Moxy MT 31 Manuals

Manuals and User Guides for Moxy MT 31. We have 2 Moxy MT 31 manuals available for free PDF download: Shop Manual, Manual

Moxy MT 31 Shop Manual (931 pages)

Brand: Moxy | Category: Trucks | Size: 46.95 MB

Chapter 0 General Index

3
Chapter 1 Index

26
- Removal of Engine Assembly
  29
- Engine Identification
  36
- Fuel System
  37
  - Schematic Diagram of the Fuel System
    37
  - Overflow Valve
    37
  - Fuel
    38
  - Fuel Filter
    39
  - Water Separating Prefilter
    39
  - Feed Pump
    41
- Diagnostic Prosedure
  42
  - Use of Diagnostic Kit, Machine
    42
  - Measurement
    44
  - Ecom Standard Settings Code
    48
- Engine Control Unit, ECU
  51
  - Wiring and Cable Duct
    52
  - Throttle Position Sensor
    52
  - Diagnostic Lamp and Switch
    55
  - Fault Codes
    56
  - How to Read Fault Codes from the ECU Control Unit
    57
  - Flash Codes Tables
    59
  - Overview of Flash Codes for Coordinator
    61
  - Renewing the Control Unit
    63
  - Removing the ECU Wiring
    64
- Cylinder Head
  68
  - Special Tools
    68
  - Cylinder Head, Parts View
    69
  - Valve Mechanism
    70
  - Dismantling
    75
  - Renewing the Valve Stem Seal
    75
  - Replacement of Valve Seats
    76
  - Machining the Valve Seats Insert
    77
  - Renewing the Valve Guides
    79
  - Renewing PDE Unit Injector Sleeves
    80
  - Assembly
    81
  - Fitting
    81
- PDE Injectors
  82
- Turbocharger
  91
- Pistons and Cylinder Liners
  97
  - Special Tools
    98
  - Connecting Rods
    99
  - Removing and Dismantling Connecting Rods and Pistons
    100
  - Renewal of Bearing Bushing in Connecting Rod
    102
  - Pistons
    104
  - Assembling Piston and Connecting Rod
    106
- Cylinderblock
  107
  - Cylinder Liner
    107
  - Removing the Cylinder Liners
    109
  - Measuring the Cylinder Liner Height
    110
  - Fitting the Cylinder Liners
    111
  - Fitting the Piston and Connecting Rod
    112
- Flywheel and Flywheel Housing
  114
  - Special Tools
    115
  - Removing the Flywheel
    115
  - Renewing the Rear Crankshaft Seal
    117
  - Removing the Flywheel Housing
    117
  - Fitting Flywheel Housing
    118
  - Fitting the Flywheel
    120
- Timing Gears
  121
  - Gear Drive
    121
  - Belt Drive Collant Pump, Generator and AC Compressor
    122
  - Renewing the Seal in the Front Cover
    123
  - Crankshaft Damper
    124
  - Timing Gear, View Exploded
    125
- Special Tools
  126
  - Crankshaft Seal
    127
  - Timing Gear Cover
    128
  - Intermediate Gear
    131
  - Crankshaft Gear
    132
  - Camshaft Gear
    133
- Camshaft
  134
- Crankshaft
  136
- Lubrication System
  138
  - Oil Pump
    138
  - Lubrication Oilways
    139
  - Oil Pressure
    140
  - Oil Cooler, Engine
    141
  - Oil Cooler View
    142
  - Renewing Seals
    143
  - Oil Filter
    144
- Centrifugal Oil Cleaner
  145
  - Dismantling and Assembly
    146
- Cooling Fan
  150
- Cooling System
  151
  - View of the Cooling System
    151
  - Circulation
    152
  - View of the Radiator System
    152
  - Disassemble the Cooling Unit
    153
  - Thermostat and Thermostat Housing
    155
  - Thermostat
    156
  - Coolant Pump
    157
  - External Cleaning
    161
  - Internal Cleaning
    161
- Specifications
  162
  - Cylinder Head
    164
  - Turbocharger
    166
  - Pistons and Cylinder Liners
    166
  - Connecting Rods
    167
  - Flywheel and Flywheel Housing
    167
  - Timing Gear
    168
  - Lubrication System
    169
- Troubleshooting Tables
  170
  - White Smoke
    170
  - White Smoke, Water Vapour
    170
  - Black Smoke When Running/Under Load
    171
  - Black Smoke on Starting
    172
  - Blue Smoke
    172
  - Fuel in the Oil
    172
  - Oil in Coolant
    173
  - Coolant/Water in Oil
    174
  - Low Oil Pressure
    175
  - High Oil Pressure (Engine Warmed Up)
    177
  - Abnormal Wear (Liner, Piston Rings, Etc.)
    177
  - Vibration, no Driven Components Engaged
    178
  - Delivery Pipe Fractures
    179
  - External Corrosion on Cylinder Liner
    179
  - Engine Difficult to Start
    179
  - Fluid Stroke
    180
  - Knocking Noise
    180
  - High Oil Consumption
    182
  - High Fuel Consumption
    183
  - Low Compression
    183
  - Low Engine Output
    183
  - Hot Engine
    185
  - Cold Engine
    186
  - Coolant Loss
    186
  - Polluted Coolant
    186
  - Engine Heater
    187
  - High Oil Temperature
    187
  - High Exhaust Temperature
    188
  - Low Charge Air Pressure
    188
  - Low Fuel Pressure
    189
  - Low System Voltage
    189
  - High System Voltage
    189
  - External Oil Leakage
    190
  - External Fuel Leakage
