch K1..K4,KV,KR _ and Kx wait for start, initialization of clutch fast fill time determination of clutch and Kx = and Kx compensating pressure...

  • Page 244: Laptop - Start Of Aeb Via Testman

    Ch 2 TRANSMISSION page Laptop - Start of AEB via Testman (AEB ⇒ Automatic determination of Filling parameters) Remove the passenger seat back and the covering plate and find the diagnistic plug Connect the Programming Adapter DPA3 to the diagnostic plug between the controller units Connect the cabel from the Programming Adapter DPA3 to the laptop Select in the main menu the item „Vehicle configuration“!

  • Page 245: Installation View

    Ch 2 TRANSMISSION page Installation view Front view = Electro hydraulic shift control = Input flange-Input trough prop shaft = Retarder valve = Axle insert “LK” = Output flange- Front axle LH = Oil filler hole Axle insert”LK” M42 x 1,5 = Coarse filter = Oil drain plug Transmission with magnetic insert M38 x 1,5 = Oil drain plug Axle insert “LK”...
  • Page 246 Ch 2 TRANSMISSION page Left side view = Input flange- Input trough prop shaft = Stator = Converter bell housing = Lifting lugs = Pressure oil line from converter clutch valve to converter clutch = Pressure oil line from electro hydraulic shift control to converter clutch valve = Electro-hydraulic shift controll = Converter clutch valve = Breather line Converter clutch...
  • Page 247 Ch 2 TRANSMISSION page Rear side view = Converter clutch valve = Pressure oil line from electro-hydraulic shift control to converter cluth valve = 1st Power take-off = Pressure oil line Clutch KR = Electro-hydraulic shift control = 2nd Power take off = Pressure oil line Clutch K1 = Pressure oil line Clutch K4 = Pressure oil line K3...

  • Page 248: Inductive Transmitter

    Ch 2 TRANSMISSION page Inductive transmitter Housing Induktive transmitter Gear wheel 608 = Induktive transmitter n-Central gear train 606 = Induktive transmitter n-Engine 612 = Induktive transmitter n-Turbine S= 1,0 - 1,5 Speed sensor Spur gear K3 Housing Clutch axle K4/K3 The speeds required for the Electronic controll unit EST-37 are detected by the following transmotters: 606 = Inductive transmitter...

  • Page 249: Transmission Diagram

    Ch 2 TRANSMISSION page Transmission diagram Retarder Converter Main pump Input Pump Engagement and Output Disangagement Differential lock Differential 606 = Inductive transmitter n – Engine and 608 = Inductive transmitter n – Central gear train 610 = Speed sensor n –...

  • Page 250: Oil Circuit Diagram

    Ch 2 TRANSMISSION page Oil circuit diagram Valve block controll circuit RV-9 TEMP Valve block control circuit LEGENDE = Main pressure = Regulated main pressure = Pilot pressure = Converter input pressure = Converter output pressure = Lubrication = Return into the sump Main oil circuit MAIN OIL CIRCUIT Not scope of supply- ZF...

  • Page 251: Measuring Points And Connections

    Ch 2 TRANSMISSION page Measuring points and connections M easur ing poi n t and values Breather To the c ooler From the c ooler To the ZF-fil ter From the filter From the filter b ypa ss to the converter From c ooler lubr ic ati on (via retarder valve) In f ront o f c onv.

  • Page 252: Troubleshooting

    Ch 2 TRANSMISSION page Troubleshooting Prerequisites for the troubleshooting 1. Oil level as well as oil quality must correspond with ZF-list of lubricants (TE-ML 03) for the new WG-Transmission Product range! 2. Transmission temperature from 80°C to 100°C ! 3. Please, pay attention that the prescribed Operation Instructions habe been used.

  • Page 253: Lay Out 6Wg-260

    Ch 2 TRANSMISSION page Lay out 6WG-260 = Input flange - Drive via universal shaft = retarder = WK = Converter = Breather = Electrohydraulic controll unit = 2nd Power take- off = Transmission pump = 1st Power take- off = Clutch axle “KV/K1”...

  • Page 254: Introduction

    Ch 2 TRANSMISSION page Introduction Abbreviations o.c. open circuit s.c. short circuit OP-Mode operating mode transmission control unit electronic engine controller power take off ZF - Display: If a fault is detected, the display shows a spanner symbol (g) for a fault. The display shows the fault code, if the gear selector is on neutral position.

  • Page 255: Display During Operation

    Ch 2 TRANSMISSION page Display during operation symbol meaning remarks 1F, 1R actual gear and direction 2F, 2R left digit shows actual gear 3F, 3R right digit shows actual direction LF, LR limp home gear F or R, no gear Clutch Cutoff F od R flashing only 6WG:...

  • Page 256: Display During Aeb-Mode

    Ch 2 TRANSMISSION page Display during AEB-Mode symbol meaning remarks AEB - Starter is plugged at the diagnostic plug AEB-Starter-button is pressed K1..K4,KV,KR calibrating clutch K1..K4,KV,KR _ and Kx wait for start, initialization of clutch Kx, x: 1, 2, 3, 4, V, R fast fill time determination of clutch and Kx = and Kx...

  • Page 257: Definition Of Operating Modes

    Ch 2 TRANSMISSION page Definition of operating modes Normal: There’s no failure detected in the transmission-system or the failure has no or slight effects on transmission control. TCU will work without or in special cases with little limitations. (see following table) Substitute clutch control: TCU can’t change the gears or the direction under the control of the normal clutch modulation.

  • Page 258: Table Of Fault Codes

    Ch 2 TRANSMISSION page Table of fault codes MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection TCU shifts transmission check the cables from failure cannot be LOGICAL ERROR AT GEAR to neutral detected in system s with TCU to shift lever...
  • Page 259 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection Customer specific S.C. TO GROUND AT Check the cables from 1) See chapter 4 TCU detected a wrong TCU to feedback voltage at the output pin, axle connection switch...
  • Page 260 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection retarder function is check the cable from availability of retarder TO GROUND OR O affected TCU to the sensor depends on default load LOAD SENSOR INPUT...
  • Page 261 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection Check the cable from S.C. TO GROUND AT No reaction, TCU to the sensor RETARDER /TORQUE TCU uses default CONVERTER TEMP.
  • Page 262 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection Check the cable from TCU uses default value S.C. TO BATTERY TCU to the sensor OP-Mode: normal VOLTAGE OR O.C.
  • Page 263 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection S.C. TO BATTERY Check the cable from TCU uses default value VOLTAGE OR O.C. AT TCU to the sensor OP-Mode: normal DLM TRACTION ADJUST...
  • Page 264 Ch 2 TRANSMISSION page MEANING OF THE Fault Possible steps Reaction of the Remarks FAULT Code to repair CODE (hex) Possible reason for fault OP-Mode: substitute check the cable from TO BATTERY VOLTAGE OR clutch control TCU to the sensor AT TURBINE SPEED INPUT TCU measures a voltage if a failure is existing at...
  • Page 265 Ch 2 TRANSMISSION page MEANING OF THE FAULT Possible steps Reaction of the Remarks Fault CODE to repair Code Possible reason for fault (hex) detection OP-Mode: substitute check the cable from TO GROUND AT INTERNAL clutch control TCU to the sensor SPEED INPUT TCU measures a voltage check the connectors...
  • Page 266 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection special mode for gear check the cable from This fault is reset after LOGICAL ERROR AT OUTPUT selection power up of TCU TCU to the sensor...
  • Page 267 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection EEC3 OP-Mode: substitute check EEC controller TIMEOUT Timeout of CAN-message clutch control check wire of CAN- EEC3 from EEC controller interference on CAN-Bus check cable to EEC...
  • Page 268 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection no reaction, if this signal is not check EEC controller ACCELERATOR LOW IDLE TCU uses default signal transmitted via CAN, check wire of CAN- SWITCH SIGNAL...
  • Page 269 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection TCU shifts to neutral check the cable from see chapter 4 TO GROUND AT CLUTCH OP-Mode: limp home TCU to the gearbox the measured resistance...
  • Page 270 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection TCU shifts to neutral check the cable from see chapter 4 AT CLUTCH the measured resistance OP-Mode: limp home TCU to the gearbox value of the valve is out of...
  • Page 271 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection TCU shifts to neutral check the cable from see chapter 4 TO GROUND AT CLUTCH OP-Mode: limp home TCU to the gearbox the measured resistance...
  • Page 272 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection check the cable from TCU shifts to neutral AT CLUTCH see chapter 4 the measured resistance TCU to the gearbox OP-Mode: limp home value of the valve is out of...
  • Page 273 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection Check the cable from S.C. TO BATTERY No reaction TCU to the device see chapter 4 VOLTAGE AT DLM OP-Mode: normal INDICATOR LAMP...
  • Page 274 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection S.C. TO GROUND AT Check the cable from No reaction 1) see chapter 4 RELAY STARTER TCU to the starter OP-Mode: normal INTERLOCK...
  • Page 275 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection no reaction see chapter 4 check the cable from TO GROUND AT OP-mode: normal TCU to the converter CONVERTER LOCK UP CLUTCH TCU detected a wrong clutch solenoid...
  • Page 276 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection no reaction see chapter 4 check the cable from AT RETARDER TCU detected a wrong OP-mode: normal TCU to the retarder voltage at the output pin, that...
  • Page 277 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection no reaction see chapter 4 check the cable from AT DIFFLOCK OR AXLE OP-mode: normal TCU to the difflock CONNECTION SOLENOID TCU detected a wrong...
  • Page 278 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection TCU shifts to neutral check pressure at SLIPPAGE AT CLUTCH TCU calculates a differential OP-Mode: limp home clutch K1 speed at closed clutch K1.
  • Page 279 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection TCU shifts to neutral check pressure at SLIPPAGE AT CLUTCH TCU calculates a differential OP-Mode: limp home clutch KV speed at closed clutch KV.
  • Page 280 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection Check pressure at SLIPPAGE AT CONVERTER converter lockup clutch LOCKUP CLUTCH TCU calculates a differential Check main pressure in speed at closed converter the system...
  • Page 281 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection Noreaction see chapter 4 C heck the cable from NGINE RAKE TCU detected a wrong OP-mode: normal TCU to the engine voltage at the output pin,...
  • Page 282 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection Check the cable from S.C. TO BATTERY No reaction TCU to joystick status VOLTAGE AT JOYSTICK OP-Mode: normal indicator STATUS INDICATOR...
  • Page 283 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection see fault codes no. 21 to check cables and fault codes no. 21 to no. TO BATTERY VOLTAGE AT connectors to sensors, 2C may be a reaction of...
  • Page 284 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection Check the cable from Output will be on until 1) see chapter 4 S.C. TO GROUND AT DLM TCU to the valve TCU power down even LONGITUDINAL OUTPUT...
  • Page 285 Ch 2 TRANSMISSION page MEANING OF THE FAULT Fault Possible steps Reaction of the Remarks CODE Code to repair Possible reason for fault (hex) detection no reaction check the cable from TO BATTERY VOLTAGE AT OP-Mode: normal TCU to the display DISPLAY OUTPUT TCU sends data to the check the connectors...

  • Page 286: Measuring Of Resistance At Actuator/Sensors And Cable

    Ch 2 TRANSMISSION page Measuring of resistance at actuator/sensors and cable Actuator: Open circuit: » R » R » ¥ Short cut to ground: » R; » 0, R » R or R » R, R » 0 (for s.c. to ground, G is connected to vehicle ground) Short cut to battery: »...
  • Page 287 Ch 2 TRANSMISSION page SHOP MANUAL MT26/31 - 08.2006...
  • Page 288 Ch 2 TRANSMISSION page SHOP MANUAL MT26/31 - 08.2006...

  • Page 289: Electronic Control Unit Est-37A

    (TCU must be ordered separate) mode. Important parts information If the Transmission 6WG310 is to be returned to Moxy Trucks AS or ZF for repair or any others reasons, the Transmission controller EST-37A is to be returned together with the Transmission.

  • Page 290: Pin In Contact For The Tcu

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pin in contact for the TCU Pole 23 Pole 45 Pole 68 Pole 46 Pole 24 Pole 1 Pole 23 Pole 45 Pole 68 Pole 46 Pole 24 Pole 1 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 291 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Not connected Ground connection Speedometer Ground connection Not connected Joint Not connected Rpm output shaft Temp sensor sump (156) Solenoid emergency retarder. Not connected Not connected Turbine RPM Relay reverse light Internal gear chain RPM Terminal block ??? Gear selector forward Solenoid Y5...

  • Page 292: Family Package Of The Est-37A

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Family package of the EST-37A Legend ref. Figure Warning lamp 4 = Display 5 = Controller VST-3 6 = Supply system connection 7 = Fine filter with maintenance switch / Cable to filter contamination switch 9 = Electro control unit EST37 10 = CAN-connection 12 = Diagnosis Laptop with ZF-Diagnostic system Testmann and AEB...

  • Page 293: Electro-Hydraulic Shift Control Unit

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Electro-hydraulic shift control unit Transmission control: The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6), follow-on slide and vibration damper.

  • Page 294: Electro-Hydraulic Control Unit Hsg-94

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Electro-hydraulic control unit HSG-94 Measuring point In front of conv. – opening pressure Clutch forward Clutch reverse Clutch K1 Clutch K2 Clutch K3 Clutch K4 System pressure SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 295: Electro Hydr. Shift Control Valve, Cross Section

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Electro hydr. shift control valve, cross section The following drafts are showing the sectional Illustrations of the HSG-94 Housing Valve block Cover Cover Plug (Cable harness) Main pressure Pressure reducing Housing valve 16 + 2 bar valve 9 bar Ma i n p r e s s u r e P r e s s u r e r e d u c i n g...
  • Page 296 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504254 504253 Tool for the Electro-hydraulic Control unit HSG-94 Page 1 504185 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 297 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 298: Disassembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page DISASSEMBLY Summary for the Tool, see chapter 2.0 Loosen socket head screws and remove selector housing. (S) Box spanner TX-27 504253 Figure1 Separate hose lines from the intermediate plate. Loosen socket head screws and separate intermediate plate as well as gaskets and intermediate sheet from gearbox housing.
  • Page 299 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove retaining clip. Figure 5 Losen socket head screws and remove cover. Demount opposite cover. Figure 6 Demount pressure regulator and remove cable harness. Figure 7 Loosen socket head screws, remove retaining plates and de- mount pressure regulator.
  • Page 300 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Loosen two socket head screws and locate the housing provisio- nally by means of adjusting screws. (Housing is spring-loaded). Now, loosen the remaining socket head screws. (S) Adjusting screws 504188 Figure 9 Separate housing from valve body by uniform loosening of the adjusting screws.

  • Page 301: Assembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page ASSEMBLY Check all components for damage and renew if necessary ! Prior to the installation, check the free travel of the moving parts in the housing ! Spools can be exchanged individually ! Prior to the assembly, oil the components according to ZF-List of lubricants TE-ML 03 ! Insert orifices with the concave side showing upward, until...
  • Page 302 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Figure17 Preload spool and remove the cylindrical pins (assembly aid) again. Figure 18 Fasten housing cover by means of socket head screws. Torque limit........... 5,5 Nm Figure 19 Introduce pressure regulators and fix them by means of retai- ning plates and socket head screws.
  • Page 303 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble opposite side The Figure on the left shows the following components: 1 = Main pressure valve (1x spool and compression spring) 2 = Follow-on slide (3x spool and compression spring) 3 = Vibration damper (3x spool and compression spring Figure 21 Install components according to Figure 21.
  • Page 304 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce cable harness and connect pressure regulators (6x). Pay attention to the installation position of the cable harness, see also markings (Figure 3) ! Figure 24 Mount flat gasket (Arrow). Introduce femal connector, with the groove facing the guide nose of the cover, until contact is obtained.
  • Page 305 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install two adjusting screws and mount gasket I. Pay attention to the different gaskets, see Figure 27 and 30 ! (S) Adjusting screws M6 504189 Figure 27 Intermediate plate – Version with strainers: Insert strainers (6x) flush-mounted into the bores of the inter- mediate plate, see Arrows ! Pay attention to the installation position –...
  • Page 306 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount duct plate (Arrow) and fasten it uniformly by means of socket head screws. Torque limit ........11 Nm (S) Box spanner TX-27 504253 Figure 31 Equip screw plugs (8x) with new O-rings and install them. Torque limit .........
  • Page 307 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install two adjusting screws (M8) and mount housing gasket. At the following steps (Figure 35 ... 39), pay attention to the installation positions of the different gaskets ! (S) Adjusting screws M8 504185 Figure 35 Mount intermediate plate.
  • Page 308 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install 2 adjusting screws (M6). Mount gasket (Arrow). (S) Adjusting screws M6 504189 Figure 39 Fasten complete valve block uniformly with socket head screws (2 pieces M6 x 105 and 21 pieces M6 x 80 mm). Pay attention to the position of the two socket head screws (M6 x 105), see Arrows ! Torque limit ........

  • Page 309: Wk-Valve

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page WK-Valve WK Solenoid shift valve WK SOLENOID VALVE Meas. point WK Connection to WK Duct plate Vent. hole Syst. pressure from hydr. contr. unit SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 310: Disassembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page DISASSEMBLY Remove hose lines. Loosen hex. head screws and separate WK-valve from housing Figure 41 Loosen socket head screws, separate selector housing from adapter plate, and remove components. Figure 42 ASSEMBLY Insert set screw 1 with Loctite (Type-No. 649). Equip both connecting fittings 2 with new O-rings and install them.
  • Page 311 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install WK-Valve components according to the Figure on the left. 1 = Solenoid valve 2 = Socket head screw + Spring washer (2x) 3 = Selector housing 4 = Piston 5 = Shim rings (empirical value, 6 units/0,5 mm thick, each) 6 = Compression spring 7 = Stop (optional, empirical value A = 3,0 mm) 8 = Connecting fitting (install new O-ring)

  • Page 312: Retarder

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Retarder Function of a retarder General: The hydrodynamic Retarder (fluid brake), installed upon request, is arranged between engine and torque converter thus achieving a good braking effect in all gears. The Retarder is a wear-free, gear-depending acting hydrodynamic-brake. The application of the Retarder is therefore especially to recommend at longer downgrade drives or to brake down out of high driving speeds, because in this way, the service brake will be saved and in an emergency case, the full braking effect (no fading) of the service brake will...

  • Page 313: Retarder Reconditioning Tool

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Retarder reconditioning tool 504193 504175 504194 Special tool - Retarder 504167 504195 504163 504182 504185 504178 504198 504184 504160 504182 Special tool - Input 504183 504169 504195 504221 504186 504196 504209 504170 504176 504175 504182...

  • Page 314: Disassembly The Retarder

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disassembly the retarder Summary for the Tools for retarder disassembly and as- sembly, see previous side Fasten the complete transmission on the assembly car. (S) Assembly car 504213 (S) Clamping bracket 504214 Figure 50 Separate pipes from selector housing.
  • Page 315 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Tilt gearbox housing 90°. Remove lock plate. Loosen hex. head screws and pull off input flange. If only operations on the transmission are necessary, the complete retarder can be separated, along with the con- verter, from the converter connecting housing by loosen- ing the screw connection (Figure 56) ! Figure 53...
  • Page 316 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Separate the complete retarder from the converter connecting housing, using lifting device. (S) Set of eye bolts 504182 Figure 57 Loosen socket head screws, separate spacer ring from stator housing. Figure 58 Loosen socket head screws and separate cover from stator housing.
  • Page 317 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Separate rectangular ring from rotor. Figure 61 Remove the rectangular ring on the opposite side. If necessary, separate the ring (Arrow) from the rotor. Figure 62 Loosen hex. head screws and remove thrust ring. Figure 63 Remove stator ring.
  • Page 318 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pry shaft seal out of the bore. (S) Pry bar 504209 Figure 65 Drive ball bearing out. Figure 66 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 319: Assembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page ASSEMBLY Insert ball bearing until contact is obtained. Figure 71 Insert ball bearing until contact is obtained. Figure 72 Fasten thrust ring by means of hex. head screws. Torque limit (M8/8.8) ......23 Nm Pay attention to the installation position –...
  • Page 320 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble dampers (3 pieces) according to Figure 25 and Figure 26. The Installation dimension B = 1,6 mm results + 0,5 from the alternating stacking of the cup spring packs (8 packs with 6 cup springs each) ! Figure 74 Ref.
  • Page 321 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce rectangular ring into the recess of the rotor (Figure 77) and preload it by means of cylindrical pins Æ 6 mm (as- sembly aid), see Figure 78 ! Install rectangular ring with the marking „Top“ see Arrow, show- ing upward (to the prime mover) ! Figure 77 Figure 78...
  • Page 322 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert ring into the cover, with the oil grooves showing down- ward. Figure 81 Introduce rectangular ring. Install rectangular ring with the marking „Top“ see Arrow, show- ing upward (to the prime mov er) ! Figure 82 Insert O-ring into the annular groove of the cover (Arrow) and grease it.
  • Page 323 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Adjust Rotor dimension (distance between Rotor – Stator ring) = 1,5 ... 2,0 mm (Figure 85 ... 89): Line up axial washer s = 1,0 mm, axial roller cage and housing disk s = 5,75 mm. Figure 85 Determine Dimension I from the housing disk to the mounting face.
  • Page 324 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount shim s = 2,5 mm (see Example A, Figure 85 - 88 Figure 89 Adjust Axial play – Ball bearing 0,10 ... 0,20 mm (Figure 90 ... 93): Check exact contact of ball bearing (Arrow) once more and place pre-assembled stator housing over the plug gauge.
  • Page 325 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount shim s = 0,3 mm (see Example B Page 2.11) with grease. Figure 93 Heat bearing inner race. (S) Hot-air blower 230 V 504193 (S) Hot-air blower 115 V 504194 Figure 94 Introduce flange shaft until contact is obtained.
  • Page 326 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clean O-ring. O-ring groove must be perfectly clean Grease O-ring (Arrow) and insert it into the annular groove of the spacer ring. Figure 97 Fasten spacer ring by means of socket head screws. Torque limit (M10/8.8, DIN 6912) ..
  • Page 327 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Fasten rotor and flange shaft on the converter, using hex. head screws. Tighten hex. head screws uniformly (180° displaced) as well as secure them with Loctite (Type-No. 243) ! Torque limit (M10/8.8) ........ 46 Nm Figure 101 Equip screw plug with new O-ring and install it.
  • Page 328 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Line up input flange and fasten it by means of disk and hex. head screws. Wet contact face of the disk with Loctite (Type-No. 574) ! Torque limit (M10/8.8) ......46 Nm Figure 105 Fix hex.

  • Page 329: Retarder Valve

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Retarder valve The braking procedure itself will be started via a hand- or foot-actuated control valve. With this valve it is possible to adjust a certain air pressure and with it the desired brake performance infinitely variable.
  • Page 330 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504185 Special tool - Press. regulator SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 331 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and mount Retarder: Install components according to Figure 107 and 108. Selector housing Screw plug (M14x1,5, Torque limit 35 Nm Screw plug (M26x1,5, Torque limit 80 Nm Screw-in sleeve Temperature sensor Torque limit 35 Nm Screw plug (M14x1,5, Torque limit 35 Nm...
  • Page 332 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install two adjusting screws and line up the gasket. (S) Adjusting screws M8 504185 Figure 111 Figure 112 Install 2 gasket. Figure 113 Line up the pre-assembled selector housing and fasten it with hex.

  • Page 333: Converter

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Converter Function of the Converter: UNCTION OF A HYDRODYNAMIC ORQUE CONVERTER CHEMATIC VIEW = Torque of the wheel Turb ine Impeller Impeller = Torque of the Turb ine wheel = Tor que of the Reaction member (Stator) From the...

  • Page 334: Converter (Wk)

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page The stator (reaction member) following the turbine, has the task to reverse the oil, streaming out of the turbine once more and to deliver it under the suitable discharge direction to the im-peller. Due to the reversion, the stator is receiving a reaction moment.
  • Page 335 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 336: Removal Of Transmission, Ass'y

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Removal of transmission, ass’y NOTE! Place the dump truck on level ground and apply parking brake Start with the propeller shaft in the articulation hinge. For best working, start the engine and turn the machine to full right direction.
  • Page 337 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Drain both hydraulic oil reservoirs, see chapter 7 maintenance - 2000 hour service in the Operating & Maintenance Manual. Main reservoir Emergency steering reservoir (Oil capacity approx. 190-200 l.) NOTE: See in the hydraulic chapter about the filling procedure.

  • Page 338: Disassemble The Exhaust Parts

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disassemble the exhaust parts Disassemble the front V-clamp and the rear clamp, remove the exhaust pipe. Disassemble the rear pipe V-clamp and the front and rear suspen- sions. Screw M12x30 ISO4017-10.9 Lift out the muffler with the suspension bracket SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 339: Disassemble Of The Hydraulic Hoses At The Transmission

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disassemble of the hydraulic hoses at the trans- mission Realease all (19 pcs) of the hydraulic hoses connected to the transmission. Realease all of the wiring on the electrical points. (Total included ground ca- bel are 11 electrical connections have to discon- nected.)
  • Page 340 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismount the protection guard for the diff and both front axle propeller shaft at differential side. From machine 810013 are screws for the propeller shaft changed to UNF thread on outer and inner sides: •...
  • Page 341 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismount the axle catcher bow. (white arrow) Dismount converter prop. shaft. (red arrow) Front screw: M12x50 ISO4014-10.9 EL Rear screw: ½” UNF x2” NS 965--8.8 Disassemble the front transmission bracket attachment. If shim are assembled, use the shims at the same place when as- semblying.
  • Page 342 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Place the transmission safely on a rack or similar. Secure the transmission. SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 343 Ch 2 TRANSMISSION page SHOP MANUAL MT26/31 - 08.2006...

  • Page 344: Manual Transmission

    Ch 2 TRANSMISSION page Manual transmission Disassembly Fasten the complete transmission on the assembly car. (S) Assembly car 504213 (S) Support 504214 Remove all oil lines. Figure 120 504160 504198 504184 504182 Special tool - Input 504183 504169 504195 504221 504186 504196 504182...
  • Page 345 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Loosen hex. head screws and lift complete retarder along with converter out of the converter bell using a lifting device. (S) Lifting chain 504198 (S) Set of eye bolts 504182 Figure 121 Drive Unfix screw union and separate cover from converter bell by means of forcing screws (3xM10).
  • Page 346 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull oil feed flange by means of special device out of the converter bell. (S) Puller device 504160 Figure 123 Remove converter safety valve (ball + spring, see arrow). Figure 124 Loosen screw connection (M8 and M12). Separate converter bell from the transmission using lifting device.
  • Page 347 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove both rectangular rings (arrow). Figure 127 Press input shaft out of the spur gear bearing. Remove released bearing inner race and spur gear. Figure 128 Press bearing inner race off the input shaft. Figure 129 Remove pressure back-up valve.
  • Page 348 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull the complete input shaft out of the gearbox housing or out of the pump. Figure 131 Squeeze out rectangular ring (arrow). Figure 132 Separate spur gear from shaft and squeeze out circlip (arrow). (S) Set of pliers 504232 Figure 133...
  • Page 349 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Fasten shaft in vice. Unscrew socket head screw and remove clamping disc. Use protective jaws! Figure 135 Pull bearing inner race and driver off the shaft. Support puller on the end face – input shaft! Pay attention to the released shims! (S) 3-leg-puller 504236...
  • Page 350 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504186 Special tool - Press. Oil Pump 504160 504195 504168 504239 504238 Special tool - Power take -off 504186 504236 504204 504203 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 351 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Loosen socket head screws (M8) and position puller device. Pull transmission pump out of the housing bore. Tapping onto the housing face will support pulling out! (S) Puller device 504160 Figure 139 Pull bearing outer race out of the bore and remove spacer.

  • Page 352: Axle Disconnection

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Axle disconnection 504184 Special tool - Axle disconnection 504210 504175 504196 504179 504167 504220 504195 Special tool - Axle disconnection 504179 504164 504233 504184 504175 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 353 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove lock plate. Loosen hex. head screws and remove disc. Pull output flange off the shaft. Figure 143 Tilt gearbox housing by 180°. Loosen hex. head screws, dismantle cover and remove filter. Figure 144 Axle disconnection device –...
  • Page 354 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismantle switch and detent pin. Figure 147 Disassemble switch and detent pin. Figure 148 Remove cover as well as circlip and drive pin out of the bore using a striker. Remove the released components. (S) Striker 504224 Figure 149...
  • Page 355 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Special tool - Gearbox housing 504225 504187 504196 504183 Special tool - Gearbox housing 504184 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 356 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 3.1.5 Countershaft Remove sealing cover and loosen hex. head screws. Figure 151 Tilt gearbox housing by 90°. Drive countershaft axle off the housing bore or the countershaft support by means of a striker. (S) Striker 504225 Figure 152...
  • Page 357 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Loosen screw connection and separate housing cover by means of back-off screws (arrows) and lifting device from the gearbox hous- ing. During the separating procedure, drive out the output shaft by tap- ping continuously downwards! (S) Back-off screws 504183...

  • Page 358: Interaxle Differential

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Interaxle differential: Description: The differential, installed in the output, has the task to transmit different torques on the vehicle axles and to function as intermediate compensation in the driving direction (longitudinal direction of the vehicle). Due to the existing differential lock, both functions can be put out of service and a rigid con-nection between the axles can be created.

  • Page 359: Interaxle Differential With Mounted Differential Carrier „Lk

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Interaxle differential with mounted Differential carrier „LK“ HA= Output Rear axle 1 = K3-Spur gear – Input 2 = Planetary gear (Ravignaux-System outer hole circle) Planet carrier Screening plate Sun gear Output shaft to the Front axle (converter-side) Internal gear Output shaft to the Rear axle (rear-side) 10 =...

  • Page 360: Interaxle Differential Disassembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Interaxle differential disassembly 504199 504222 504231 Special tool - Differential 504164 504233 504167 504182 504220 504195 Lift differential out of the gearbox by means of lifting device. (S) Lifting device 504198 (S) Set of eye bolts 504182 Figure 157 Remove plate and disassemble bearing inner race.
  • Page 361 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Squeeze out both rectangular rings (arrow) and remove them. Figure 160 Remove bush. Figure 161 Squeeze out snap ring and pull output shaft off the planet carrier. Figure 162 Squeeze out circlip (sun gear fixing). (S) Set of external pliers 504231 Figure 163...
  • Page 362 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull bearing inner race off the internal gear. (S) Quick-acting grip 504252 or grab sleeve 504247 (S) Basic tool 504246 Figure 164 Squeeze out snap ring. Figure 165 Press internal gear and planet carrier out of the internal gear. Figure 167 shows the released components! Figure 166...
  • Page 363 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Carefully drive in roll pin (arrow) until contact is obtained. Figure 168 Drive out planet bolt and remove planet gears. Figure 169 Press output shaft far enough downward until the sun gear can be removed, also see Figure 171! Figure 170 Squeeze out snap ring (arrow) and separate output shaft from...
  • Page 364 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page If necessary, pry baffle ring out of the planet carrier bore, squeeze out snap ring (Figure 172) and drive out needle bearing (Figure 173). Figure 172 Assembly the interaxle diff, see the section: Interaxle differential assembly Figure 173 SHOP MANUAL MT26/31 - 08.2006...

  • Page 365: Clutches, Powershift Transmission

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clutches, Powershift transmission 1 = Input flange - Drive via universal shaft 2 = Retarder 3 = WK 2 = Converter 5 = Breather 6 = Electrohydraulic control unit 7 = 2 Power take-off 8 = Transmision pump 9 = 1...

  • Page 366: Multi-Disk Clutch

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disk clutch The multi-speed reversing transmission in countershaft design is power shiftable by hydrauli-cally actuated multi-disk clutches. All gears are constantly meshing and carried on antifriction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 6-speed reversing transmission is equipped with 6 multi-disk clutches.

  • Page 367: Clutch Chart

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clutch chart PRESSURE REGULATOR UNDER VOLTAGE ENGAGED CLUTCHES DRIVING DIRECTION Y1 Y2 Y3 Y4 Y5 Y6 Speed FORWARD REVERSE NEUTRAL KR K4 K1 K3 KV K2 ENGAGED CLUTCH POSTITIONS ON VALVE BLOCK CONSEC.

  • Page 368: Plate Clearanse In The Single Multi-Disc Clutches

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Plate clearanse in the single Multi-disc clutches Type K1 (mm) K2 (mm) K3 (mm) K4 (mm) KV (mm) KR (mm) WG-310 2,6 +0,2 2,2 +0,2 2 , 2 + 0 , 2 2 , 2 + 0 , 2 2 , 8 + 0 , 2 2 , 2 + 0 , 2...

  • Page 369: Oil Circuit Diagram

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil circuit diagram RV-9 TEMP Valve block control circuit LEGENDE = Main pressure = Regulated main pressure = Pilot pressure = Converter input pressure = Converter output pressure = Lubrication = Return into the sump MAIN OIL CIRCUIT Not scope of supply- ZF Air reservoir 8 bar...

  • Page 370: Disassemble Multi-Disc Clutches

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disassemble Multi-disc clutches Disassemble clutch K4/K3, KR/K2 and KV/K1 by means of lifting device. At the disassembly of the clutch K4/K3, slightly lift clutch KR/K2 and displace it in arrow direction, see figure on the left! (S) Set of eye bolts 504182 Figure 175...
  • Page 371 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Lift output shaft by means of pry bar until the bearing outer race is free. (S) Pry bar 504209 Figure 179 Take output shaft out of the housing. Figure 180 Pull bearing outer race out of the housing bore. (S) Internal puller 504202 (S) Counter support...
  • Page 372 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 509114 504236 504243 504237 Special tool - Coupling K3 + K4 Page 1/2 504227 504207 504190 504217 504238 504195 504175 504208 504216 504248 504211 Special tool - Coupling 504206 K3 + K4 Page 2/2 504237 504211...
  • Page 373 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismantle multi-disc clutch – K3/K4 Fasten clutch by means of clamping ring (S) on the assembly car. (S) Clamping ring 504226 504227 Figure 185 Pull roller bearing off plate carrier. (S) 3-leg puller 504236 Figure 186 Separate spur gear K3 from plate carrier.
  • Page 374 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Squeeze snap ring out. Disassemble end shim and plate pack K3. Figure 189 Tilt plate carrier 90°. Loosen slotted nut. Slotted nut is secured with Loctite! To prevent damage to the thread, heat up slotted nut prior to loosen it (abt.
  • Page 375 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove adjusting ring. Figure 193 Pull off tapered roller bearing. (S) 3-leg puller 504236 Figure 194 Squeeze out snap ring. Disassemble end shim and plate pack K4. Figure 195 Pre-load compression spring by means of special device (S). Squeeze out snap ring and remove the released components.
  • Page 376 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Separate both pistons with compressed air from the plate carrier. Figure 197 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 377: Dismantle Multi-Disc Clutch Kr/K2

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismantle multi-disc clutch KR/K2 504215 504175 504250 504243 Special tool - Coupling KR + K2 504227 504206 504218 504207 504251 504243 504215 504245 504243 504195 504237 504244 504211 504175 Fasten clutch by means of clamping ring (arrow) on the assembly car.
  • Page 378 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Tilt plate carrier by 90°. Loosen slotted nut. Slotted nut is secured with Loctite! To prevent damage to the thread, heat slotted nut prior to loosen it (abt. 120° C)! (S) Hook spanner 504215 Figure 199 Pull tapered roller bearing off plate carrier.
  • Page 379 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull tapered roller bearing off plate carrier. (S) Grab sleeve 504251 (S) Basic tools 504243 Figure 203 Squeeze snap ring out. Disassemble end shim and plate pack K2. Figure 204 Tilt plate carrier by 90°. Loosen slotted nut.
  • Page 380 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull tapered roller bearing from plate carrier. (S) 3-leg puller 504237 Figure 207 Remove adjusting rings. Figure 208 Squeeze out snap ring. Disassemble end shim and plate pack KR. Figure 209 Pull tapered roller bearing off plate carrier. (S) Grab sleeve 504244 (S) Basic tool...
  • Page 381 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504195 504169 504209 504240 504238 Special tool - Coupling KV + K1 504227 504213 504218 504207 504238 504211 504216 504175 504237 504217 504242 504237 504217 504215 Special tool - Coupling KV + K1 Page 2/2 504206 504169...
  • Page 382 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismantle multi-disc clutch KV/K1 Fasten clutch by means of clamping ring on the assembly car. Loosen slotted nut (Figure 211). Slotted nut is secured with Loctite! To prevent damage to the thread, heat the slotted nut prior to loosen it (abt.
  • Page 383 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove disc. Figure 213 Pull cylindrical gear K1 off plate carrier. (S) 3-leg puller 504237 Figure 214 The figure on the left shows the spur gear bearing -K1. Bearing 1 is available only as sub-assembly. If the disassembly of the plate pack-side ball bearing (arrow) is necessary –...
  • Page 384 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull ball bearing from plate carrier (Figure 217 and 218). Pay attention to the released balls! (S) Pry bar 504209 Figure 217 Figure 218 Squeeze out snap ring. Disassemble end shim and plate pack K1. Figure 219 Tilt plate carrier by 90°.
  • Page 385 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull tapered roller bearing off plate carrier. (S) Grab sleeve 504242 (S) Basic tool 504238 Figure 221 Pull spur gear KV off plate carrier. (S) 3-leg puller 504237 Figure 222 Remove shim and ring. Figure 223 Pull tapered roller bearing off plate carrier (Figure 224).

  • Page 386: Manual Transmission Assembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Manual transmission assembly Mount studs (arrows). Wet thread with Loctite (type-no. 243)! Depending on the transmission version, differences concerning number and length of the studs are possible. See in this connection the corresponding Spare Parts List.
  • Page 387 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert bearing outer race (arrow) into housing bore until contact is obtained. Figure 234 Position pre-assembled pto-shaft in the housing and insert bearing outer race until contact is obtained. Figure 235 Adjust axial gap – power take-off bearing max. 0,10 mm, using shim(s) and circlip.
  • Page 388 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Reassemble multi-disc clutch-K3/K4 Lift plate carrier with the K4-side showing downwards into the clamping ring (S) and fix it. Now, tilt plate carrier by 180°. Insert both roll pins (6x24 and 3,5x24 mm) flush into the end face- side bore of the plate carrier, see arrow/Figure 239 (S) Clamping ring 504226...
  • Page 389 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil O-rings and piston bearing surfaces. Uniformly insert piston K3 until contact is obtained. Observe the installation position of the piston, see Figure! Figure 243 Introduce intermediate washer and compression spring. Figure 244 Lay guide ring with the chamfer (arrow) showing upwards over compression spring and line up snap ring.
  • Page 390 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disc clutch-K4 The following sketch or table show plate stacking and installation position of the components. Figure 248 Item. Designation Quantity s (mm) Remark Plate carrier Piston Outer plate 1,85 One-side coated Outer plate Coated on both sides Inner plate...
  • Page 391 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance-K4 (Figure 249 ... 251)! To ensure a correct measuring result, initially install plate pack without oil! Install plate pack according to the sketch or table (page 3.31 or 3.32). Figure 249 Insert end shim and fix it by means of snap ring.
  • Page 392 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and install spur gear -K4 (Figure 252 ... 257): The figure on the left shows the components of the spur gear-K4 Bearing inner race Bearing outer race Shim (optional, empirical value s = 5,4 mm) Spur gear Figure 252 Check axial gap –...
  • Page 393 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce spur gear until all inner plates are accommodated. Figure 256 Heat up bearing inner race (spur gear bearing) and position it until contact is obtained Use protective gloves! Figure 257 Heat bearing inner race (clutch support) and line it up until con- tact is obtained Use protective gloves! Figure 258...

  • Page 394: Multi-Disc Clutch-K3

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disc clutch-K3 The following sketch or table show plate stacking and installation position of the components! Figure 259 Item. Designation Quantity s (mm) Remark Plate carrier Piston Outer plate 1,85 One-,side coated Outer plate Coated on both sides Inner plate...
  • Page 395 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance-K3 (Figure 261 ... 263) ! To ensure a correct measuring result, initially install plates without oil! Install plate pack according to the sketch or table (page 3.36 or 3.37). Figure 261 Introduce end shim and fix it by means of snap ring Figure 262...
  • Page 396 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Heat up bearing inner race and line it up until contact is obtained. Use protective gloves! Figure 264 Lift plate carrier out of the clamping ring (S). To ensure the exact contact of the components, pre-load the bear- ing with 100 000 N (10 To.) .
  • Page 397 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce spur gear until all inner plates are accommodated. Figure 268 Heat roller bearing and position it until contact is obtained. Use protective gloves! Figure 269 Introduce bearing inner race. Figure 270 Check function of clutches K3 and K4 by means of compressed air.
  • Page 398 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Squeeze in and engage rectangular rings (3x, see arrows). Figure 272 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 399 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Reassemble multi-disc clutch-KR/K2 Lift plate carrier with the KR-side showing downward into clamping ring and fix it. Tilt plate carrier 180°. Insert both roll pins (6x24 and 3,5x24 mm) flush into the spur gear side bore of the plate carrier (arrow).
  • Page 400 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil O-rings and piston bearing surfaces. Uniformly insert K2-piston until contact is obtained. Pay attention to the installation position of the piston, see figure! Figure 279 Introduce intermediate plate and compression spring. Figure 280 Lay guide ring with the chamfer (arrow) showing upwards over the compression spring and line up snap ring.

  • Page 401: Multi-Disc Clutch-Kr

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disc clutch-KR Multi-disc clutch-KR The following sketch or table show plate stacking and installation position of the components! Figure 283 Item. Designation Quantity s (mm) Remark Plate carrier Piston Outer plate 1,85 One-side coated Outer plate Coated on both sides...
  • Page 402 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance-KR (Figure 285 ... 287) ! To ensure a correct measuring result, initially install plate pack without oil! Install plate pack according to the sketch or table (Figure 283). Figure 285 Insert end shim and fix it by means of snap ring.
  • Page 403 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and install spur gear KR (Figure 288 ... 296): The figure on the left shows the components of the spur gear KR. 1 = Bearing inner race 2 = Shims , s = 3,0 and s = 3,10 mm ( Σ...
  • Page 404 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-load tapered roller bearing with about 50 000 N (5 t) and determine axial gap by means of dial indicator. In case of deviations from the required axial gap, correct with suitable shims (Item.
  • Page 405 Ch 2 TRANSMISSION page Heat up bearing inner race (spur gear support) and position it until contact is obtained. Use protective gloves! Figure 296 Heat bearing inner race (clutch support)and position it until contact is obtained. Use protective gloves! Figure 297 SHOP MANUAL MT26/31 - 08.2006...

  • Page 406: Multi-Disc Clutch-K2

    Ch 2 TRANSMISSION page Multi-disc clutch-K2 The following sketch or table show plate stacking and installation position of the components! Figure 299 Item. Designation Quantity s (mm) Remark Plate carrier Piston Outer plate 1,85 One-side coated Outer plate Coated on both sides Inner plate Inner plate Inner plate...
  • Page 407 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance-K2 (Figure 300 ... 302) To ensure a correct measuring result, initially install plates without oil! Install plate pack according to the sketch or table See Fig 299 and 308. Figure 300 Insert end shim and fix it by means of snap ring.
  • Page 408 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and install spur gear K2 (Figure 303 ... 312): Supercool gear wheel 1 (abt. -80 °C ) and heat up gear wheel 2 ( abt. 120 °C ). Squeeze snap ring (arrow), pre-load it and join both parts together with a hydraulic press until the snap ring is engaged in the annular groove of gear wheel 2.
  • Page 409 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Determine measure I (bearing measure). Measure I e.g..........76,27 mm (S) Digital depth gauge 504175 Figure 307 Determine measure II (shaft measure). Measure II e.g..........74,14 mm Figure 308 CALUCALTION EXAMPLE “C“: Measure I e.g.:.
  • Page 410 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Line up spur gear until all inner plates are accommodated. Figure 310 Line up shim e.g. s = 2.20 mm (see calculation example/ page 3.50). Figure 211 Heat up bearing inner race (spur gear support) and line it up until contact is obtained.
  • Page 411 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Lift plate carrier off the clamping ring (S). To ensure the exact contact of the components, pre-load bearing with 100 000 N (10 t) (Figure 314). Support at the lower as well as the upper bearing race! Use pressure piece (S)! (S) Pressure pieces...
  • Page 412 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Assemble multi-disc clutch-KV/K1 Lift plate carrier with the KV-side showing downwards into clamp- ing ring (S) and fix it. Tilt plate carrier by 180°. Insert both roll pins (6x24 and 3,5x24 mm) flush into the face bore of the plate carrier (arrow).
  • Page 413 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil O-rings and piston bearing surfaces. Uniformly insert K1-piston until contact is obtained. Pay attention to the installation position of the piston, see figure! Figure 324 Introduce intermediate washer and compression spring Figure 325 Lay guide ring with the chamfer (arrow) showing upwards over the compression spring and line up snap ring..

  • Page 414: Clutch-Kv

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clutch-KV The following sketch or table show plate equipment and installation position of the components.! Figure 328 Item Designation Quantity s (mm) Remark Plate carrier Piston Outer plate 1,85 One-side coated Outer plate Coated on both sides Inner plate Inner plate...
  • Page 415 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance-KV (Figure 330 ... 332) ! To ensure a correct measuring result, initially install plate pack without oil! Install plate pack according to the sketch or table (previous page) Figure 330 Introduce end shim and fix it by means of snap ring..
  • Page 416 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and install spur gear-KV (Figure 335 ... 343): The figure on the left shows the components of spur gear KV. = Bearing inner race = Bearing outer race = Ring = Shim(s) optionally, empirical value s = 1,7 mm = Spur gear Figure 335 Check axial gap –...
  • Page 417 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-load tapered roller bearing with about 50 000 N (5 t) and de- termine axial gap with the dial indicator In case of deviations from the required axial gap, correct with suitable shim (Item 4/Figure 335)! (S) Pry bar 504209...
  • Page 418 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Heat up bearing inner race (spur gear support) and bring it into contact. Use protective gloves! Figure 343 Heat up bearing inner race (clutch support) and bring it into con- tact. Use protective gloves! Tilt plate carrier by 180°.

  • Page 419: Multi-Disc Clutch-K1

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disc clutch-K1 The following sketch or table show plate stacking and installation position of the components! Figure 348 Item Designation Number s (mm) Remark Plate carrier Piston Outer plate 1,85 One-side coated Outer plate Coated on both sides Inner plate...
  • Page 420 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance -K1 (Figure 350 ... 352) ! To ensure a correct measuring result, initially install plate pack without oil! Install plate pack according to sketch or table (page 3.65 or 3.66). Figure 350 Introduce end shim and fix it by means of snap ring.
  • Page 421 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and install spur gearK1 (Figure 353 ... 360): The figure on the left shows the components of spur gear K1. 1 = Ball bearing (compl.) 2 = Snap ring 3 = Spur gear Prior to the installation of the components, radially align plate pack by means of spur gear and center it, see Figure 354!
  • Page 422 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Press in ball bearing until contact is obtained. Install ball bearing with the lubricating groove (arrow) showing downwards! Apply pressing-in tool only to the bearing outer race! Figure 357 Heat up second ball bearing and introduce it until contact is ob- tained.
  • Page 423 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Line up shim s = 1,2 mm. Figure 361 Heat bearing inner race and line it up until contact is obtained. Use protective gloves! Figure 362 Lift plate carrier off the clamping ring (S) To ensure the exact contact of the components, pre-load bearing with 100 000 N (10 t) (Figure 363).
  • Page 424 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check functioning of the clutches -KV and -K1 by means of com- pressed air! At correctly installed components, closing or opening of the clutches is clearly audible. Figure 365 Squeeze in and engage rectangular rings (3x, see arrows). Figure 366 3.2.5 Install countershaft gear and multi-disc clutches Adjust axial gap of the countershaft gear bearing = 0,00 ...
  • Page 425 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Determine measure I. Measure I e.g.......... 61,85 mm (S) Digital depth gauge 504175 Figure 369 Position countershaft gear over lower bearing inner race and place upper bearing inner race on top. Repeatedly rotate countershaft gear to ensure centering of the Figure 370 components...
  • Page 426 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert bearing outer races-KV/K1, -KR/K2 and -K3/K4 into the housing bores until contact is obtained, see arrows. Figure 373 Position clutchKV/K1 by means of lifting device. (S) Set of eye bolts 504182 Figure 374 Position clutch-KR/K2.
  • Page 427 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Axially fix spur gear K3 by means of special device and eye bolt (arrow)- The spur gear fixing prevents the plates from slipping off when lifting the clutch into position. (S) Assembly device 504208 (S) Eye bolt 504190...

  • Page 428: Interaxle Differential Assembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Interaxle differential assembly 504199 504222 504231 Special tool - Differential 504233 504164 504167 504220 504195 504182 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 429 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Close bores (6x , arrows) by means of set screws. Insert set screws with Loctite (type-no. 243)! Figure 380 Press needle sleeve with the reinforced lining facing the pressing- in tool until contact is obtained and fix it by means of snap ring. (S) Pressing-in sleeve 504222 Figure 381...
  • Page 430 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Fix sun gear by means of circlip. Figure 384 The figure on the left show the components of the planetary gear. Thrust washer Needle rollers ( 30 units) Disc Planetary shaft Planetary gear Install components 1 to 3.
  • Page 431 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert planet carrier into the internal gear. Figure 388 Insert bearing outer race (arrow) into the internal gear carrier until contact is obtained. Figure 389 Supercool internal gear until contact is obtained. Use protective gloves! Figure 390 Fix internal gear carrier by means of snap ring.
  • Page 432 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Heat up bearing inner race until contact is obtained. Use protective gloves! Figure 392 Introduce output shaft. Figure 393 Fix output shaft by means of snap ring (arrow). Figure 394 Squeeze in and engage both rectangular rings (arrows). Figure 395 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 433 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Line up bush (arrow). Figure 396 Heat up bearing inner race until contact is obtained. Use protective gloves! Figure 397 Insert plate. Figure 398 Lift differential into housing by means of lifting device. (S) Set of eye bolts 504182 Figure 399...
  • Page 434 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Position upper oil baffle and fasten both oil baffles by means of hex. head screws (5x) and hex. nut (1x). Mount flat washers! Secure hex. head screw with Loctite (type-no. 243)! Torque limit (M8/8.8) ......... = 23 Nm Figure 400 Pre-assemble housing cover (version with intermediate axle differential) and mount it.
  • Page 435 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Expand the two snap rings. Introduce ball bearing with the annular groove showing upwards until the upper snap ring is engaged in the groove of the ball bear- ing. (S) Clamping pliers 504730 Figure 404 Insert gear wheel until contact is obtained.
  • Page 436 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount bearing outer race. Uniformly press on bearing outer race and determine measure II from bearing outer race to mounting face. Measure II e.g.......... 64,00 mm Take several measuring points and determine average value! (S) Straight edge 504170...
  • Page 437 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert both cylindrical pins (arrow 1 and 2) until contact is obtained. Fasten housing cover by means of screw connection. Drive in roll pin (arrow 3) flush-mounted. Torque limit (M10/8.8) ........= 46 Nm Figure 412 Insert ball bearing until contact is obtained.
  • Page 438 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install shaft seal with the sealing lip facing the oil chamber. When using the specified driver (S), the exact installation position is obtained! Grease sealing lip! (S) Driver 504164 Depending on the version, different shaft sealing rings can be necessary! Outer diameter rubber-coated –...

  • Page 439: Adjust Bearing Pre-Load Of The Clutches

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Adjust bearing pre-load of the clutches Adjust bearing pre-load of the clutch -K3/K4= 0,00 ... 0,05 mm (Figure 420 ... 422): Insert bearing inner race into the outer race. Housing dimensions: Uniformly press on bearing inner race and determine measure I from the mounting face to bearing inner race.
  • Page 440 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount O-ring (arrow) and grease it. Heat up inner diameter of the bearing cover (bearing seat). Figure 425 Grease rectangular rings (3 x ,arrows) and centrically align them. Figure 426 Install two adjusting screws. Line up bearing cover by means of hex.
  • Page 441 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Housing dimension: Determine measure I from bearing outer race to mounting face. Measure I e.g.......... 15,68 mm Figure 429 Cover dimension: Determine measure II from contact/bearing outer race to mounting face Measure II e.g..
  • Page 442 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Uniformly pull bearing cover until contact is obtained Torque limit (M10/8.8) ......= 46 Nm Observe the radial installation position, see marking (arrows). Figure 433 Adjust bearing pre-load of clutch-KV/K1 = 0,00 ... 0,05 mm (Figure 433 ...
  • Page 443 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page CALCULATION EXAMPLE “ H “: Measure I e.g........52,67 mm Measure II e.g........− 50,75 mm Difference ..........= 1,92 mm Bearing pre-load e.g......+ 0,03 mm Gives shim(s) 1,95 mm Insert shim.
  • Page 444 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Tilt transmission housing. Install countershaft axle Centrically align countershaft gear and install adjusting screw (S) Adjusting screw 504187 Figure 441 Supercool pin and insert it until contact is obtained. Use protective gloves! Figure 442 Remove adjusting screw and fix bolt by means of hex.
  • Page 445 Ch 2 TRANSMISSION page SHOP MANUAL MT26/31 - 08.2006...

  • Page 446: Install Emergency Steering Pump

    Ch 2 TRANSMISSION page Install emergency steering pump 504210 Special tool - Emergency Steering Pump 504730 SHOP MANUAL MT26/31 - 08.2006...
  • Page 447 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Tilt gearbox housing 180°. Insert O-ring (arrow) into the annular groove and grease it. Figure 445 Introduce emergency steering pump until contact is obtained and fasten it by means of hex. head screws. Torque limit (M8/8.8) ....

  • Page 448: Transmission Control. The Pump

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Transmission control. The pump See: (in this chapter) Electro hydr. shift control valve, cross section Clutch chart Oil circuit diagram The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is located in the transmission on the engine-dependent input shaft.
  • Page 449 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504186 Special tool - Press. Oil Pump 504160 504168 504195 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...

  • Page 450: Hydraulic Pump

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Hydraulic pump Press needle sleeve (arrow) with the reinforced shell facing the pressing-in tool until contact is obtained. (S) Pressing-in tool 504168 Figure 447 Insert disc s = 1,3 mm and position bearing outer race until contact is obtained.
  • Page 451 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install O-ring (arrow) and mount pump flange. Figure 451 Fasten pump flange or pump by means of hex. head bolts. Torque limit (M12/8.8) ....M = 79 Nm Wet thread of the two hex. head screws (position see arrows) with Loctite, type-no.
  • Page 452 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Axle disconnection – version with intermediate SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 453 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504184 Special tool - Axle disconnection 504210 504175 504196 504179 504167 504220 504195 Special tool - Axle disconnection 504184 504179 504175 504164 504233 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 454 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert ball bearing until contact is obtained. Figure 460 Adjust ball bearing by means of disc s = 4,0 mm, shim (option- ally) and circlip without gap. Figure 461 Position compression spring, piston and shift fork. Stop screw as well as rectangular ring will be installed later! Figure 462...
  • Page 455 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert disc with chamfer (arrow) showing upwards Figure 464 Pre-load compression spring, install sliding blocks and sliding sleeve. Observe the installation position of the slid- sleeve – the large chamfer at the outer diameter showing downwards! Figure 465 Adjust shifting travel by means of measuring device (S)
  • Page 456 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Determine measure I, see figure on the left! Measure I e.g........32,90 mm (S) Digital depth gauge 504175 Figure 468 Mount flat gasket and determine measure II from mounting face to bore root (stop face/socket head screw). Measure II e.g..
  • Page 457 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce rectangular ring (VITON) into the annular groove of the piston (arrow) and oil it. Figure 471 Mount switch. 1 = Lock 2 = Sealing ring (s = 1,5 mm) 3 = Switch Figure 472 Install two adjusting screws and mount flat gasket.
  • Page 458 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert perforated plate (1) and filter insert (2) into the housing bore (arrow/Figure 476). Close bore with a plug up to the assembly of the hydraulic oil feed (3). Figure 475 Figure 476 Install shaft seal (arrow) with the sealing lip facing the oil cham- ber.
  • Page 459 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Line up output flange. Wet contact surface of the disc with sealing compound (Loctite, type-no. 574) and fasten output flange with hex. head screws. Torque limit (M10/8.8) ..... M = 46 Nm Figure 479 Fix hex.
  • Page 460 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Provide screw plugs ( 1 and 2 ) with new O-ring and install them. Mount gasket and fasten cover plate (3) by means of hex. head screws. Torque limit (screw plug) ......M = 140 Nm Torque limit (M8/8.8) ......
  • Page 461 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Determine measure I from bearing inner race to end face/driver Measure I e.g......... 9,64 mm Figure 487 Determine measure II ( A – B). Measure II e.g..........10,64 mm Figure 488 CALCULATION EXAMPLE “...
  • Page 462 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Position driver against shoulder and fix it by means of clamping disc and socket head screw. Torque limit (M10/8.8, DIN 6912) ..M = 32 Nm Figure 490 Press on bearing inner race until contact is obtained. Figure 491 Squeeze in circlip (arrow) and line up drive gear.
  • Page 463 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce pre-assembled input shaft until contact is obtained. Ensure overlapping of the fitting key with the fitting key groove. Figure 494 Adjust axial gap of the input shaft bearing = 0,0 ... 0,05 mm (Figure 495 ...

  • Page 464: Input Converter Bell

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Input converter bell 504160 504198 504184 504182 Special tool - Input 504183 504169 504195 504221 504186 504196 504209 504170 504176 504175 504182 504198 504193 504175 504194 Special tool - Retarder 504185 504167 504195 504163 504182...
  • Page 465 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert bearing outer race into housing bore until contact is obtained and install bearing inner race, see arrow! Figure 498 Laterally introduce spur gear (arrow) with the long collar show- ing upwards and bring it into position. Figure 499 Insert both roll pins (Æ...
  • Page 466 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Heat up bearing inner race and line it up until contact is ob- tained. Use protective gloves! Figure 502 Position bearing outer race against shoulder. Figure 503 Adjust axial gap of the drive gear bearing = 0,03 ...
  • Page 467 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert needle sleeve (arrow) with the reinforced shell facing the pressing-in tool until contact is obtained. (S) Driver 504169 (S) Handle 504195 Figure 506 Install two adjusting screws and mount gasket (arrow 1). Install converter safety valve (disc, compression spring and ball), see arrow 2.
  • Page 468 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount flat gasket (arrow) and install bearing cover Observe radial installation position! Torque limit (M10/8.8) ..... M = 46 Nm Figure 510 Wet thread of the screw-in sleeves (1 and 2) with Loctite type- no.
  • Page 469 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove input shaft and heat housing bore (about 120° C). Perform the following steps (Figure 515 ... 517) in direct chronological order! (S) Preheating sleeve 504229 (S) Hot-air blower 220V 504193 (S) Hot-air blower 110 V 504194 Figure 514 Grease rectangular ring (arrow) and centrically align it.
  • Page 470 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Fasten converter bell by means of hex. head screws. Torque limit (M8/10.9) ....M = 34 Nm Torque limit (M12/10.9) ....M = 115 Nm Figure 518 Insert O-ring (arrow) into the annular groove of the converter bell.
  • Page 471 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Tilt gear 90°. Insert pot flush-mounted to the housing face. Wet sealing surface with Loctite (type-no. 262)! Figure 522 Install breather (arrow). Figure 523 Provide screw plug (arrow 1) with new O-ring and install it. Mount both retaining plates (arrow 2).

  • Page 472: Inductive Transmitters And Speed Sensor

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Inductive transmitters and speed sensor Assembly and settings The following sketches show the installation position of the individual inductive transmitters and the speed sensor. 606 : Inductive transmitter – Engine and 608 : Inductive transmitter n –...
  • Page 473 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504175 Special tool - Ind.Transmitter 504177 504177 504175 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 474 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page The following figures describe the assembly or setting of the inductive transmitter n-engine (606)! The assembly of the inductive transmitter n-turbine (612) and n – central gear train (608) must be accordingly carried out! Pay attention to different setting dimension ,,X“: Induct.
  • Page 475 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Screw out plug gauge and determine measure II (also see Figure 533). Measure II e.g......... 30,10 mm Figure 534 CALCULATION EXAMPLE “ M “: Measure II e.g........30,10 mm mm) ....e.g.. − Measure X (0,5 + 0,3 0,60 mm...
  • Page 476 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install speed sensor n-output (31), Figure 540 ... 545: Setting measure X = 1,0 + 0,5 See also chapter 2.2 ,Testing & Adjusting Figure 540 The figure on the left shows the speed sensor (Hall sensor) 1 = Speed sensor 2 = O-ring 3 = Setting plate(s)
  • Page 477 Ch 2 TRANSMISSION page CALCULATION EXAMPLE “ N “: Measure I e.g......... 39,20 mm − Measure X (1,0 mm) e.g.... 1,20 mm + 0,5 Gives installation measure 38,00 mm CALCULATION EXAMPLE “ N “ Measure II e.g........ 39,00 mm −...

  • Page 478: Differential Carrier „Lk

    Ch 2 TRANSMISSION page Differential Carrier „LK“ Tools 504731 504170 504718 Tool for LK - differential Page 1 504720 504170 504173 504175 504186 504186 504231 504721 504722 505155 504171 504198 504172 504196 8344 504213 504715 504721 Tool for LK - differential Page 2 505153 504726...

  • Page 479: Disasembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disasembly Version: with Limited-slip differential DL-2400 (45% Interlock value) Fasten transmission on the assembly car. (S) Assembly car 504213 (S) Clamping bracket 504214 Figure 550 Loosen screw plug (Arrow) and drain oil. Figure 551 Remove oil line.
  • Page 480 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Tilt transmission 90°. Separate differential carrier from gearbox housing, using lifting device. (S) Lifting chain 3-rope 504198 Figure 554 Remove shim. Figure 555 Fasten differential carrier on the assembly car. Loosen hex. head screws and separate cover by means of back- off screws from the housing.
  • Page 481 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mark radial installation position of the seal retainer as well as of the bearing cover to the axle drive housing. The LH resp. RH seal retainer as well as the bearing cover are different; mark the components with one resp.
  • Page 482 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Separate flange shaft and seal retainer from bearing cover. (S) Plastic mallet 504196 Figure 561 Squeeze circlip out and remove shim. (S) Set of external pliers 504231 Figure 562 Press flange shaft out of the ball bearing. Figure 563 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 483 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull bearing inner race from differential housing. Disassemble the opposite bearing inner race accordingly. (S) Two-leg puller 504731 Figure 564 Loosen locking screws. Figure 565 Loosen both socket head screws. Figure 566 Separate crown wheel from differential housing, using back-off screws.
  • Page 484 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Demount housing cover and disassemble components. Figure 568 Heat slotted nut (about 120° C). Slotted nut is secured with Loctite ! (S) Hot-air blower 230 V 504193 (S) Hot-air blower 115 V 504194 Figure 569 Loosen slotted nut and remove disk.
  • Page 485 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Press drive pinion out of the differential housing (Figure 572) and disassemble both bearing outer races. Pay attention to the released components ! Figure 572 Press bearing inner race from the drive pinion. (S) Grab sleeve 8327 Figure 573...

  • Page 486: Assembly

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Assembly Drive pinion If crown wheel or drive pinion are damaged, both parts (bevel gear set) must be renewed together ! Pay attention to equal mating numbers ! Adjust Contact pattern – Bevel gear set (Draft to Figure 581) Carry out the following measuring operations with utmost accuracy ! Inaccurate measurements give a faulty contact pattern ! Ref.
  • Page 487 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert stop disk (2) and plug gauge (1) into the bearing bore (drive pinion). (S) Stop disk 505157 (S) Plug gauge 505156 Figure 575 Introduce both fitting pieces (3) into the bearing bores (differential bearing).
  • Page 488 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Read Dimension I (pinion dimension), see Arrow ! Dimension I e.g........198,00 mm Figure 579 Measure Dimension II (bearing width). Dimension II e.g........42,30 mm EXAMPLE: „ O “: Dimension I e.g.
  • Page 489 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Press bearing inner race over the drive pinion until contact is obtained. Figure 583 Adjust the Rolling moment of the Drive pinion bearing T = 3,5 ... 4,5 Nm (without shaft seal) (Figure 584 ... 588): Line up adjusting ring e.g.
  • Page 490 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Line up the disk and tighten slotted nut. Torque limit ........1200 Nm During the tightening, rotate the drive pinion several times in both directions ! (S) Hook spanner 504726 (S) Counter support 504724 (S) Power amplifier 504719...
  • Page 491 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Line up the clutch sleeve. Mount disk and tighten slotted nut finally. Wet thread of slotted nut with Loctite (Type-No. 262) ! During the tightening, rotate the pinion several times in both directions ! Torque limit ..........

  • Page 492: Differential Dl-2400, Interlock Value 45

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Differential DL-2400, Interlock value 45% The following Perspective Illustration shows the components of the differential and its installation position. Socket head screws (2x) Thrust ring Housing cover Side gear Thrust washer (steel) Differential bevel gear Thrust washer (brass) Differential axle...
  • Page 493 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page At the following assembly sequence, pay attention to the installation position of the components, see also Perspective Illustration/ Page 4.14 ! Oil the components according to ZF-List of lubricants TE-ML 05 ! Install both thrust washers.
  • Page 494 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert complete differential spider. Figure 596 Install second side gear. Figure 597 Introduce thrust ring. Figure 598 Install plate pack B alternating, starting with one inner plate. Pay attention to the Note, Page 4.14 ! Figure 599 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 495 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check the Assembly play of the internal components = 0,2 ... 0,8 mm (Figure 600 ... Example “P“): Determine Dimension I from the mounting face to the outer plate. Dimension I e.g......... 4,30 mm (S) Digital Depth gauge 504175...
  • Page 496 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Fix housing cover with two socket head screws. Torque limit (M10/8.8) ........ 46 Nm Figure 603 Install adjusting screws (3 pieces) and press differential into the crown wheel until contact is obtained. (S) Adjusting screws 504722 Figure 604...
  • Page 497 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert the differential into the axle drive housing, using lifting de- vice. (S) Gripper tongs 505155 Adjust Backlash – Bevel gear set 0,20 ... 0,30 mm and Bearing rolling moment – Differential T = 3 ... 4 Nm Figure 607 (Figure 608 ...
  • Page 498 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install two adjusting screws. Introduce bearing cover I and fasten it provisionally with four screws. Torque limit ..........79 Nm (S) Adjusting screws 504186 Figure 611 Tilt axle drive housing 90°. Mount bearing outer race, press it uniformly on and determine Dimension I from the mounting face to the bearing outer race.
  • Page 499 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install O-ring (Arrow). Figure 615 Install two adjusting screws. Introduce bearing cover II and position it uniformly against shoul- der, using four screws. Torque limit ..........79 Nm During the tightening of the screws, rotate the crown wheel several times in both directions ! Now, relax the differential bearing by tapping onto both bearing covers (use plastic mallet) !
  • Page 500 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check Contact pattern (Figure 618 and 619): Wet some coasting flanks and traction flanks of the crown wheel with marking ink. Figure 618 Roll the crown wheel several times in both directions over the drive pinion.
  • Page 501 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 4.2.3 Pre-assemble and install Flange shaft Lay seal retainer upon a plane base. Press shaft seal in, with the sealing lip facing the oil chamber. Wet outer diameter with spirit ! Grease sealing lip ! At application of the prescribed Special tool (S), the exact installation position is obtained! (S) Driver...
  • Page 502 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Heat bearing bore (about 90° C). (S) Hot-air blower 230 V 504193 (S) Hot-air blower 115 V 504194 Introduce the flange shaft and fasten it uniformly by means of hex. Figure 624 head screws.

  • Page 503: Mount Differential Carrier On The Transmission

    Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install connecting pipe and breather, see Arrow ! Install new sealing ring (Cu) ! Figure 628 Mount Differential carrier on the Transmission Adjust Axial play – Output shaft 0,3 mm (Figure 629 ..633): + 0,2 0,3 + Figure 629...
  • Page 504 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Determine Dimension II from the end face – clutch sleeve to the end face – drive pinion. Dimension II e.g........49,00 mm EXAMPLE S Dimension I e.g........ 291,90 mm − Dimension II e.g.
  • Page 505 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce differential carrier until contact is obtained, using lifting device. (S) Lifting chain 504198 Figure 634 Tilt transmission 90°. Fasten differential carrier on the gearbox housing, using socket head screws. Torque limit (M30/10.9) ......1900 Nm Prior to the commissioning of the unit, carry out the oil filling according to the Operating Instructions !
  • Page 506 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Use shims to get the correct position for the rear flange. The flange shall be vertical accordingly to the plane and center of the articulated bearing. The cardan joint in articulated hinge, shall have the same distance from center to both end of the axle.
  • Page 507 Ch 2 TRANSMISSION page Gear Use 2 tools No:037002 for position control of the flange. It is very important for the cardan axle lifetime that it is correct. The valid tolerance at the engine side tool is: + 0,7 - ÷ 1,3 mm. See figure 647 ! Trans- 037002...
  • Page 508 Ch 2 TRANSMISSION page SHOP MANUAL MT26/31 - 08.2006...
  • Page 509 (TCU must be ordered separate) mode. Important parts information If the Transmission 6WG310 is to be returned to Moxy Trucks AS or ZF for repair or any others reasons, the Transmission controller EST-37A is to be returned together with the Transmission.
  • Page 510 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pin in contact for the TCU Pole 23 Pole 45 Pole 68 Pole 46 Pole 24 Pole 1 Pole 23 Pole 45 Pole 68 Pole 46 Pole 24 Pole 1 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 511 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Not connected Ground connection Speedometer Ground connection Not connected Joint Not connected Rpm output shaft Temp sensor sump (156) Solenoid emergency retarder. Not connected Not connected Turbine RPM Relay reverse light Internal gear chain RPM Terminal block ??? Gear selector forward Solenoid Y5...
  • Page 512 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Family package of the EST-37A Legend ref. Figure Warning lamp 4 = Display 5 = Controller VST-3 6 = Supply system connection 7 = Fine filter with maintenance switch / Cable to filter contamination switch 9 = Electro control unit EST37 10 = CAN-connection 12 = Diagnosis Laptop with ZF-Diagnostic system Testmann and AEB...
  • Page 513 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Electro-hydraulic shift control unit Transmission control: The six clutches of the transmission are selected via the 6 proportional valves P1 to P6. The proportional valve (pressure regulator unit) is composed of pressure regulator (e.g. Y6), follow-on slide and vibration damper.
  • Page 514 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Electro-hydraulic control unit HSG-94 Measuring point In front of conv. – opening pressure Clutch forward Clutch reverse Clutch K1 Clutch K2 Clutch K3 Clutch K4 System pressure SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 515 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Electro hydr. shift control valve, cross section The following drafts are showing the sectional Illustrations of the HSG-94 Housing Valve block Cover Cover Plug (Cable harness) Main pressure Pressure reducing Housing valve 16 + 2 bar valve 9 bar Ma i n p r e s s u r e P r e s s u r e r e d u c i n g...
  • Page 516 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504254 504253 Tool for the Electro-hydraulic Control unit HSG-94 Page 1 504185 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 517 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 518 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page DISASSEMBLY Summary for the Tool, see chapter 2.0 Loosen socket head screws and remove selector housing. (S) Box spanner TX-27 504253 Figure1 Separate hose lines from the intermediate plate. Loosen socket head screws and separate intermediate plate as well as gaskets and intermediate sheet from gearbox housing.
  • Page 519 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove retaining clip. Figure 5 Losen socket head screws and remove cover. Demount opposite cover. Figure 6 Demount pressure regulator and remove cable harness. Figure 7 Loosen socket head screws, remove retaining plates and de- mount pressure regulator.
  • Page 520 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Loosen two socket head screws and locate the housing provisio- nally by means of adjusting screws. (Housing is spring-loaded). Now, loosen the remaining socket head screws. (S) Adjusting screws 504188 Figure 9 Separate housing from valve body by uniform loosening of the adjusting screws.
  • Page 521 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page ASSEMBLY Check all components for damage and renew if necessary ! Prior to the installation, check the free travel of the moving parts in the housing ! Spools can be exchanged individually ! Prior to the assembly, oil the components according to ZF-List of lubricants TE-ML 03 ! Insert orifices with the concave side showing upward, until...
  • Page 522 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Figure17 Preload spool and remove the cylindrical pins (assembly aid) again. Figure 18 Fasten housing cover by means of socket head screws. Torque limit........... 5,5 Nm Figure 19 Introduce pressure regulators and fix them by means of retai- ning plates and socket head screws.
  • Page 523 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble opposite side The Figure on the left shows the following components: 1 = Main pressure valve (1x spool and compression spring) 2 = Follow-on slide (3x spool and compression spring) 3 = Vibration damper (3x spool and compression spring Figure 21 Install components according to Figure 21.
  • Page 524 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce cable harness and connect pressure regulators (6x). Pay attention to the installation position of the cable harness, see also markings (Figure 3) ! Figure 24 Mount flat gasket (Arrow). Introduce femal connector, with the groove facing the guide nose of the cover, until contact is obtained.
  • Page 525 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install two adjusting screws and mount gasket I. Pay attention to the different gaskets, see Figure 27 and 30 ! (S) Adjusting screws M6 504189 Figure 27 Intermediate plate – Version with strainers: Insert strainers (6x) flush-mounted into the bores of the inter- mediate plate, see Arrows ! Pay attention to the installation position –...
  • Page 526 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount duct plate (Arrow) and fasten it uniformly by means of socket head screws. Torque limit ........11 Nm (S) Box spanner TX-27 504253 Figure 31 Equip screw plugs (8x) with new O-rings and install them. Torque limit .........
  • Page 527 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install two adjusting screws (M8) and mount housing gasket. At the following steps (Figure 35 ... 39), pay attention to the installation positions of the different gaskets ! (S) Adjusting screws M8 504185 Figure 35 Mount intermediate plate.
  • Page 528 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install 2 adjusting screws (M6). Mount gasket (Arrow). (S) Adjusting screws M6 504189 Figure 39 Fasten complete valve block uniformly with socket head screws (2 pieces M6 x 105 and 21 pieces M6 x 80 mm). Pay attention to the position of the two socket head screws (M6 x 105), see Arrows ! Torque limit ........
  • Page 529 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page WK-Valve WK Solenoid shift valve WK SOLENOID VALVE Meas. point WK Connection to WK Duct plate Vent. hole Syst. pressure from hydr. contr. unit SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 530 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page DISASSEMBLY Remove hose lines. Loosen hex. head screws and separate WK-valve from housing Figure 41 Loosen socket head screws, separate selector housing from adapter plate, and remove components. Figure 42 ASSEMBLY Insert set screw 1 with Loctite (Type-No. 649). Equip both connecting fittings 2 with new O-rings and install them.
  • Page 531 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install WK-Valve components according to the Figure on the left. 1 = Solenoid valve 2 = Socket head screw + Spring washer (2x) 3 = Selector housing 4 = Piston 5 = Shim rings (empirical value, 6 units/0,5 mm thick, each) 6 = Compression spring 7 = Stop (optional, empirical value A = 3,0 mm) 8 = Connecting fitting (install new O-ring)
  • Page 532 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Retarder Function of a retarder General: The hydrodynamic Retarder (fluid brake), installed upon request, is arranged between engine and torque converter thus achieving a good braking effect in all gears. The Retarder is a wear-free, gear-depending acting hydrodynamic-brake. The application of the Retarder is therefore especially to recommend at longer downgrade drives or to brake down out of high driving speeds, because in this way, the service brake will be saved and in an emergency case, the full braking effect (no fading) of the service brake will...
  • Page 533 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Retarder reconditioning tool 504193 504175 504194 Special tool - Retarder 504167 504195 504163 504182 504185 504178 504198 504184 504160 504182 Special tool - Input 504183 504169 504195 504221 504186 504196 504209 504170 504176 504175 504182...
  • Page 534 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disassembly the retarder Summary for the Tools for retarder disassembly and as- sembly, see previous side Fasten the complete transmission on the assembly car. (S) Assembly car 504213 (S) Clamping bracket 504214 Figure 50 Separate pipes from selector housing.
  • Page 535 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Tilt gearbox housing 90°. Remove lock plate. Loosen hex. head screws and pull off input flange. If only operations on the transmission are necessary, the complete retarder can be separated, along with the con- verter, from the converter connecting housing by loosen- ing the screw connection (Figure 56) ! Figure 53...
  • Page 536 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Separate the complete retarder from the converter connecting housing, using lifting device. (S) Set of eye bolts 504182 Figure 57 Loosen socket head screws, separate spacer ring from stator housing. Figure 58 Loosen socket head screws and separate cover from stator housing.
  • Page 537 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Separate rectangular ring from rotor. Figure 61 Remove the rectangular ring on the opposite side. If necessary, separate the ring (Arrow) from the rotor. Figure 62 Loosen hex. head screws and remove thrust ring. Figure 63 Remove stator ring.
  • Page 538 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pry shaft seal out of the bore. (S) Pry bar 504209 Figure 65 Drive ball bearing out. Figure 66 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 539 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page ASSEMBLY Insert ball bearing until contact is obtained. Figure 71 Insert ball bearing until contact is obtained. Figure 72 Fasten thrust ring by means of hex. head screws. Torque limit (M8/8.8) ......23 Nm Pay attention to the installation position –...
  • Page 540 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble dampers (3 pieces) according to Figure 25 and Figure 26. The Installation dimension B = 1,6 mm results + 0,5 from the alternating stacking of the cup spring packs (8 packs with 6 cup springs each) ! Figure 74 Ref.
  • Page 541 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce rectangular ring into the recess of the rotor (Figure 77) and preload it by means of cylindrical pins Æ 6 mm (as- sembly aid), see Figure 78 ! Install rectangular ring with the marking „Top“ see Arrow, show- ing upward (to the prime mover) ! Figure 77 Figure 78...
  • Page 542 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert ring into the cover, with the oil grooves showing down- ward. Figure 81 Introduce rectangular ring. Install rectangular ring with the marking „Top“ see Arrow, show- ing upward (to the prime mov er) ! Figure 82 Insert O-ring into the annular groove of the cover (Arrow) and grease it.
  • Page 543 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Adjust Rotor dimension (distance between Rotor – Stator ring) = 1,5 ... 2,0 mm (Figure 85 ... 89): Line up axial washer s = 1,0 mm, axial roller cage and housing disk s = 5,75 mm. Figure 85 Determine Dimension I from the housing disk to the mounting face.
  • Page 544 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount shim s = 2,5 mm (see Example A, Figure 85 - 88 Figure 89 Adjust Axial play – Ball bearing 0,10 ... 0,20 mm (Figure 90 ... 93): Check exact contact of ball bearing (Arrow) once more and place pre-assembled stator housing over the plug gauge.
  • Page 545 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Mount shim s = 0,3 mm (see Example B Page 2.11) with grease. Figure 93 Heat bearing inner race. (S) Hot-air blower 230 V 504193 (S) Hot-air blower 115 V 504194 Figure 94 Introduce flange shaft until contact is obtained.
  • Page 546 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clean O-ring. O-ring groove must be perfectly clean Grease O-ring (Arrow) and insert it into the annular groove of the spacer ring. Figure 97 Fasten spacer ring by means of socket head screws. Torque limit (M10/8.8, DIN 6912) ..
  • Page 547 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Fasten rotor and flange shaft on the converter, using hex. head screws. Tighten hex. head screws uniformly (180° displaced) as well as secure them with Loctite (Type-No. 243) ! Torque limit (M10/8.8) ........ 46 Nm Figure 101 Equip screw plug with new O-ring and install it.
  • Page 548 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Line up input flange and fasten it by means of disk and hex. head screws. Wet contact face of the disk with Loctite (Type-No. 574) ! Torque limit (M10/8.8) ......46 Nm Figure 105 Fix hex.
  • Page 549 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Retarder valve The braking procedure itself will be started via a hand- or foot-actuated control valve. With this valve it is possible to adjust a certain air pressure and with it the desired brake performance infinitely variable.
  • Page 550 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504185 Special tool - Press. regulator SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 551 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and mount Retarder: Install components according to Figure 107 and 108. Selector housing Screw plug (M14x1,5, Torque limit 35 Nm Screw plug (M26x1,5, Torque limit 80 Nm Screw-in sleeve Temperature sensor Torque limit 35 Nm Screw plug (M14x1,5, Torque limit 35 Nm...
  • Page 552 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Install two adjusting screws and line up the gasket. (S) Adjusting screws M8 504185 Figure 111 Figure 112 Install 2 gasket. Figure 113 Line up the pre-assembled selector housing and fasten it with hex.
  • Page 553 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Converter Function of the Converter: UNCTION OF A HYDRODYNAMIC ORQUE CONVERTER CHEMATIC VIEW = Torque of the wheel Turb ine Impeller Impeller = Torque of the Turb ine wheel = Tor que of the Reaction member (Stator) From the...
  • Page 554 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page The stator (reaction member) following the turbine, has the task to reverse the oil, streaming out of the turbine once more and to deliver it under the suitable discharge direction to the im-peller. Due to the reversion, the stator is receiving a reaction moment.
  • Page 555 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 556 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Removal of transmission, ass’y NOTE! Place the dump truck on level ground and apply parking brake Start with the propeller shaft in the articulation hinge. For best working, start the engine and turn the machine to full right direction.
  • Page 557 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Drain both hydraulic oil reservoirs, see chapter 7 maintenance - 2000 hour service in the Operating & Maintenance Manual. Main reservoir Emergency steering reservoir (Oil capacity approx. 190-200 l.) NOTE: See in the hydraulic chapter about the filling procedure.
  • Page 558 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disassemble the exhaust parts Disassemble the front V-clamp and the rear clamp, remove the exhaust pipe. Disassemble the rear pipe V-clamp and the front and rear suspen- sions. Screw M12x30 ISO4017-10.9 Lift out the muffler with the suspension bracket SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 559 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disassemble of the hydraulic hoses at the trans- mission Realease all (19 pcs) of the hydraulic hoses connected to the transmission. Realease all of the wiring on the electrical points. (Total included ground ca- bel are 11 electrical connections have to discon- nected.)
  • Page 560 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismount the protection guard for the diff and both front axle propeller shaft at differential side. From machine 810013 are screws for the propeller shaft changed to UNF thread on outer and inner sides: •...
  • Page 561 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismount the axle catcher bow. (white arrow) Dismount converter prop. shaft. (red arrow) Front screw: M12x50 ISO4014-10.9 EL Rear screw: ½” UNF x2” NS 965--8.8 Disassemble the front transmission bracket attachment. If shim are assembled, use the shims at the same place when as- semblying.
  • Page 562 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Place the transmission safely on a rack or similar. Secure the transmission. SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 563 Ch 2 TRANSMISSION page SHOP MANUAL MT26/31 - 08.2006...
  • Page 564 Ch 2 TRANSMISSION page Manual transmission Disassembly Fasten the complete transmission on the assembly car. (S) Assembly car 504213 (S) Support 504214 Remove all oil lines. Figure 120 504160 504198 504184 504182 Special tool - Input 504183 504169 504195 504221 504186 504196 504182...
  • Page 565 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Loosen hex. head screws and lift complete retarder along with converter out of the converter bell using a lifting device. (S) Lifting chain 504198 (S) Set of eye bolts 504182 Figure 121 Drive Unfix screw union and separate cover from converter bell by means of forcing screws (3xM10).
  • Page 566 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull oil feed flange by means of special device out of the converter bell. (S) Puller device 504160 Figure 123 Remove converter safety valve (ball + spring, see arrow). Figure 124 Loosen screw connection (M8 and M12). Separate converter bell from the transmission using lifting device.
  • Page 567 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove both rectangular rings (arrow). Figure 127 Press input shaft out of the spur gear bearing. Remove released bearing inner race and spur gear. Figure 128 Press bearing inner race off the input shaft. Figure 129 Remove pressure back-up valve.
  • Page 568 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull the complete input shaft out of the gearbox housing or out of the pump. Figure 131 Squeeze out rectangular ring (arrow). Figure 132 Separate spur gear from shaft and squeeze out circlip (arrow). (S) Set of pliers 504232 Figure 133...
  • Page 569 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Fasten shaft in vice. Unscrew socket head screw and remove clamping disc. Use protective jaws! Figure 135 Pull bearing inner race and driver off the shaft. Support puller on the end face – input shaft! Pay attention to the released shims! (S) 3-leg-puller 504236...
  • Page 570 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504186 Special tool - Press. Oil Pump 504160 504195 504168 504239 504238 Special tool - Power take -off 504186 504236 504204 504203 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 571 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Loosen socket head screws (M8) and position puller device. Pull transmission pump out of the housing bore. Tapping onto the housing face will support pulling out! (S) Puller device 504160 Figure 139 Pull bearing outer race out of the bore and remove spacer.
  • Page 572 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Axle disconnection 504184 Special tool - Axle disconnection 504210 504175 504196 504179 504167 504220 504195 Special tool - Axle disconnection 504179 504164 504233 504184 504175 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 573 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove lock plate. Loosen hex. head screws and remove disc. Pull output flange off the shaft. Figure 143 Tilt gearbox housing by 180°. Loosen hex. head screws, dismantle cover and remove filter. Figure 144 Axle disconnection device –...
  • Page 574 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismantle switch and detent pin. Figure 147 Disassemble switch and detent pin. Figure 148 Remove cover as well as circlip and drive pin out of the bore using a striker. Remove the released components. (S) Striker 504224 Figure 149...
  • Page 575 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Special tool - Gearbox housing 504225 504187 504196 504183 Special tool - Gearbox housing 504184 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 576 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 3.1.5 Countershaft Remove sealing cover and loosen hex. head screws. Figure 151 Tilt gearbox housing by 90°. Drive countershaft axle off the housing bore or the countershaft support by means of a striker. (S) Striker 504225 Figure 152...
  • Page 577 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Loosen screw connection and separate housing cover by means of back-off screws (arrows) and lifting device from the gearbox hous- ing. During the separating procedure, drive out the output shaft by tap- ping continuously downwards! (S) Back-off screws 504183...
  • Page 578 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Interaxle differential: Description: The differential, installed in the output, has the task to transmit different torques on the vehicle axles and to function as intermediate compensation in the driving direction (longitudinal direction of the vehicle). Due to the existing differential lock, both functions can be put out of service and a rigid con-nection between the axles can be created.
  • Page 579 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Interaxle differential with mounted Differential carrier „LK“ HA= Output Rear axle 1 = K3-Spur gear – Input 2 = Planetary gear (Ravignaux-System outer hole circle) Planet carrier Screening plate Sun gear Output shaft to the Front axle (converter-side) Internal gear Output shaft to the Rear axle (rear-side) 10 =...
  • Page 580 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Interaxle differential disassembly 504199 504222 504231 Special tool - Differential 504164 504233 504167 504182 504220 504195 Lift differential out of the gearbox by means of lifting device. (S) Lifting device 504198 (S) Set of eye bolts 504182 Figure 157 Remove plate and disassemble bearing inner race.
  • Page 581 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Squeeze out both rectangular rings (arrow) and remove them. Figure 160 Remove bush. Figure 161 Squeeze out snap ring and pull output shaft off the planet carrier. Figure 162 Squeeze out circlip (sun gear fixing). (S) Set of external pliers 504231 Figure 163...
  • Page 582 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull bearing inner race off the internal gear. (S) Quick-acting grip 504252 or grab sleeve 504247 (S) Basic tool 504246 Figure 164 Squeeze out snap ring. Figure 165 Press internal gear and planet carrier out of the internal gear. Figure 167 shows the released components! Figure 166...
  • Page 583 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Carefully drive in roll pin (arrow) until contact is obtained. Figure 168 Drive out planet bolt and remove planet gears. Figure 169 Press output shaft far enough downward until the sun gear can be removed, also see Figure 171! Figure 170 Squeeze out snap ring (arrow) and separate output shaft from...
  • Page 584 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page If necessary, pry baffle ring out of the planet carrier bore, squeeze out snap ring (Figure 172) and drive out needle bearing (Figure 173). Figure 172 Assembly the interaxle diff, see the section: Interaxle differential assembly Figure 173 SHOP MANUAL MT26/31 - 08.2006...
  • Page 585 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clutches, Powershift transmission 1 = Input flange - Drive via universal shaft 2 = Retarder 3 = WK 2 = Converter 5 = Breather 6 = Electrohydraulic control unit 7 = 2 Power take-off 8 = Transmision pump 9 = 1...
  • Page 586 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disk clutch The multi-speed reversing transmission in countershaft design is power shiftable by hydrauli-cally actuated multi-disk clutches. All gears are constantly meshing and carried on antifriction bearings. The gear wheels, bearings and clutches are cooled and lubricated with oil. The 6-speed reversing transmission is equipped with 6 multi-disk clutches.
  • Page 587 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Clutch chart PRESSURE REGULATOR UNDER VOLTAGE ENGAGED CLUTCHES DRIVING DIRECTION Y1 Y2 Y3 Y4 Y5 Y6 Speed FORWARD REVERSE NEUTRAL KR K4 K1 K3 KV K2 ENGAGED CLUTCH POSTITIONS ON VALVE BLOCK CONSEC.
  • Page 588 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Plate clearanse in the single Multi-disc clutches Type K1 (mm) K2 (mm) K3 (mm) K4 (mm) KV (mm) KR (mm) WG-310 2,6 +0,2 2,2 +0,2 2 , 2 + 0 , 2 2 , 2 + 0 , 2 2 , 8 + 0 , 2 2 , 2 + 0 , 2...
  • Page 589 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil circuit diagram RV-9 TEMP Valve block control circuit LEGENDE = Main pressure = Regulated main pressure = Pilot pressure = Converter input pressure = Converter output pressure = Lubrication = Return into the sump MAIN OIL CIRCUIT Not scope of supply- ZF Air reservoir 8 bar...
  • Page 590 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Disassemble Multi-disc clutches Disassemble clutch K4/K3, KR/K2 and KV/K1 by means of lifting device. At the disassembly of the clutch K4/K3, slightly lift clutch KR/K2 and displace it in arrow direction, see figure on the left! (S) Set of eye bolts 504182 Figure 175...
  • Page 591 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Lift output shaft by means of pry bar until the bearing outer race is free. (S) Pry bar 504209 Figure 179 Take output shaft out of the housing. Figure 180 Pull bearing outer race out of the housing bore. (S) Internal puller 504202 (S) Counter support...
  • Page 592 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 509114 504236 504243 504237 Special tool - Coupling K3 + K4 Page 1/2 504227 504207 504190 504217 504238 504195 504175 504208 504216 504248 504211 Special tool - Coupling 504206 K3 + K4 Page 2/2 504237 504211...
  • Page 593 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismantle multi-disc clutch – K3/K4 Fasten clutch by means of clamping ring (S) on the assembly car. (S) Clamping ring 504226 504227 Figure 185 Pull roller bearing off plate carrier. (S) 3-leg puller 504236 Figure 186 Separate spur gear K3 from plate carrier.
  • Page 594 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Squeeze snap ring out. Disassemble end shim and plate pack K3. Figure 189 Tilt plate carrier 90°. Loosen slotted nut. Slotted nut is secured with Loctite! To prevent damage to the thread, heat up slotted nut prior to loosen it (abt.
  • Page 595 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove adjusting ring. Figure 193 Pull off tapered roller bearing. (S) 3-leg puller 504236 Figure 194 Squeeze out snap ring. Disassemble end shim and plate pack K4. Figure 195 Pre-load compression spring by means of special device (S). Squeeze out snap ring and remove the released components.
  • Page 596 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Separate both pistons with compressed air from the plate carrier. Figure 197 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 597 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismantle multi-disc clutch KR/K2 504215 504175 504250 504243 Special tool - Coupling KR + K2 504227 504206 504218 504207 504251 504243 504215 504245 504243 504195 504237 504244 504211 504175 Fasten clutch by means of clamping ring (arrow) on the assembly car.
  • Page 598 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Tilt plate carrier by 90°. Loosen slotted nut. Slotted nut is secured with Loctite! To prevent damage to the thread, heat slotted nut prior to loosen it (abt. 120° C)! (S) Hook spanner 504215 Figure 199 Pull tapered roller bearing off plate carrier.
  • Page 599 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull tapered roller bearing off plate carrier. (S) Grab sleeve 504251 (S) Basic tools 504243 Figure 203 Squeeze snap ring out. Disassemble end shim and plate pack K2. Figure 204 Tilt plate carrier by 90°. Loosen slotted nut.
  • Page 600 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull tapered roller bearing from plate carrier. (S) 3-leg puller 504237 Figure 207 Remove adjusting rings. Figure 208 Squeeze out snap ring. Disassemble end shim and plate pack KR. Figure 209 Pull tapered roller bearing off plate carrier. (S) Grab sleeve 504244 (S) Basic tool...
  • Page 601 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page 504195 504169 504209 504240 504238 Special tool - Coupling KV + K1 504227 504213 504218 504207 504238 504211 504216 504175 504237 504217 504242 504237 504217 504215 Special tool - Coupling KV + K1 Page 2/2 504206 504169...
  • Page 602 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Dismantle multi-disc clutch KV/K1 Fasten clutch by means of clamping ring on the assembly car. Loosen slotted nut (Figure 211). Slotted nut is secured with Loctite! To prevent damage to the thread, heat the slotted nut prior to loosen it (abt.
  • Page 603 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Remove disc. Figure 213 Pull cylindrical gear K1 off plate carrier. (S) 3-leg puller 504237 Figure 214 The figure on the left shows the spur gear bearing -K1. Bearing 1 is available only as sub-assembly. If the disassembly of the plate pack-side ball bearing (arrow) is necessary –...
  • Page 604 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull ball bearing from plate carrier (Figure 217 and 218). Pay attention to the released balls! (S) Pry bar 504209 Figure 217 Figure 218 Squeeze out snap ring. Disassemble end shim and plate pack K1. Figure 219 Tilt plate carrier by 90°.
  • Page 605 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pull tapered roller bearing off plate carrier. (S) Grab sleeve 504242 (S) Basic tool 504238 Figure 221 Pull spur gear KV off plate carrier. (S) 3-leg puller 504237 Figure 222 Remove shim and ring. Figure 223 Pull tapered roller bearing off plate carrier (Figure 224).
  • Page 606 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Manual transmission assembly Mount studs (arrows). Wet thread with Loctite (type-no. 243)! Depending on the transmission version, differences concerning number and length of the studs are possible. See in this connection the corresponding Spare Parts List.
  • Page 607 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Insert bearing outer race (arrow) into housing bore until contact is obtained. Figure 234 Position pre-assembled pto-shaft in the housing and insert bearing outer race until contact is obtained. Figure 235 Adjust axial gap – power take-off bearing max. 0,10 mm, using shim(s) and circlip.
  • Page 608 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Reassemble multi-disc clutch-K3/K4 Lift plate carrier with the K4-side showing downwards into the clamping ring (S) and fix it. Now, tilt plate carrier by 180°. Insert both roll pins (6x24 and 3,5x24 mm) flush into the end face- side bore of the plate carrier, see arrow/Figure 239 (S) Clamping ring 504226...
  • Page 609 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil O-rings and piston bearing surfaces. Uniformly insert piston K3 until contact is obtained. Observe the installation position of the piston, see Figure! Figure 243 Introduce intermediate washer and compression spring. Figure 244 Lay guide ring with the chamfer (arrow) showing upwards over compression spring and line up snap ring.
  • Page 610 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disc clutch-K4 The following sketch or table show plate stacking and installation position of the components. Figure 248 Item. Designation Quantity s (mm) Remark Plate carrier Piston Outer plate 1,85 One-side coated Outer plate Coated on both sides Inner plate...
  • Page 611 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance-K4 (Figure 249 ... 251)! To ensure a correct measuring result, initially install plate pack without oil! Install plate pack according to the sketch or table (page 3.31 or 3.32). Figure 249 Insert end shim and fix it by means of snap ring.
  • Page 612 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and install spur gear -K4 (Figure 252 ... 257): The figure on the left shows the components of the spur gear-K4 Bearing inner race Bearing outer race Shim (optional, empirical value s = 5,4 mm) Spur gear Figure 252 Check axial gap –...
  • Page 613 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce spur gear until all inner plates are accommodated. Figure 256 Heat up bearing inner race (spur gear bearing) and position it until contact is obtained Use protective gloves! Figure 257 Heat bearing inner race (clutch support) and line it up until con- tact is obtained Use protective gloves! Figure 258...
  • Page 614 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disc clutch-K3 The following sketch or table show plate stacking and installation position of the components! Figure 259 Item. Designation Quantity s (mm) Remark Plate carrier Piston Outer plate 1,85 One-,side coated Outer plate Coated on both sides Inner plate...
  • Page 615 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance-K3 (Figure 261 ... 263) ! To ensure a correct measuring result, initially install plates without oil! Install plate pack according to the sketch or table (page 3.36 or 3.37). Figure 261 Introduce end shim and fix it by means of snap ring Figure 262...
  • Page 616 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Heat up bearing inner race and line it up until contact is obtained. Use protective gloves! Figure 264 Lift plate carrier out of the clamping ring (S). To ensure the exact contact of the components, pre-load the bear- ing with 100 000 N (10 To.) .
  • Page 617 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Introduce spur gear until all inner plates are accommodated. Figure 268 Heat roller bearing and position it until contact is obtained. Use protective gloves! Figure 269 Introduce bearing inner race. Figure 270 Check function of clutches K3 and K4 by means of compressed air.
  • Page 618 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Squeeze in and engage rectangular rings (3x, see arrows). Figure 272 SHOP MANUAL MT26/31 - 08.2006 SHOP MANUAL MT26/31 - 08.2006...
  • Page 619 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Reassemble multi-disc clutch-KR/K2 Lift plate carrier with the KR-side showing downward into clamping ring and fix it. Tilt plate carrier 180°. Insert both roll pins (6x24 and 3,5x24 mm) flush into the spur gear side bore of the plate carrier (arrow).
  • Page 620 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Oil O-rings and piston bearing surfaces. Uniformly insert K2-piston until contact is obtained. Pay attention to the installation position of the piston, see figure! Figure 279 Introduce intermediate plate and compression spring. Figure 280 Lay guide ring with the chamfer (arrow) showing upwards over the compression spring and line up snap ring.
  • Page 621 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Multi-disc clutch-KR Multi-disc clutch-KR The following sketch or table show plate stacking and installation position of the components! Figure 283 Item. Designation Quantity s (mm) Remark Plate carrier Piston Outer plate 1,85 One-side coated Outer plate Coated on both sides...
  • Page 622 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Check plate clearance-KR (Figure 285 ... 287) ! To ensure a correct measuring result, initially install plate pack without oil! Install plate pack according to the sketch or table (Figure 283). Figure 285 Insert end shim and fix it by means of snap ring.
  • Page 623 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-assemble and install spur gear KR (Figure 288 ... 296): The figure on the left shows the components of the spur gear KR. 1 = Bearing inner race 2 = Shims , s = 3,0 and s = 3,10 mm ( Σ...
  • Page 624 Ch 2 Ch 2 TRANSMISSION TRANSMISSION page page Pre-load tapered roller bearing with about 50 000 N (5 t) and determine axial gap by means of dial indicator. In case of deviations from the required axial gap, correct with suitable shims (Item.
  • Page 625 Ch 2 TRANSMISSION page Heat up bearing inner race (spur gear support) and position it until contact is obtained. Use protective gloves! Figure 296 Heat bearing inner race (clutch support)and position it until contact is obtained. Use protective gloves! Figure 297 SHOP MANUAL MT26/31 - 08.2006...
  • Page 626 DRIVE LINE CH 3 PAGE Chapter 3 Drive Line Index 3 Drive Line ......................... 2 3.1 Introduction ......................2 3.2 Front Axle Drive Assembly.................. 3 3.2.1 Front Axle Drive Unit ......................3 3.2.2 Front Wheel Hub Reduction Drive..................4 3.3 Rear Axle Drive Assembly................... 5 3.3.1 Rear Axle Drive Unit ......................
  • Page 627 CH 3 DRIVE LINE PAGE 3 Drive Line 3.1 Introduction The Drive Line consists of the components transferring the power from the engine to the transmission, and from the transmission to each wheel, and also wheels, and brakes. Right Tandem Housing Rear Axle Rear Axle...
  • Page 628 DRIVE LINE CH 3 PAGE 3.2 Front Axle Drive Assembly 3.2.1 Front Axle Drive Unit The Front Axle Drive Unit transfers the power from the transmission to each front wheel. Removal Rise both front wheels off the ground using a floor jack or a crane. WARNING!__________________________________________ Be aware of the risk of injury to people and equipment when handling heavy objects!
  • Page 629 CH 3 DRIVE LINE PAGE 3.2.2 Front Wheel Hub Reduction Drive The Front Wheel Hub Reduction Drive has a planetary drive, reducing axle speed, increasing torque to each front wheel. Disassembly Remove front axle drive assembly (Ref. 3.2.1) Release the four bolts connecting the reduction gear to the drive shaft. Assembly Connect the reduction gear to the drive shaft and tighten the four bolts.
  • Page 630 DRIVE LINE CH 3 PAGE 3.3 Rear Axle Drive Assembly 3.3.1 Rear Axle Drive Unit The Rear Axle Drive Unit transfers and distributes the power from the engine to the rear wheels, as well as being the main carrier of the dumper body loads. Disassembly Place dumper in a location where lifting capacity to rise the rear wagon from ground is available.
  • Page 631 CH 3 DRIVE LINE PAGE 3.3.2 Rear Axle Differential The Rear Axle Differential distributes the power between left and right rear wheel tandem housing. Removal Remove rear axle unit from dumper (Ref 3.3.1) Release eight bolts, and remove pinion cover. Save the shims behind. Remove circlip inside pinion, and withdraw seal plug, using a slide hammer equipped with an M16 adapter.
  • Page 632 DRIVE LINE CH 3 PAGE 3.3.3 Rear Axle Hub Assembly The four Rear Axle Hubs are carriers for the drive shafts for each rear wheel, and also act as brackets for the rear wheel brake calipers. Removal Rise wheel off the ground using a floor jack. Remove actual wheel (Ref.3.4.1) Thoroughly clean the rear axle hub assembly and the area around for any accumulated dirt.
  • Page 633 CH 3 DRIVE LINE PAGE 3.3.4 Tandem Housing Internal Parts All internal parts in the tandem housing can be changed without removing the housing from the rear axle. Removal Remove both actual axle hub assemblies from actual housing (Ref. 3.3.5). Brake callipers can be left in place on hubs.
  • Page 634 DRIVE LINE CH 3 PAGE View of the pinion in the tandem housing. Tandem housing Screw M10 x 25 Tandem housing Cover Screw M10 x 25 Snap ring Cover Thrust washer Snap ring O-ring Thrust washer Shim cover pinion bearing (0.1mm) O-ring Shim cover pinion bearing (0.3mm) Shim cover pinion bearing (0.1mm)
  • Page 635 CH 3 DRIVE LINE PAGE Pinion basic dimensions 181 mm 183,5 mm SHOP MANUAL MT26/31 - 12.2004 SHOP MANUAL MT26/31 - 12.2004...
  • Page 636 DRIVE LINE CH 3 PAGE Calculation Calculation example: Measure B 2,65 mm Measure A 2,45 mm Differance 0,20 mm Give shims 0,10 mm. See also the SPI 03/2004 SHOP MANUAL MT26/31 - 12.2004 SHOP MANUAL MT26/31 - 12.2004...
  • Page 637 CH 3 DRIVE LINE PAGE Shims SHOP MANUAL MT26/31 - 12.2004 SHOP MANUAL MT26/31 - 12.2004...
  • Page 638 DRIVE LINE CH 3 PAGE 3.3.5 Tandem Housing Each Tandem Housing is a main part of the rear wheel suspension, as well as containing the rear wheel reduc- tion drive, distributing the power from the rear axle to each rear wheel. Removal Remove rear axle drive assembly from dumper.
  • Page 639 CH 3 DRIVE LINE PAGE 3.3.6 Tandem Bearing The Tandem Bearings are the suspension for the tandem housing. The bearings are mounted to the rear axle, and carries all the loads on the rear wheels. Removal Remove actual tandem housing. (Ref. 3.3.6) Draining of oil is not necessary if removal takes place just for work on the tandem bearing.
  • Page 640 DRIVE LINE CH 3 PAGE 3.4 Wheels 3.4.1 Wheel Removal Use a floor jack or a crane to lift the dumper to rise the actual wheel off the ground. Place on safety stand. Remove all wheel nuts except one of the upper. Place a wheel handling tool under the wheel and lift to take the weight of the wheel.
  • Page 641 CH 3 DRIVE LINE PAGE 3.5 Propeller Shafts The Propeller Shafts connects the engine, transmission and Rear Axle Drive the wheel axles, and transfer the torque to the different axle Assembly drives. Engine/Trans- mission Transmission Engine Intermediate Drive Shaft Fig 3.13 Propeller Shafts Front Axle Drive Shafts 3.5.1 Engine/Transmission Propeller Shaft...
  • Page 642 DRIVE LINE CH 3 PAGE 3.5.2 Front Axle Drive Shaft The Front Axle Drive Shafts transfer the power from the transmission to the front axle reduction drives. Removal Rise both front wheels off the ground using a floor jack or a crane. WARNING!_______________________________________________________________ Be aware of the risk of injury to people and equipment when handling heavy objects! Place dumper on safety stands.
  • Page 643 CH 3 DRIVE LINE PAGE 3.5.3 Intermediate Drive Shaft Assembly The Intermediate Drive Shaft Assembly transfers the power from the trans- mission to the rear axle drive assembly, and consists of three main parts The front part of the drive shaft connects the transmission trough the articu- lation bearing to the center part of the drive shaft which is supported in the rear frame.
  • Page 644 DRIVE LINE CH 3 PAGE 3.5.3.1 Front Intermediate Drive Shaft Removal Rise the dumper body, and place on safety stand. Thoroughly clean the shaft and the area around for any accumulated dirt. The front drive shaft is removed through the shaft tunnel in the articulation bearing. Release the four bolts securing the shaft to the transmission rear output flange.
  • Page 645 CH 3 DRIVE LINE PAGE 3.5.3.2 Center Intermediate Drive Shaft Removal Rise the dumper body, and place on safety stand. Thoroughly clean the shaft and the area around for any accumulated dirt. Remove the parking brake unit (Ref.3.6.1) Unscrew the four bolts securing the center shaft to the front intermediate drive shaft. (Ref. 3.5.3.1) Unscrew the four bolts securing the center shaft to the rear intermediate drive shaft.
  • Page 646 DRIVE LINE CH 3 PAGE 3.5.3.3 Rear Intermediate Drive Shaft Removal Secure dumper from rolling with wheel blocks, as removing this shaft unables parking brake to lock the rear wheels. Rise the dumper body, and place on safety stand. Thoroughly clean the shaft and the area around for any accumulated dirt. Release the four bolts securing the drive shaft to the center rear axle drive shaft.
  • Page 647 CH 3 DRIVE LINE PAGE 3.5.4 Engine Output Flange Flexible Coupling The Engine Output Flange Flexible Coupling is located inside the engine flywheel, and absorbs engine vibra- tions, thereby reducing vibration and sound created by the engine. Disassembly Remove the engine/transmission drive shaft. (Ref.
  • Page 648 DRIVE LINE CH 3 PAGE 3.6 Brakes 3.6.1Service Brakes The Service Brakes are controlled by the brake pedal, and is acting on all six wheels, devided into two separat brake circuits. The disc brake units are hydraulically operated, assisted by pressurized air. 3.6.1.2 Disc Brake Pads The Service Brakes are equipped with totally eight brake calipers, and each caliper has two brake pads.
  • Page 649 CH 3 DRIVE LINE PAGE 3.6.1.3 Front Brake Calipers The two front wheel brake units are equipped with two calipers on each hub. Removal Rise both front wheels off the ground using a floor jack or a crane. Place dumper on safety stands. Remove actual wheel (Ref.
  • Page 650 DRIVE LINE CH 3 PAGE 3.6.1.4 Rear Brake Calipers The rear wheels are equipped with one brake caliper on each hub. Disassembly Rise wheel off the ground using a floor jack or a crane. WARNING!_______________________________________________________________ Be aware of the risk of injury to people and equipment when handling heavy objects! Place dumper on safety stand.
  • Page 651 Remove the four alignment pins. Thoroughly clean all removed parts. Note: If any defects are discovered making installation of new parts necessary, contact Moxy representative for assistance as a major overhaul involves use of special tools. Assembly Position the brake disc on the hub. Tighten the 12 bolts securing the disc to the wheel hub loosely.
  • Page 652 DRIVE LINE CH 3 PAGE 3.6.1.5 Rear Brake Discs Disassembly Remove the brake caliper on actual wheel hub. (Ref. 3.6.1.4) Drain the oil from the actual tandem housring. Remove the actual rear axle hub assembly. (Ref. 3.3.3) WARNING!____________________________ Be aware of the risk of injury to people and equipment when handling heavy objects! Place hub assembly on on wheel shaft flange.
  • Page 653 CH 3 DRIVE LINE PAGE 3.6.1.6 Bleeding Brake System Circuits Any maintenance performed on the brake system involving opening of a circuits, shall always be followed up with bleeding the circuit. Note: Before bleeding, and during the process, keep reservoir topped with brake fluid. Use fresh fluid according to Operation and Maintenance Manual.
  • Page 654 DRIVE LINE CH 3 PAGE 3.6.2 Parking Brake 3.6.2.1 Parking Brake Unit The Parking Brake is the dumper secondary braking system. The system consists of a spring operated, air released, disc brake, mounted on the intermediate shaft. The Parking Brake Unit operates the disc brake, and is mounted on a bracket located between the rear frame members.
  • Page 655 CH 3 DRIVE LINE PAGE 3.6.2.2 Parking Brake Release Air Cylinder The Parking Brake Release Air Cylinder disengages the parking brake by compressed air. Disassmbly Remove the parking brake unit (Ref. 3.6.2.1) Place unit on work bench. Remove parking brake covers. Engage the parking brake manually to remove the clevis pin from the operating arm.
  • Page 656 DRIVE LINE CH 3 PAGE 3.6.2.3 Parking Brake Caliper Replacement The Parking Brake Caliper is spring loaded to locked position. Removal Remove the parking brake unit (Ref. 3.6.2.1) Remove the parking brake release air cylinder (Ref. 3.6.2.2) Remove caliper from mounting bracket by unscrewing four bolts. Replacement Position caliper on bracket.
  • Page 657 CH 3 DRIVE LINE PAGE 3.6.2.4 Parking Brake Disc Replacement The Parking Brake Disk is mounted on rear end of center intermediate shaft. Disassembly Remove the parking brake unit (Ref. 3.6.2.1) Remove rear intermediate drive shaft (Ref. 3.5.6) Remove the 12 bolts securing the brake disc to the center intermediate drive shaft. Assembly Position the brake disc on the center intermediate drive shaft rear flange.
  • Page 658 Ch 5 HYDRAULIC SYSTEM 710655 - page Chapter 5 Hydraulic system SHOP MANUAL MT 26 / 31 10.2006...
  • Page 659 710655 - HYDRAULIC SYSTEM Ch 5 page Hydraulic system Index Components, capacities and oil types ..........4 Hydraulic system main function......................5 System pressure..........................6 Hydraulic parts view ........................7 Hydraulic circuits ..........................9 Hydraulic cirquit with item numbers....................11 Hydraulic cirquit with hoses item number ..................13 Startup test procedure ..............
  • Page 660 Park brake pressure control / adjusting ..................69 Service brake parts ........................70 Service and park brake cirquit view....................71 Accumulators..................72 Description of the Accumulators....................72 Filling table of Correction Factors ....................75 Accumulator charging:........................76 Accumulator valve ........................77 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 661 BIO oil can be used • BIO oil cannot be mixed with hydraulic oil and system need to be flushed • Type of BIO oil to be accepted by Moxy Hydraulic tank MT26: • Two chamber tank • Volume total •...
  • Page 662 A separate pump (2) feeds the cooling fan motor which provides sufficient fan speed to maintain engine operating temperature within given limits. Accumulator 1,0 litre left hand side. Park brake Accumulator 4,3 litre Accumulator 3,0 litre right hand side. left hand side. Rear service brake Front service brake SHOP MANUAL MT 26 / 31 10.2006...
  • Page 663 710655 - HydrAULiC SySTeM Ch 5 page System pressure Brake system pressure: • Front brake circuit 131 ±8,6 bar • Rear brake circuit 131 ±7,0 bar Pressure monitoring switches: • Main pump (1) 5.0 ± 0.1 bar N/C • Emergency steering pump (1) 3.2 ±0.1 bar N/C •...
  • Page 664 3170 3380 0640 3820 Pr.switch N/O- 3.5b Retarder and exhaust brake on 0210 3180 4780 Pr.switch N/C- 145.0b Low prssure warning, Cirquit 2 0230 accumulator cirquit 1 and 2 Front brake 3530 4480 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 665 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 666 Ch 5 HYDRAULIC SYSTEM 710655 - page Hydraulic circuits SHOP MANUAL MT 26 / 31 10.2006...
  • Page 667 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 668 2880 2460-3 Reducing valve 2980 Reg. low Transmission 2460-4 Relief valve pressure retarder valve 2460-5 Check valve Reg. high 2460-6 Pressure drain valve pressure 2460-7 Pressure safety valve 2460-8 Throttle valve 1350 2400 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 669 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 670 710655 - page Hydraulic cirquit with hoses item number 1190 1700 5960 4440 4840 4840 4560 4330 4710 3240 2180 1960 4050 2770 2460 3520 2443 2400 2700 2880 2980 1430 1350 4170 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 671 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 672 Ch 5 HYDRAULIC SYSTEM 710655 - page SHOP MANUAL MT 26 / 31 10.2006...
  • Page 673 710655 - HYDRAULIC SYSTEM Ch 5 page Main pump Hydraulic filter cirquit Hydraulic filter: • Filter head w/by-pass valve and separate return inlets (with check valves) for tilt/fan and steering • Oil refill through filter head • Pressure test point (optional) •...
  • Page 674 Control Before startup - Check that all connections are located in the same positions as before removal, and that all hoses are correctly routed. Perform startup test procedure. Ref. section: Startup test procedure. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 675 710655 - HYDRAULIC SYSTEM Ch 5 page Main pump pressure adjusting Connect the manometer to the test point 0230 under- neath the filter rack left hand side. Low pressure Test the high pressure 280 bar with to run the engine 1000 rpm and turn the steering cylinder to end stop.
  • Page 676 Ch 5 HYDRAULIC SYSTEM 710655 - page Main pump circuit Tank 1430 4170 Orbitrol LS SHOP MANUAL MT 26 / 31 10.2006...
  • Page 677 710655 - HYDRAULIC SYSTEM Ch 5 page Main pump parts list Item Description Item Description SHOP MANUAL MT41 - 10.2005...
  • Page 678 Ch 5 HYDRAULIC SYSTEM 710655 - page Main pump exploded view SHOP MANUAL MT 26 / 31 10.2006...
  • Page 679 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 680 Ch 5 HYDRAULIC SYSTEM 710655 - page Main pump exploded view 810073- Hose connection SHOP MANUAL MT 26 / 31 10.2006...
  • Page 681 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 682 Ch 5 HYDRAULIC SYSTEM 710655 - page Main pump section draving Section B - B Section A - A SHOP MANUAL MT 26 / 31 10.2006...
  • Page 683 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 684 Put in seal carrier 6 and snap ring 5. (Carefully, do not damage the shaft seal) Readjust the max. volume screw 4 with dimension A and fasten the nut (torque 50 Nm). Fasten rear cover bolts 1 with 290 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 685 710655 - HYDRAULIC SYSTEM Ch 5 page Steering system Description: The steering system is built up of a Danfoss orbitrol steering unit (900), a Danfoss flow amplifier (330), and two steering cylinders (1190). When the orbitrol is activated, a controlled oil flow is directed to the flow amplifier. This oil flow is amplified in the flow amplifier and the total oil flow is directed to the steering cylinders.
  • Page 686 Control Before startup - Check that all connections are located in the same positions as before removal, and that all hoses are correctly routed. Perform startup test procedure. Ref. section: Startup test procedure. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 687 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 688 Ch 5 HYDRAULIC SYSTEM 710655 - page SHOP MANUAL MT 26 / 31 10.2006...
  • Page 689 710655 - HYDRAULIC SYSTEM Ch 5 page Steering Pressure Adjustment Steering Pressure Adjustment Steering pressure: See the section “Main pump pres- sure adjusting” Loosen steering master valve (Orbitrol) Remove hose supports to pull valve down to access adjusting port. Remove plug next to master valve mounting flange 8mm Allen /Unbrako key.
  • Page 690 Check that all connections are located in the same positions as before removal, and that all hoses are correctly routed. Install cover, and fit the four bolts. Tighten the bolts. Perform startup test procedure. Ref. section: Startup test procedure. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 691 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 692 P Oil from the hydraulic pump / check valve 2880 Oil flow from the main pump Oil flow from Retur line the emergency to the steering pump Hydraulic filter / tank SHOP MANUAL MT 26 / 31 10.2006...
  • Page 693 710655 - HYDRAULIC SYSTEM Ch 5 page Steering Cylinder Steering cylinders: • Double acting • • Cylinder diameter 100mm • Piston diameter 63mm • Stroke 515mm • End cushion The Steering Cylinders are located on each side of the articulation hinge. Removal Thoroughly clean the steering cylinder and the area around for any accumulated dirt.
  • Page 694 Ch 5 HYDRAULIC SYSTEM 710655 - page 380 Nm To/from Steering Valve 380 Nm Rear pivot bolt Steering Cylinder (left side shown) 380 Nm Front pivot bolt 380 Nm SHOP MANUAL MT 26 / 31 10.2006...
  • Page 695 710655 - HYDRAULIC SYSTEM Ch 5 page Steering cylinder, sectional drawing. Torque limit: Pos. 3: 1370 Nm Pos. 7: 5 Nm Pos. 13: 450 Nm Steering cylinder ass’y Pos Qt’y Description Screw Bushing Piston Steering Piston seal O-ring Locking screw Casing O-ring Backup ring...
  • Page 696 Control Before startup - Check that all connections are located in the same positions as before removal, and that all hoses are correctly routed. Perform startup test procedure. Ref. section: Startup test procedure. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 697 710655 - HYDRAULIC SYSTEM Ch 5 page 1190 SHOP MANUAL MT41 - 10.2005...
  • Page 698 P Oil from the hydraulic pump / check valve 2880 Oil flow from the main pump Oil flow from Retur line the emergency to the steering pump Hydraulic filter / tank SHOP MANUAL MT 26 / 31 10.2006...
  • Page 699 710655 - HYDRAULIC SYSTEM Ch 5 page Tilting system Tilt Servo Valve The Tilt Servo Valve is located in the cab in console on drivers right hand side. Access is obtained by removing console side cover. Removal Thoroughly clean the tilt servo valve and the area around for any accumulated dirt.
  • Page 700 Access is obtained by removing left front tire, and removing the cover behind the tire. The cover is secured with four bolts. Some of the connection are accessed from behind under the cab. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 701 710655 - HYDRAULIC SYSTEM Ch 5 page Tilt valve exploded, assemble view Removal Thoroughly clean the tilting valve and the area around for any accumulated dirt. Place a container below the valve to catch any hydraulic fluid spilt during removal. Mark each hydraulic line for proper location and plug lines as they are removed from valve.
  • Page 702 Drain valve Item 23,24,25,26 Plug Item 12,18 Seal kit Item 21(2x)25,32, seals on 12 and 18 Tie-rod kit Item 3,4,5,6 Measuring plug Item Seal kit Item 10,11,12 10 Nm Apply corrosion protection Apply SHOP MANUAL MT 26 / 31 10.2006...
  • Page 703 710655 - HYDRAULIC SYSTEM Ch 5 page Tilting circuit 1960 From the Return line solenoid valve through the (2790) PRM Connector block (4050)-T and to the tank. 1700 2250 2170 2180 1430 To Shutle valve (730)-1 and Steering valve (330)-LS From steering valve (330)-EF Signal line...
  • Page 704 Ch 5 HYDRAULIC SYSTEM 710655 - page View of the tilting system Right Left cylinder cylinder 1960 2180 4050 Return oil to the 2790 filter/tank 1430 Oil from steering valve EF SHOP MANUAL MT 26 / 31 10.2006...
  • Page 705 710655 - HYDRAULIC SYSTEM Ch 5 page Solenoid valve cirquit 3956 2790 A 2790 B 2790 C 2790D To the tilting servo valve From accumulator valve 3820-1 3820-2 N/O 3,0b Retur oil 3900 Retur oil (6,0 bar) 3820-1 Pressure switch 3820-2 Pressure switch Retur oil 3956...
  • Page 706 Tilting servo pressure, control / adjusting Solenoidblokk Diff lock on the right 1960 hand side of the trans- Engine mission. exhaust Retarder brake brake valve 3900 2790 Pressure adjusting valve Test point 2460 3530 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 707 710655 - HYDRAULIC SYSTEM Ch 5 page Tilt cylinders: • Double acting • • Cylinder diameter 115mm • Piston diameter 70mm • Stroke 2290mm Upper pivot Tool 516311 bolt 250 Nm Tool 1848 Tool 1848 Lower pivot bolt 250 Nm SHOP MANUAL MT41 - 10.2005...
  • Page 708 Control Check that all connections are located in the same posi- tions as before removal, and that all hoses are correctly routed. Perform startup test procedure. Ref. section: Startup test procedure. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 709 710655 - HYDRAULIC SYSTEM Ch 5 page Tilt cylinder, sectional drawing. Torque limit: Pos 1: 1370 Nm Pos 5: 5 Nm Pos 11: 500 Nm 9 10 11 12 13 14 15 16 Tilting cylinder ass'y Pos Qt’y Description Piston O-ring Piston seal Steering...
  • Page 710 Ch 5 HYDRAULIC SYSTEM 710655 - page SHOP MANUAL MT 26 / 31 10.2006...
  • Page 711 710655 - HYDRAULIC SYSTEM Ch 5 page Fan system Fan and accumulator pump. • Variable axial piston pump • LS – operated • Mounted at rear of transmission • Driven by the engine • Ratio 1.05 : 1 • Maximum volume 28 ccm •...
  • Page 712 Ch 5 HYDRAULIC SYSTEM 710655 - page Viftekrets Fan cirquit 2400 2442 1430 2700 2460 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 713 710655 - HYDRAULIC SYSTEM Ch 5 page Pump pressure adjustment Controll main pressure. Remove the plug and assemble to the pump housing the test connector. Connecting the manometer connection to the pump. Release the electrical connector from the solenoid valve. Run the engine with 1500 O/min , read the manometer, the high pressure shall now be adjusted to 250 ±3.0 bar Adjust the low pressure to 30 ±2.0bar (idle)
  • Page 714 Before startup - Check that all connections are located in the same positions as before removal, and that all hoses and tubes are correctly routed. Perform startup test procedure. Ref. section: Startup test procedure. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 715 710655 - HYDRAULIC SYSTEM Ch 5 page Disassemble the fan and fan motor 1 Drain the cooling system. 2 Remove the pipeline between the engine and the air cooler. 3 Remove clamping band for the hose and wiring 4 Disassemble the inlet cooling hoses from the thermostat housing 5 Disassemble the hydraulic hoses from the fan motor 6 Disassemble the pipe clamps from the radiator shield 7 Disassemble bracket between engine and the fan rack...
  • Page 716 Install the hydraulic lines. Control Check that all connections are located in the same position as before removal, and that all hoses are correctly routed. From thermo- From static pump valve thermo- static valve To tank SHOP MANUAL MT 26 / 31 10.2006...
  • Page 717 710655 - HYDRAULIC SYSTEM Ch 5 page Tilt / auxiliary operation servo (diff. lock, engine and retarder brake): • Pressure reduction valve 35 ±0.5bar (fan pump at maximum pressure engine at idle) Operating pressure: • Diff. lock 10 ±0.1bar • Engine brake 10 ±0.1bar •...
  • Page 718 Apply a light coat of oil to the hose fitting seals. Install the connectors in valve body, and tighten. Install the hydraulic lines. Control Check that all connections are located in the same position as before removal, and that all hoses are correctly routed. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 719 710655 - HYDRAULIC SYSTEM Ch 5 page Water to Water from the cab the cab heater heater 2990 2980 Water Hot water return from the to the engine engine Hose 45 Hose 44 Return oil Oil flow to the from the gathering auxilary block and...
  • Page 720 Foot brake valve Æ VDB Service brake front Ø VDB Service brake rear Ø N/O 3,0b N/O 3,0b NOTE ! From machine 810053 P(cut in) 175 bar (6,0 bar) P(cut out) 210 bar SHOP MANUAL MT 26 / 31 10.2006...
  • Page 721 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 722 If for some reason the Park Brake oil pressure drops below approx 108 bar the spring force will apply the Park- ing Brake as an emergency brake. The warning light come on at 110 bar. Chamber Spring Spacer Retaining ring Cotter pin Cotter pin Washer Spacer Adjuster plug Lining assembly SHOP MANUAL MT 26 / 31 10.2006...
  • Page 723 710655 - HYDRAULIC SYSTEM Ch 5 page Parking brake cirquit veiw Oil from the Hose to the solenoid 2460 accumulator control valve block P1 Relief valve pump Parking brake adjusting pressure. Relief valve Service brake Hose to the rear adjusting pressure. frame park brake unit 3380...
  • Page 724 Ch 5 HYDRAULIC SYSTEM 710655 - page Parking brake cirquit Lhs 1,0L Lhs 1,0L Rhs 1,0L Rhs 1,0L Rhs 1,0L P (cut in) 175 bar P (cut out) 210 bar SHOP MANUAL MT 26 / 31 10.2006...
  • Page 725 710655 - HYDRAULIC SYSTEM Ch 5 page Parking brake view 3510 3520 4440 2880 Service 4840 Brake cirquit rear 2460 4440 4710 3240 2790 4330 4560 Service Brake cirquit front SHOP MANUAL MT41 - 10.2005...
  • Page 726 The warning light coming on when pressure is lower than 110 bar. Park brake Park brake: adjusting • Relief valve (3) 135 +5.0bar pressure Outer side view Pressure switch Pos. 3380 Pressure switch Pos. 3180 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 727 710655 - HYDRAULIC SYSTEM Ch 5 page Service brake parts The service brake consist of: Hydraulic pump, Accumulators, Accumulator valve, Brake valve, Control valve, and calippers. Accumulator 1,0 litre left hand side. Park brake Accumulator 4,3 litre Accumulator 3,0 litre right hand side.
  • Page 728 Service Brake 3520 cirquit rear 4440 2880 4840 2460 3 litre (Service brake ACCII 4330 front) ACCI 4,3 liter (Service brake 1 litre 4510 rear) (Park 4050 brake) Service 3240 Brake cirquit front SHOP MANUAL MT 26 / 31 10.2006...
  • Page 729 If the pressure of the gas contained in the nitrogen bottle is greater than the maximum permissible operating pressure of the accumulator, a pressure regulator must be fitted to the nitrogen bottle. Moxy recommends that the precharge should be checked during the first week following commissioning of the system.
  • Page 730 W 21,7 x 1/ 14” (female) Moxy No. 515151 Germany W 24,32 x 1/ 14” (female) Moxy No. (Incl. 515148) Italy W 21,7 x 1/ 14” (male) Moxy No. 515152 0,960 x 1/ 14” (male) Moxy No. 515150 SHOP MANUAL MT 26 / 31 10.2006...
  • Page 731 710655 - HYDRAULIC SYSTEM Ch 5 page Operating Instructions Only fluids in Group 2 as defined by the Pressure Equipment Directive 97/23/EC are permitted for use in A and AP Series accumulators – see Piston Accumulator Operating Instructions, bulletin 1240-T1. Before installation, refer to the pressure and temperature limits shown on the nameplate.
  • Page 732 To allow for the effects of temperature transfer, the accumulator should be allowed to stand for a minimum of 15 minutes to allow the temperature to stabilize before a final reading of the precharge pressure is taken. SHOP MANUAL MT 26 / 31 10.2006...
  • Page 733 710655 - HYDRAULIC SYSTEM Ch 5 page Accumulator charging: • Minimum charging (start) 175 ± 2 bar • Maximum charging (relief) 210 bar (there should be a difference of min. 15 bar from this value and maximum fan pressure of 250 bar) •...
  • Page 734 Ch 5 HYDRAULIC SYSTEM 710655 - page Accumulator valve SHOP MANUAL MT 26 / 31 10.2006...
  • Page 735 710655 - HYDRAULIC SYSTEM Ch 5 page SHOP MANUAL MT41 - 10.2005...
  • Page 736 Ch 6 ELECTRICAL SYSTEM page Chapter 6 Electrical system SHOP MANUAL MT26-31 - 08.2006...
  • Page 737 Ch 6 ELECTRICAL SYSTEM page El.system Index Description of el. system ..............4 General description ........................4 Welding on the dump truck......................4 Battery hazard prevention ......................5 How to use the electrical documentation..................6 Faultfinding, what to do ........................6 Practical example ...........................7 Description of circuit symbols ......................8 Electrical parts view........................9 Spesification of electrical components...........
  • Page 738 Ch 6 ELECTRICAL SYSTEM page Circuit 03 Power supply / start ....................59 Circuit 04 Work light / Extra high beam ..................60 Circuit 05 Heated mirrors......................61 Circuit 06 Fan and A/C ......................63 Circuit 09 Rewerse and work light rear..................65 Circuit 10 Gauge and Instrument light ..................66 Circuit 10 Gauge and Instrument light.
  • Page 739 Ch 6 ELECTRICAL SYSTEM page Description of el. system General description Voltage The truck has a 24V system. The batteri ÷ is used as ground connection. Supply Two batteries, each 12V/230Ah, are connected together in serial connection to provide the system with 24V. The batteries are located in the right hand side fender.
  • Page 740 Ch 6 ELECTRICAL SYSTEM page Note! · Keep the batteries in good condition. · Batteri power assistance: see Operating and Maintenance manual · When exchanging electrical components: allways turn off the battery main switch. · Remember that a open circuit symptom in a warning light circuit might be a broken bulb.
  • Page 741 Ch 6 ELECTRICAL SYSTEM page How to use the electrical documentation The electrical documentation consists of three different types of documents: map drawings, circuit drawings and a cross reference list. Each document includes a different quantity of component numbers. Map drawing (abbreviation: M..) A map drawing shows the physical location of a component and its component number.
  • Page 742 Ch 6 ELECTRICAL SYSTEM page Practical example Start with the index on page 1 to find the correct map description. Page 1 Index Index Page 6.1. 20 Map 01 El.system, starting and charging The correct map descrip- tion leads to the page number, for instance page Cross refer- ence list...
  • Page 743 Ch 6 ELECTRICAL SYSTEM page Description of circuit symbols Circuit 03 Power supply / start C 03 Square frames : Component number or connec- tion point input or output in an other circuit Balloon frames: Component number or con- nection point with direkt influ- ence in the circuit.
  • Page 744 Ch 6 ELECTRICAL SYSTEM page Electrical parts view Principal components CT1 WDB monitor and CAN tie unit Note: From machine 710655 24 Central lubrication main unit 145 Battery 146 Alternator 150 Starter 165 Main switch 209 Compressor, A/C 240 EST37 Transmission controll unit TCU 244 CT1 WDB monitor and CAN tie unit 340 IVC4B Valve adjuster box 342 Solenoid valve brake activation...
  • Page 745 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 746 Ch 6 ELECTRICAL SYSTEM page Spesification of electrical components. Engine: 146 Alternator 80A, 1 pole. Specifications Alternator 28V 35 - 80A Output at 6000 rpm. 2500 W Gear ratio 3,5:1 Number of poles Resistance in rotor approx. 11.2 ohm +/- 5% Resistance in stator, Phase-Phase 0.085 ohms +/- 0.001 Brushes, min, length...
  • Page 747 Ch 6 ELECTRICAL SYSTEM page Charge testing The alternator must not be run without the battery connected. The rectifiers can otherwise overload and be damaged. Output test Connect a calibrated test instrument with load resistor as illustrated. Start the engine and let it run for a few minutes before carrying out the test.
  • Page 748 Ch 6 ELECTRICAL SYSTEM page 150 Starter 512510 Voltage: 24 V Max power consumption: 6,7 kW (9,1 hp) Bosch JE: Assembly Specifications Power 6.7 kW Direction of rotation (viewed towards flywheel housing) Anti-clockwise Min. diameter of commutator 42.5 mm Min. length of carbon brushes 17.5 mm Spring pressure of carbon brushes 47-53 N...
  • Page 749 Ch 6 ELECTRICAL SYSTEM page Integral parts 1 Solenoid switch 2 Coupling lever 3 Field windings with pole shoes 4 Rotor with commutator 5 Starter pinion 6 Brush holder with four carbon brushes Exploded view drawing 1 Excitation winding 2 Bolt 3 Compression spring 4 Bearing 5 Bolt...
  • Page 750 Ch 6 ELECTRICAL SYSTEM page Renewal Carbon brushes Equipment required Four spring locks are required to renew the carbon brushes and springs simply and safely. These can be easily made from thin sheet steel which is cut into four pieces approximately 20 x 40 mm. Work description Before renewal, the starter motor should be removed.
  • Page 751 Ch 6 ELECTRICAL SYSTEM page 500 Control unit S6 Power supply: Nominal 24 V DC . The Control unit is transient and reverse voltage protected by a series diode. See also description in chapter 1, Section: Engine Managment System Function of EMS control unit: The control unit collects information which it processes into signals that control the fuel volume and injection timing.
  • Page 752 Ch 6 ELECTRICAL SYSTEM page How the pins are connected is shown below: Connector Voltage supply, +24 V to unit injectors. cyl 4 Voltage supply, +24 V to unit injectors. cyl 5 Not used. Voltage supply, +24 V to unit injectors. cyl 6 Not used.
  • Page 753 Ch 6 ELECTRICAL SYSTEM page How the pins are connected is shown below: Connector Voltage supply, + 24V to the control unit. Earth connection for the control unit to chassis. Input signal + 24V, from the ignition lock (when the key is in the drive position). Not used.
  • Page 754 Ch 6 ELECTRICAL SYSTEM page Spesification of electrical components 502 Sensor accelerator pedal potentiometer Acc. Pedal position Min. Ω Ω Measure between A and C: 1,7 k 2,6 k Ω Ω Measure between B and C: 2,9 k 2,0 k Ω...
  • Page 755 Ch 6 ELECTRICAL SYSTEM page Spesification of electrical components 541 Engine speed sensor Resistance: 486-594 W Inductance: 187-253 mH Measure between: 541- 1 and 2 Distance between sensor and flywheel/gear ring: 0,5- 1,5mm Location of engine speed sensors on the engine. Engine speed sensors The detail shows some of the holes in the flywheel 1 Engine speed sensor 1, T28...
  • Page 756 Ch 6 ELECTRICAL SYSTEM page 542 Sensor engine coolant temperature From machine 81001 - 810001 the temperature sensor Pos 542 is placed as shown Ω 37334 5041 -40 C Ω Resistance vs temperature 13329 1491 -20 C Ω 5382 355 Ω...
  • Page 757 Ch 6 ELECTRICAL SYSTEM page 543 Sensor engine boost temperature The charge air temperature sensor detects the temperature in the intake manifold. The control unit uses the signal from the sensor to finely adjust the fuel quantity so that black smoke is not produced.
  • Page 758 Ch 6 ELECTRICAL SYSTEM page Flashing code list for the EMS control unit. See in Chapter 1 SHOP MANUAL MT26-31 - 08.2006...
  • Page 759 Ch 6 ELECTRICAL SYSTEM page General coordinator connection diagram 710655 - CC Ret See also the wiring diagram C18 CC Res CC Acc 66.5 CC on/off Temp Not activated Exhaust brake Activated Ignition (15) Not activated Diagnosis lamp Engine start (50) Activated Diag.
  • Page 760 Ch 6 ELECTRICAL SYSTEM page Coordinator description (Scania) page 1. 710655 - Pin I/O Name Description Comment GND (earth) (U31) GND for the Coordinator Charge warning lamp The alternator (-s) is connected A CAN message is sent to the COO. The charge lamp indicates if for alternator 1 directly to the S6.
  • Page 761 Ch 6 ELECTRICAL SYSTEM page Coordinator description (Scania) page 2. 710655 - Name Description Comment CAN high Droop adjust enable Adjustment of the droop value. When this pin is connected to +24 V, it is possible adjust the droop value via pin 52 and 53 on COO. The actual droop value is then shown on the tachometer.
  • Page 762 Ch 6 ELECTRICAL SYSTEM page Transmission: 156 Main connector for transmission. Data for the Proportional valves in the shift control unit: Measure point: Connector pos 156 Ω Resistance: 10 % at 20 Current: 100 to 500 mA Pressure range: 0,8 bar to 8,3 bar Operating unit Connect with Wiring to...
  • Page 763 Ch 6 ELECTRICAL SYSTEM page Spesification of electrical components 616 Sensor, retarder temperature TCU 800 Ω to 1500 Ω Resistance: 614 Solenoid valve lock-up clutch Voltage: 24 V 60 Ω to 80 Ω Resistance: Current: 0,25 A to 0,35 A 200 Sensor retarder oil temperature −30 °C - +150 °C Operating temperature:...
  • Page 764 Ch 6 ELECTRICAL SYSTEM page Transmission sensors for speed pick-up. 606 Transmission input shaft and 608 Transmission turbine 1050 Ω ± 10% at 20 °C Resistance: Torque limit: 30 Nm Distance between sensor and gear ring: 0,5 mm + 0,3 mm 610 Hall-Sensor of the Output Working range: 2 Hz to 5 Khz...
  • Page 765 Ch 6 ELECTRICAL SYSTEM page 50 Low pressure switch, warning Accumulator connector block accumulator cirquit 1 Note: Machine 810001 - 810052 N/C- 145,0 bar Machine 810053 - N/C- 110,0 bar 53 Low pressure switch, warning accumulator cirquit 2 Machine 810001 - 810052 N/C- 145,0 bar Machine 810053 - N/C- 110,0 bar...
  • Page 766 Ch 6 ELECTRICAL SYSTEM page Spesification of electrical components 55 Pressure switch, retarder activated 60 Pressure switch, engine brake activated 75 Sensor fuel gauge Voltage: 0,7 Ω Resistance at high position: 78,0 Ω Resistance at low position: 112A Flow sensor emergency steering circuit 112A Switches, pressure drop: <...
  • Page 767 Ch 6 ELECTRICAL SYSTEM page  CT1 introduction MT26/31 from machine 710655 -   MT36/41 from machine 810053     •  •  •  •  •         ...
  • Page 768  Ch 6 ELECTRICAL SYSTEM page  CT1 Tecnical data      •  •  •  •  •  •               ...
  • Page 769 Ch 6 ELECTRICAL SYSTEM page                                    ...
  • Page 770 Ch 6 ELECTRICAL SYSTEM page          •  •  •                      ...
  • Page 771 Ch 6 ELECTRICAL SYSTEM page Position list. List Comp. Opt- Description Map no: Circuit no.: Engine revolution counter and hour meter Switch, test warning light brake fluid A2 Warning light, brake fluid B2 Warning light, emergency steering C1 Warning WDB error (from 810053) C2 Warning light, parking brake A1 Warning light, engine coolant temperature A2 Warning light, battery charge...
  • Page 772 Ch 6 ELECTRICAL SYSTEM page Comp. Opt- Description Map no: Circuit no.: Motor, windscreen wiper Switch, engine brake and retarder brake request Switch for parking brake on/off Low pressure switch brake circuit 1 Pressure switch, parking brake activated Low pressure switch brake circuit 2 Pressure switch, brake lights Pressure switch, retarder activated Rotating beacon...
  • Page 773 Ch 6 ELECTRICAL SYSTEM page Comp. Opt- Description Map no: Circuit no.: AA Fusebox, supply connection A1 Fuse, ignition A2 Fuse, low beam A3 Fuse, high beam A4 Fuse, wiper supply C14-C20 A5 Fuse, SPARE A6 Fuse, heater and A/C AF Fusebox, supply connection B1 Fuse, engine controller C03-C18...
  • Page 774 Ch 6 ELECTRICAL SYSTEM page Comp. Opt- Description Map no: Circuit no.: E2 Fuse, headlights E3 Fuse, starter C03-C18 E4 Fuse, Parking light right hand side E5 Fuse, Parking light left hand side E6 Fuse, spare space EA Fusebox, supply connection G1 Fuse, radio supply unit Flasher relay, direction light and hazard light B Flasher relay, direction light and hazard light,...
  • Page 775 Ch 6 ELECTRICAL SYSTEM page Comp. Opt- Description Map no: Circuit no.: Back up alarm Rear light left hand side M01-M03 C02- C21- C24 Rear light right hand side M01-M03 C02- C21- C24 Connection point, gear restriction C19- C28- C29- C30 Battery M01-M02 C03 Alternator...
  • Page 776 Ch 6 ELECTRICAL SYSTEM page Comp. Opt- Description Map no: Circuit no.: Relay, wiper/ washer and horn C14-C20 Relay, extra reverse/ backward working lights on mirror arms Heater unit A Fan heater unit B Fan heater unit Switch, A/C thermostat in heater unit Resistance in heater unit Motor for air intake selection heater unit Switch for air intake selection heater unit...
  • Page 777 Ch 6 ELECTRICAL SYSTEM page Comp. Opt- Description Map no: Circuit no.: Pressure switch, park brake system M02- M07 C20- Solenoid, parking brake C20- Detent magnet, tip control lever C22- Pressure switch for detent magnet control, tip C22- system Cable set, front frame View at the map Cable set, cab roof View at the map...
  • Page 778 Ch 6 ELECTRICAL SYSTEM page Comp. Opt- Description Map no: Circuit no.: 1001 Connector, main net right hand side, el. View at the map Central to switches 1002 Connector, main net right hand side, el. View at the map Central to switches 1003 Connector, main net right hand side, el.
  • Page 779 Ch 6 ELECTRICAL SYSTEM page 122 126 59A 59B 127 123 Map 01 El.system, outside front and rear 122 126 59A 59B 127 123 1003246 1003246 SHOP MANUAL MT26-31 - 08.2006...
  • Page 780 Ch 6 ELECTRICAL SYSTEM page Map 02 El.system, Front frame Accumulator valve block (2460) 1012 1013 1014 112A 112B AC filter SHOP MANUAL MT26-31 - 08.2006...
  • Page 781 Ch 6 ELECTRICAL SYSTEM page Map 03 El.system, Rear frame To Cab El.sentral Rear Central 1015 Lubrication (Map 9) block 1 Central lubrication 2 Rear light RHS 3 Rear light LHS 4 Free 5 Working light 6 Signal, Buzzer 7 Signal to the Buzzer SHOP MANUAL MT26-31 - 08.2006...
  • Page 782 Ch 6 ELECTRICAL SYSTEM page Map 04 El.system, Sensors on Engine (Injection To cab cables) (Behind cover) To battery + (cable starter - alternator) To the main switch (battery ) SHOP MANUAL MT26-31 - 08.2006...
  • Page 783 Ch 6 ELECTRICAL SYSTEM page Map 05 El.system, Sensors on Engine SHOP MANUAL MT26-31 - 08.2006...
  • Page 784 Ch 6 ELECTRICAL SYSTEM page Map 06 El.system, Sensors on Transmission NOTE: Look in the shop manual chapter 2 Installation viev / Inductive transmitter when assembly the induct. transmitter. SHOP MANUAL MT26-31 - 08.2006...
  • Page 785 Ch 6 ELECTRICAL SYSTEM page Map 07 El.system, Cab outside and ceiling G909 G904 G915 SHOP MANUAL MT26-31 - 08.2006...
  • Page 786 Ch 6 ELECTRICAL SYSTEM page Map 08 Cab lower Map 08 SHOP MANUAL MT26-31 - 08.2006...
  • Page 787 Ch 6 ELECTRICAL SYSTEM page Map 09 Fuse box and relays 11 12 13 14 E.g.: 95-E,A E.g.: 95-E,3 11 12 E.g.: 1011,4 13 14 SHOP MANUAL MT26-31 - 08.2006...
  • Page 788 Ch 6 ELECTRICAL SYSTEM page Map 10 Heater unit 265A 265B SHOP MANUAL MT26-31 - 08.2006...
  • Page 789 Ch 6 ELECTRICAL SYSTEM page Map 11 El.system, Instrument panel SHOP MANUAL MT26-31 - 08.2006...
  • Page 790 Ch 6 ELECTRICAL SYSTEM page Map 12 Cab innside, lower panel 954C 205A SHOP MANUAL MT26-31 - 08.2006...
  • Page 791 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 792 Ch 6 ELECTRICAL SYSTEM page Circuits Circuit 01 Compartment and cab light SHOP MANUAL MT26-31 - 08.2006...
  • Page 793 Ch 6 ELECTRICAL SYSTEM page Circuit 02 Brake light SHOP MANUAL MT26-31 - 08.2006...
  • Page 794 Ch 6 ELECTRICAL SYSTEM page Circuit 03 Power supply / start SHOP MANUAL MT26-31 - 08.2006...
  • Page 795 Ch 6 ELECTRICAL SYSTEM page Circuit 04 Work light / Extra high beam SHOP MANUAL MT26-31 - 08.2006...
  • Page 796 Ch 6 ELECTRICAL SYSTEM page Circuit 05 Heated mirrors SHOP MANUAL MT26-31 - 08.2006...
  • Page 797 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 798 Ch 6 ELECTRICAL SYSTEM page Circuit 06 Fan and A/C SHOP MANUAL MT26-31 - 08.2006...
  • Page 799 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 800 Ch 6 ELECTRICAL SYSTEM page Circuit 09 Rewerse and work light rear SHOP MANUAL MT26-31 - 08.2006...
  • Page 801 Ch 6 ELECTRICAL SYSTEM page Circuit 10 Gauge and Instrument light SHOP MANUAL MT26-31 - 08.2006...
  • Page 802 Ch 6 ELECTRICAL SYSTEM page Circuit 10 Gauge and Instrument light. 810053- SHOP MANUAL MT26-31 - 08.2006...
  • Page 803 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 804 Ch 6 ELECTRICAL SYSTEM page Circuit 11 Lighter SHOP MANUAL MT26-31 - 08.2006...
  • Page 805 Ch 6 ELECTRICAL SYSTEM page Circuit 12 Rotating beacon SHOP MANUAL MT26-31 - 08.2006...
  • Page 806 Ch 6 ELECTRICAL SYSTEM page Circuit 13 Radio SHOP MANUAL MT26-31 - 08.2006...
  • Page 807 Ch 6 ELECTRICAL SYSTEM page Circuit 14 Wiper, washer and horn SHOP MANUAL MT26-31 - 08.2006...
  • Page 808 Ch 6 ELECTRICAL SYSTEM page Cirquit 15 Seat belt warning SHOP MANUAL MT26-31 - 08.2006...
  • Page 809 Ch 6 ELECTRICAL SYSTEM page Cirquit 16 Heated chair and chair compressor SHOP MANUAL MT26-31 - 08.2006...
  • Page 810 Ch 6 ELECTRICAL SYSTEM page Cirquit 18 Engine serial no: 810001 - 810035 SHOP MANUAL MT26-31 - 08.2006...
  • Page 811 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 812 Ch 6 ELECTRICAL SYSTEM page Cirquit 18 Engine serial no: 810036-810052 SHOP MANUAL MT26-31 - 08.2006...
  • Page 813 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 814 Ch 6 ELECTRICAL SYSTEM page Cirquit 18 Engine serial no: 810053- SHOP MANUAL MT26-31 - 08.2006...
  • Page 815 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 816 Ch 6 ELECTRICAL SYSTEM page Cirquit 19 Transmission serial no. 810001-810052 SHOP MANUAL MT26-31 - 08.2006...
  • Page 817 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 818 Ch 6 ELECTRICAL SYSTEM page Cirquit 19 Transmission serial no. 810053- SHOP MANUAL MT26-31 - 08.2006...
  • Page 819 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 820 Ch 6 ELECTRICAL SYSTEM page IVC4B Connector pinout EST 37 pinout 57 Retarder solenoid output, active low Pos Description 58 VPS1 (not used) Ground 59 SD2 (not used) Ground 60 SDDL (not used) Speed sensor ground supply 61 EU2 (not used) (turbine, engine, int.
  • Page 821 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 822 Ch 6 ELECTRICAL SYSTEM page Cirquit 20 Brake warning light 810001 - 810052 SHOP MANUAL MT26-31 - 08.2006...
  • Page 823 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 824 Ch 6 ELECTRICAL SYSTEM page Cirquit 20-1 Brake warning light - WDB 810053- SHOP MANUAL MT26-31 - 08.2006...
  • Page 825 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 826 Ch 6 ELECTRICAL SYSTEM page Cirquit 20-2 WDB Brake monitoring 810053- SHOP MANUAL MT26-31 - 08.2006...
  • Page 827 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 828 Ch 6 ELECTRICAL SYSTEM page Cirquit 21 Head light SHOP MANUAL MT26-31 - 08.2006...
  • Page 829 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 830 Ch 6 ELECTRICAL SYSTEM page Cirquit 22 Tilt magnet (servo valve) SHOP MANUAL MT26-31 - 08.2006...
  • Page 831 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 832 Ch 6 ELECTRICAL SYSTEM page Cirquit 24 Direction and hazard light SHOP MANUAL MT26-31 - 08.2006...
  • Page 833 Ch 6 ELECTRICAL SYSTEM page SHOP MANUAL MT26-31 - 08.2006...
  • Page 834 Ch 6 ELECTRICAL SYSTEM page Cirquit 25 Cooling fan SHOP MANUAL MT26-31 - 08.2006...
  • Page 835 Ch 6 ELECTRICAL SYSTEM page Cirquit 26 Emergency steering SHOP MANUAL MT26-31 - 08.2006...
  • Page 836 Ch 6 ELECTRICAL SYSTEM page Cirquit 27 Hydraulic oil filter SHOP MANUAL MT26-31 - 08.2006...
  • Page 837 Ch 6 ELECTRICAL SYSTEM page Cirquit 28 Central lubrication, Groeneveld SHOP MANUAL MT26-31 - 08.2006...
  • Page 838 Ch 6 ELECTRICAL SYSTEM page Cirquit 29 Central lubrication, Lincoln SHOP MANUAL MT26-31 - 08.2006...
  • Page 839 Ch 6 ELECTRICAL SYSTEM page Cirquit 30 Gear restriction SHOP MANUAL MT26-31 - 08.2006...
  • Page 840 FRONT WAGON CH 7 PAGE Chapter 7 Front Wagon Index 7.1 Introduction ......................2 7.2 Front Axle Suspension ..................3 7.2.1 Shock Absorber ........................4 7.2.2 Chain Limiter........................5 7.2.3 Rubber Cushion ........................6 7.2.4 Panhard Bar ........................7 7.2.5 Suspension Bearing......................8 7.2.6 Cross Tube Bushings ......................
  • Page 841 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.1 Introduction The Front Wagon is built up around the front frame, which is the base for the engine and the trans- mission. The frame is resting on the front suspension, and connected to the rear wagon in the articulation bearing.
  • Page 842 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.2 Front Axle Suspension The Front Axle Suspension consists of two independent suspension arms connected to each other via the cross tube. Rubber cushions are acting as springs, and take the weight resting on the suspension which also are equipped with dual sets of shock absorbers.
  • Page 843 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.2.1 Shock Absorber The Shock Absorbers reduce the motion in the wheel suspension when driving on rough road condition. Removal Thoroughly clean the front suspension. Remove actual wheel (Ref. 3.4.1) Front frame must be supported on safety stands, not the suspension. Use a floor jack under the cross tube to release the weight on the chain limiter, and compress the absorbers slightly.
  • Page 844 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.2.2 Chain Limiter The Chain Limiters stop the suspension arms from swinging to far when dumper is rised by crane or by jack, and also limits the suspension motion under extreme driving conditions. The limiter have an important function in the suspension, and the dumper should not be used without.
  • Page 845 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.2.3 Rubber Cushion The Rubber Cushions are acting as springs in the front wheel suspension. Cushions should be replaced in pairs. Removal Thoroughly clean the front suspension. Cushions are accessed by removing the actual wheel (Ref. 3.4.1) Front frame must be supported on safety stands, not the suspension.
  • Page 846 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.2.4 Panhard Bar The Panhard Bar restrict the sideways motion and stabilises in the front suspension. Removal Thoroughly clean the front suspension. Remove the two bolts securing the bar to the front frame. Save the shims.
  • Page 847 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.2.5 Suspension Bearing The Suspension Bearings are the pivot points for the front wheel suspension arms. Removal Thoroughly clean the front suspension. Remove actual wheel (Ref. 3.4.1) Front frame must be supported on safety stands, not the suspension. Remove shock absorber lower fastening bolts.
  • Page 848 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE Suspension Bearing Bearing Cover Chain Hoist Chain Hoist Fig 7.7 Suspension Bearing SHOP MANUAL MT26/31 - 12.2004 SHOP MANUAL MT26/31 - 12.2004...
  • Page 849 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.2.6 Cross Tube Bushings The Cross Tube connects the left and right front suspension arms. The suspension arms rotate relative to the cross tube on the cross tube bushings. Removal Thoroughly clean the front suspension.
  • Page 850 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.3 Articulation Hinge System The Articulation Hinge System consists of the Articulation Hinge, and the Articulation Bearing. The articulation hinge is the turning point of the steering motion, and the articulation bearing permits the front wagon and the rear wagon to roll relative to each other during driving.
  • Page 851 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.3.1 Articulation Bearing To measure the wear on the articulation bearing, place the truck on level ground, with front and rear frame in line. For axial measurement place a dial indicator on the articulation bearing as shown in figure 7.10. Open the bonnet and the lift the front wagon in the lifting points with 800 kp.
  • Page 852 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE Removal Thoroughly clean the articulation bearing and the area around for accumulated dirt. Disconnect the intermediate drive shaft in the articulation hinge. (Ref. 3.5.3) Support the drive shaft, as it rotates when rear wagon is moved.
  • Page 853 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE Installation Position articulation bearing on articulation hinge flange Tighten the 26 bolts. Move the rear wagon into position to enter the bolts fastening the bearing to the front frame. Tighten the 26 bolts. Connect the lubrication line.
  • Page 854 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.3.2 Articulation Hinge To measure the wear on the articulation hinge, place the truck on level ground, with front and rear frame in line. Place a hydraulic jack under center of lower articulation hinge bolt according to Fig 7.10 Lift with a force of 1800 kp, and read the dial indicator.
  • Page 855 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE Remove the four bearings and the two distance rings from the hinge. Check the condition of the seal rings for possible re-use. Installation Install new seal rings if necessary. Install the four bearings and the two distance rings in the hinge. Position the articulation hinge on rear frame, and install the hinge bolts.
  • Page 856 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.4 Fenders, Mudguards and Bonnet Fenders, Mudguards and Bonnet are together with the hydraulic tank, diesel fuel tank and cab, the bodywork of the dumper. Fenders and mudguards are exposed parts which are likely to be beaten up under heavy use, and should be replaced if damaged, as misalignment will reduce the protection for the internal parts, and reduce service life.
  • Page 857 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.4.1 Fender RH The right hand Fender contains an air supply tank, and the safety support for the cab, accessed by a hatch. The hatch is also the base for the right hand head lamp, as well as serving as working platform for engine mainte- nance.
  • Page 858 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.4.2 Fender LH The left hand Fender contains an air supply tank, the air dryer unit, the battery main switch and the batteries, accessed by a hatch. The hatch is also the base for the left hand head lamp, as well as serving as working platform for engine maintenance.
  • Page 859 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.4.3 Mudguard The Mudguards cover the front halves of the front wheels, and also act as a bridge from the fender working platform towards the diesel fuel tank on the right side, and to the cab door and hydraulic tank/central lubrication on the left side.
  • Page 860 The bonnet can also be locked with the key to keep unauthorized personnel from opening. For maintenance on the bonnet lock and release mechanism, the bonnet must be opened. If the bonnet can not be opened do to a malfunction in the mechanism, contact Moxy for information on how to proceed.
  • Page 861 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE Bonnet Lock Lock Bracket Adjusting Nuts Adjustable Bonnet Lock Receptacle Release Wire Release Mechanism Release Handle Fig 7.20 Bonnet Lock Assembly SHOP MANUAL MT26/31 - 12.2004 SHOP MANUAL MT26/31 - 12.2004...
  • Page 862 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.4.5 Bonnet Removal Thoroughly clean the bonnet and the area around for accumulated dirt. Open the bonnet, and secure with the catcher. (Ref. Operation and Maintenance Manual 2.19) Replace two nut with lifting eyes. (See Fig 7.21) Attach lifting device in the two lifting eyes, and use a crane to lift to take up the weight of the bonnet.
  • Page 863 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.5 Cab The cab is tilted to gain access for maintenance, but if the cab has to be removed from the dumper for some reason, proceed as follows. 7.5.1 Cab Removal Thoroughly clean the cab and the area around for accumulated dirt.
  • Page 864 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE Remove the locking rings and drive the hinge bolts inwards to free the cab from the front frame. Retrieve the bolts. Lift the cab off the dumper, and place on woodblocks, resting on the mounting brackets. WARNING!__________________________________________ Be aware of the risk of injury to people and equipment when handling heavy objects!
  • Page 865 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.5.2 Cab Ventilation Control Panel The Cab Ventilation Control Panel is located in the driver’s side console, in a far right position. Removal Make sure the battery main switch is turned off. The control panel is fastened in similar manner as a car radio, and can be removed inserting special tools to release the locks.
  • Page 866 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.5.3 Cab Ventilation Unit The Ventilation Unit provides temperature regulated air to all outlets in the cab ventilation system. Heat is provided from the engine cooling system, circulating through the heater unit, and cooling is provided from the air conditioning evaporizer.
  • Page 867 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE Remove the instructor back rest by unscrewing two bolts, and pushing approx. 5 cm down to free the attach- ment to the rear wall panel. Remove instructor seat, by unscrewing four bolts. Remove the access door for the electrical central by loosening the four fasteners.
  • Page 868 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.5.4 Cab Door The Cab Door is the only access to the cab, and should close properly to ensure driver safety and comfort. If door for some reason has to be removed, proceed as follows. Open door fully and pry rear bottom corner of door panel out to disengage some of the velcro securing panel, to get access to the four bolts fastening the door check arm to the door.
  • Page 869 CH 7 CH 7 FRONT WAGON FRONT WAGON PAGE PAGE 7.5.5 Door Damper Cylinder The Door Damper Cylinder keeps the door in open position when opened, and dampens the door movement. Removal Remove floor mat and rear kick panel. (Ref. 7.5.3) From outside, pull out the expansion lining from the sliding window channel, starting from the end at bottom center.
  • Page 870 FRONT WAGON FRONT WAGON CH 7 CH 7 PAGE PAGE 7.5.6 Steering Column The adjustable steering column comprises the steering wheel and the control handle for lights, turn signals, horn and windscreen wiper/washer. Removal Check that the steering is in neutral position, and ensure that the articulation lock is engaged. Make sure the battery main switch is turned off.
  • Page 871 CH 7 FRONT WAGON PAGE SHOP MANUAL MT26/31 - 12.2004...
  • Page 872 REAR WAGON CH 8 PAGE Chapter 8 Rear Wagon Index 8.1 Introduction ......................2 8.2 Dumper Body......................3 8.2.1 Dumper Body ........................3 8.2.2 Tilt Bearing .......................... 4 SHOP MANUAL MT26/31 - 12.2004...
  • Page 873 CH 8 CH 8 REAR WAGON REAR WAGON PAGE PAGE 8.1 Introduction The Rear Wagon main part is the rear frame which is the base for the dumper body, and the support for the rear axles. The rear wagon is connected to the front wagon in the articulation bearing. The tiltable dumper body is attached to the rear frame in the tilt bearing.
  • Page 874 REAR WAGON REAR WAGON CH 8 CH 8 PAGE PAGE 8.2 Dumper Body 8.2.1 Dumper Body Thoroughly clean the dumper body and tilt bearings for accumulated dirt. To remove Dumber Body, remove the hydraulic tilt cylinders (Ref.5.12) Hook the crane to the dumper body front lifting point, and lift the body to release the safety stand, and lower the body until resting on the rear frame.
  • Page 875 CH 8 REAR WAGON PAGE 8.2.2 Tilt Bearing If tilt bearings only are going to be replaced it is not necessary to disconnect the tilt cylinders, tail gate operating chains, and remove the body. Remove the six bolts securing each tilt bearing bolt to the dumper body.. Disconnect lubrication lines if equipped.
  • Page 876 OPTIONAL EQUIPMENT CH 9 PAGE Chapter 9 Optional Equipment Index 9 Optional Equipment ....................2 9.1 Automatic Tail Gate ....................2 9.2 Automatic Central Lubrication................5 9.2.1 Lubrication Unit ........................6 9.2.2 Lubrication Lines......................... 7 9.2.3 Metering Block ........................7 9.3 Cab Hydraulic Tilting Unit ...................
  • Page 877 OPTIONAL EQUIPMENT OPTIONAL EQUIPMENT 9 Optional Equipment The MOXY trucks are usually equipped with a number of options. For maintenance purposes the more complex of these options will be described in this chapter. 9.1 Automatic Tail Gate The optional automatic tail gate is closed when dumper body is down in transport position, and opens as the body is tilted.
  • Page 878 OPTIONAL EQUIPMENT OPTIONAL EQUIPMENT CH 9 CH 9 PAGE PAGE Unhook the chain links in front of each arm by opening the top shackle. To remove tailgate, both arms have to be removed first. Attach a crane to the actual arm, and loosen the six bolts attaching the arm to the tail gate. Remove the lubrication line if equipped.
  • Page 879 CH 9 PAGE 4 CH 9 PAGE 4 OPTIONAL EQUIPMENT OPTIONAL EQUIPMENT Lift the tail gate and place on dumper body. Secure tail gate temporary with large clamps. Lift each arm in position and secure arm bearing. to the bracket by tightening four bolts. Attach the lubrication line if equipped.
  • Page 880 OPTIONAL EQUIPMENT OPTIONAL EQUIPMENT CH 9 CH 9 PAGE PAGE 9.2 Automatic Central Lubrication The Central Lubrication System takes care of some of the daily maintenance, and greases a number of loca- tions automatically as the dumper is running. Left Front Right Front Suspension Suspension...
  • Page 881 CH 9 PAGE 6 CH 9 PAGE 6 OPTIONAL EQUIPMENT OPTIONAL EQUIPMENT 9.2.1 Lubrication Unit The lubrication unit is located in the compartment on the left hand mud guard, just behind the cab door. The unit is programmed to pump grease into the lubrication circuit at predetermined intervals, and in predeter- mined quantities.
  • Page 882 OPTIONAL EQUIPMENT OPTIONAL EQUIPMENT CH 9 CH 9 PAGE PAGE 9.2.2 Lubrication Lines The lubrication lines distribute the media from the lubrication unit to the doser blocks and from the dosers to each lubrication point. Removal Thoroughly clean the actual line and the area around for any accumulated dirt. Disconnect the electrical connection to the lubrication unit to make sure no one activates the system.
  • Page 883 CH 9 PAGE 8 OPTIONAL EQUIPMENT 9.3 Cab Hydraulic Tilting Unit The hydraulic tilting unit makes tilting of cab safe and easy, by means of a manual hydraulic pump and cylin- der. Removal Thoroughly clean the cab tilting unit and the area around for accumulated dirt. Tilt the cab and place on safety stand.
  • Page 884 User Manual Operation Instructions 2.1A-30008-A04 ® Quicklub VDC-Pumps 223 (without) and 233 (with Data Logger) Microprocessor, Control Unit and Membrane Keypad 4354a01 810-55400-1 LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259...
  • Page 885 User Manual Operation Instructions 2.1A-30008-A04 Fields of Application for Quicklub Progressive Central Lubrication Pumps Industry - Machines Pump Type Pump: Quicklub 223, 233 Reservoir: 2 l - 2XL , 2XLBO 4 l - 4XLBO 8 l - 8XLBO Filling from the bottom 4l, 8l –...
  • Page 886 User Manual Operation Instructions 2.1A-30008-A04 Table of Contents Page Page Fields of Application ............2 Reading of the data memory “QuickData” (only P233) ..21 Low-level control for grease ..........21 Introduction ..............4 When the reservoir is filled .......... 21 When the reservoir is empty ........

  • Page 887: Introduction

    User Manual Operation Instructions 2.1A-30008-A04 Introduction Explanation of Symbols Used The following description standards are used in this manual: Furthermore, you will find the following text symbols in this manual: Safety Instructions Listing of applicable statements Structure of safety instructions: - Subpoint of applicable statements Pictogram 1.

  • Page 888: Safety Instructions

    User Manual Operation Instructions 2.1A-30008-A04 Safety Instructions Appropriate Use General Safety Instructions Use the 223 and 233 pumps only for dispensing lubricants Lincoln Quicklub centralized lubrication systems in centralized lubrication systems. The pump is designed - are designed state-of-the-art. for intermittent operation. - can be assembled for safe operation.

  • Page 889: Pump Models

    User Manual Operation Instructions 2.1A-30008-A04 Safety Instructions, continuation Operation, Maintenance and Repair, continuation Lincoln Quicklub centralized lubrication systems ATTENTION! - must be operated only with installed pressure relief val- Risk of bursting if the reservoir is overfilled! When filling the reservoir by means of - must be refilled in regular intervals with clean lubricant pumps with a large delivery volume do not exceed the max.
  • Page 890 User Manual Operation Instructions 2.1A-30008-A04 Identification Code – DC Pump Models P223 Examples of model designations NOTE P223 - 4 - X - L - 1 - K6 - 24 - 2A - 6. - 15 - MF00 Any pump combinations other than the follow- P223 - 2 - X - L - BO 1 - K7 - 24 - 2A - 6.

  • Page 891: Identification Code Vdc

    User Manual Operation Instructions 2.1A-30008-A04 Identification Code – DC Pump Models P233 Examples of model designations NOTE P233 - 4 - X - L - 1 - K6 - 24 - 2A - 6. - 15 - MDF00 Any pump combinations other than the follow- P233 - 2 - X - L - BO 1 - K7 - 24 - 2A - 6.

  • Page 892: P223

    User Manual Operation Instructions 2.1A-30008-A04 Description Quicklub centralized lubrication pumps Are compact multi-line pumps consisting of the following components: - Housing with integrated motor - Reservoir with stirring paddle and fixed paddle - P223: Control printed circuit board (p.c.b.) P233: Data logger (control p.c.b.

  • Page 893: P233 With Datalogger

    User Manual Operation Instructions 2.1A-30008-A04 Description, continuation P233 with data logger Control p.c.b. MDF00 The control unit is installed in the housing of the pump behind the membrane keypad (see pos. 11, fig. 2, page 9) as an integrated p.c.b. MDF00. The data logger (fig.

  • Page 894: Operating States

    User Manual Operation Instructions 2.1A-30008-A04 Description, continuation Control Unit, continuation Pump Display Operating states Failure in the power supply no indication Functions, processes, settings, faults or malfunctions of the Power supply ON right segment pump are indicated on a membrane keypad as shown on the illuminated survey: Failure in the membrane key pad...

  • Page 895: Pump Element B7 With Bypass Check Valve

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Pump elements with fixed lubrication output, continuation 1003a95 Fig. 7 The pump element sucks in lubricant 1004a95 Fig. 8 The pump element dispenses lubricant Eccentric Piston Spring Check valve Pump element B7 with bypass check valve 6251b04 6250b04 Fig.

  • Page 896: Check Valve

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Pump elements with fixed lubrication output, continuation Check valve Arrangement of the pump elements 1164b95 Fig. 11 Hydraulic diagram of the pump Reservoir with stirring paddle Pump Check valve, spring-loaded Pressure relief valve Return line Pressure line 1163a95...

  • Page 897: Setting Of Adjustable Pump Elements

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Pump elements with adjustable lubricant output, continuation 4159a98 Fig. 14 Sectional view: adjustable element adjusting spindle SW 16 pump element body control piston (SW ~ with over flats) gasket delivery piston counternut SW 24 pump cylinder setting dimension...

  • Page 898: Retrofit Adjustment Of Max. Lubricant Output

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Setting of adjustable pump elements, continuation Retrofit adjustment of max. lubricant output Unscrew the adjusting spindle (pos.1 ) from the pump NOTE element body (pos.3) until “S” is approx. 30 mm. In order to ensure that the lubricant out- Screw counter nut (Pos.2) onto stop collar of the adjusting put setting will be as exact as possible,...

  • Page 899: Return Line Connection

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Pressure relief valve with grease return (optional), continuation Fault indication In the case of a blockage in the system, the grease pushes out the red pin at the pressure relief valve, thus indicating that there is a fault.

  • Page 900: Pause Time

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Control p.c.b. with or without data memory, continuation The pause time Pause time - determines the frequency of the lubrication cycles within a working cycle. - is started and stopped with the power supply via the machine contact or the driving switch.

  • Page 901: Membrane Keypad

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Membrane keypad 4360a04 4360a01 Fig. 23 P223 membrane keypad Fig. 24 P233 membrane keypad with display and reading window Display Key for acknowledgment of fault Reading window for Key for triggering an addi- indications and setting of time (shift ”QuickData“...

  • Page 902: Operator Keys Of The Membrane Keypad

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Display of the membrane keypad, continuation If there is no feedback from the piston detector (initiator) Monitoring time / Malfunction within 30 minutes (monitoring time) from completion of the pause time or from triggering an additional lubrication, the jump switches off immediately.

  • Page 903: Reset Of The Pause Time

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Operator keys of the membrane keypad Reset of the pause time Operator keys of the keypad in the programming mode Setting of the pause time by - single key activation for one hour/ minute - permanent activation for quick run Settings of the monitoring relay 4222a99...

  • Page 904: Reading Of The Data Memory "Quickdata" (Only P233)

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Reading of the data memory “QuickData“ (only P 233) Read data memory via a suitable laptop with integrated or, if not available, external infrared interface (see User Manual “Diagnostic Software QuickData“. To be able to read from the reading window, place the infrared interface of the laptop at a maximum distance of 1 m horizontally in front of it, and then read the data.

  • Page 905: When The Reservoir Is Empty

    User Manual Operation Instructions 2.1A-30008-A04 Mode of Operation, continuation Low-level control for grease, continuation During the rotating motion of the stirring paddle there is no When the reservoir is empty backpressure from the lubricant. The guiding plate with NOTE the round solenoid no longer moves towards the center of rotation of the stirring paddle.

  • Page 906: Setting An Operation

    User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation Factory Settings Programming steps Factory Setting Description Page 6 hours Pause time 4215a99 0.30 0 minutes Pause time 4217a99 Lubrication cycles: 1 cycle (metering device cycle) 4218a99 Signal output of the fault relay: NO (normally open) Signalizing during the failure or low-level indi...

  • Page 907: Display Mode

    User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation, continuation Three possible modes of operation and settings can be se- Display mode lected on the keypad. Programming mode (page 26 ff) Operating mode (page 29 ff) Display Mode In the display mode the user receives information on functions and malfunctions.
  • Page 908 User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation, continuation Display Mode, continuation Display Press A test display is made when the voltage is applied; all segments and decimal points are illuminated for 2 sec- onds. 2 sec. 4207a99 NOTE If *EP* is displayed after the display test, this indicates that the button or the key- pad is defective.

  • Page 909: Programming Mode

    User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation, continuation Programming Mode Setting Pause Time P1 and P2 Display press To access to the programming mode, press both but- 4215a99 tons at the same time > 4 seconds, so that “P1” appears 4222a99 4214a99 in the display.
  • Page 910 User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation, continuation Programming Mode, continuation P3: Setting number of cycles If lube points are divided via sub-divider valves (SSV 6) and IMPORTANT a main divider valve (SSV 6, SSV 8), never exceed a maxi- Settings are only possible in connection mum of 18 (24) lube points.
  • Page 911 User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation, continuation Programming Mode, continuation Completing the programming Press button. „ P -“ is displayed. IMPORTANT In order to avoid a wrong program, make sure to always carry out the programming 4214a99 order completely, i.e. setting of P1 4221a99 (hours), P2 (minutes), P3 (number of 6001a02...

  • Page 912: Operating Mode

    User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation, continuation Operating Mode Display Press IMPORTANT The operating mode is accessible only during the pause time, and cannot be operated during the running time (pump operating 6001a02 time). Precondition: When the voltage supply is applied, the segment (On) is lit.
  • Page 913 User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation, continuation Operating Mode, continuation (hours) after two sec. 4225a99 . 10 (minutes) after two sec. 4226a99 number of the automatically triggered lube cycles, after two sec. countable up to 9999 cycles. Then counting starts from the beginning again. Example 0625 cycles: 4277a00 Display for thousands and hundreds...
  • Page 914 User Manual Operation Instructions 2.1A-30008-A04 Setting and Operation, continuation Operating Mode, continuation P3: Number of metering device cycles after two sec. 4218a99 Display of the metering device cycles after two sec. 4219a99 P4: Programming of the output signal after two sec. 6252b04 Display of the output signal “normally closed“...

  • Page 915: Maintenance, Repair And Tests

    User Manual Operation Instructions 2.1A-30008-A04 Maintenance, Repair and Tests Maintenance The maintenance is essentially limited to refilling the res- NOTE ervoir with clean lubricant in good time. However, check Whenever work is done on the central- regularly whether the lubricant is really dispensed to all ized lubrication system, particular atten- the lubrication points.

  • Page 916: Repair

    User Manual Operation Instructions 2.1A-30008-A04 Maintenance, Repair and Tests, continuation Repair Use only original Lincoln spare parts for repair on the Pump pumps. The pump should be returned to the factory for warranty work or major repairs. Replace pump element Remove the pressure relief valve from the pump element.

  • Page 917: Tests

    User Manual Operation Instructions 2.1A-30008-A04 Maintenance, Repair and Tests, continuation Tests To check the pump operation it is possible to perform an Operational Test / Triggering an Additional Lubrication additional test (see paragraph ”Additional lubrication cy- Cycle cle“, page 19). Check the Pressure Relief Valve 1st option Connect the pressure gauge (0-600 bar;...

  • Page 918: Troubleshooting

    User Manual Operation Instructions 2.1A-30008-A04 Troubleshooting NOTE The pump operation can be checked from the outside by observing whether the stir- ring paddle is rotating (e.g. by triggering an additional lubrication). 6001a02 Additionally, during the operating time of the 4209a99 pump a circulating illuminated segment Fig.
  • Page 919 User Manual Operation Instructions 2.1A-30008-A04 Troubleshooting, continuation Fault: The pump does not deliver lubricant Cause: Remedy: Reservoir empty. * LL * display on the membrane keypad Fill up the reservoir with clean grease. Let the pump run is flashing. (trigger additional lubrication cycle, see fig. 30, page19) until lubricant shows at all lube points.

  • Page 920: Technical Data

    User Manual Operation Instructions 2.1A-30008-A04 Technical Data PUMP TORSION TORQUES Admissible operating temperature ....-40° C to 70° C Install pump ..............18 Nm Number of outlets ............1,2 or 3 Electric motor on housing ..........12 Nm Reservoir capacity ..........2 l, 4 l, 8 l Pump element in housing ..........

  • Page 921: Electrical Data

    User Manual Operation Instructions 2.1A-30008-A04 Technical Data, continuation Electrical Data Motor PUMP DC gear motor (interference-suppressed) Input - Operating voltage ............. 24VDC Rated voltage ........12 VDC, -20% / +30% - Max. current input 24V ........... 3 A Max. operating current ........... 2.0 A - Speed ............

  • Page 922: Electrical Connection Vdc

    User Manual Operation Instructions 2.1A-30008-A04 Technical Data, continuation Electrical connection VDC Observe the safety instructions (page 6) and the techni- NOTE cal data (pages 37 and 38)! For connection of the low-level control Make sure of the connection and the type of construction observe the respective connection dia- of your P223, 233.

  • Page 923: Dimensions

    User Manual Operation Instructions 2.1A-30008-A04 Technical Data, continuation Dimensions - 2 l reservoir 1166b01 Fig. 50 Dimensions - 2 l reservoir Page 40 of 48 LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259...
  • Page 924 User Manual Operation Instructions 2.1A-30008-A04 Technical Data, continuation Dimensions - 2 l reservoir with filling from the top 1167b01 Fig. 51 Dimensions - 2 l reservoir with filling from the top Page 41 of 48 LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259...
  • Page 925 User Manual Operation Instructions 2.1A-30008-A04 Technical Data, continuation Dimensions - 2 l flat-type reservoir 1168b01 Fig. 52 Dimensions - 2 l flat-type reservoir Page 42 of 48 LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259...
  • Page 926 User Manual Operation Instructions 2.1A-30008-A04 Technical Data, continuation Dimensions - 4 l reservoir 1169b04 Fig. 53 Dimensions - 4 l reservoir Page 43 of 48 LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259...
  • Page 927 User Manual Operation Instructions 2.1A-30008-A04 Technical Data, continuation Dimensions - 8 l reservoir 1170b04 Fig. 54 Dimensions - 8 l reservoir Page 44 of 48 LINCOLN GmbH & Co. KG • Postfach 1263 • D-69183 Walldorf • Tel +49 (6227) 33-0 • Fax +49 (6227) 33-259...

  • Page 928: Attaching Boreholes Of The 2L, 4L, And 8L Pump

    User Manual Operation Instructions 2.1A-30008-A04 Technical Data, continuation Attaching boreholes of the 2 l, 4 l and 8 l pump 1171b03 Fig. 55 Attaching boreholes of the 2 l, 4 l and 8 l pump NOTE Tighten pump models with 2 l-flat-type, 4 l and 8 l reservoir with three fastening screws (see point R 9,5).

  • Page 929: Quicklub List Of Lubricants

    User Manual Operation Instructions 2.1A-30008-A04 Lubricants, continuation Quicklub List of Lubricants IMPORTANT Use lubricants with solid matter additives only after having consulted the manufacturer of the sys- tem! 6001a02 Proven lubricants: Manufacturer Designation Base soap Min. delivery temperature AUTOL Top 2000 Ca-complex -10 °C AUTOL...

  • Page 930: Biodegradable Lubricants

    User Manual Operation Instructions 2.1A-30008-A04 Lubricants, continuation Quicklub List of Lubricants, continuation IMPORTANT Use lubricants with solid matter additives only after having consulted the manufacturer of the sys- tem! 6001a02 Biodegradable lubricants Proven lubricants: Manufacturer Designation Base soap min. delivery temperature ARAL Aralub BAB EP 2 Li/Ca...

  • Page 931: Declaration By The Manufacturer

    Manual para el usuario Instrucciones de funcionamiento 2.1E-30008-A04 Declaration by the Manufacturer Herstellererklärung Declaration by the Déclaration du fabricant Dichiarazione del im Sinne der EG-Richtlinie manufacturer as defined by conformément à la directive costruttore ai sensi della Maschinen 98/37/EG, machinery directive 98/37/EEC 98/37/CEE, annexe II B direttiva 98/37/CEE in Anhang II B...

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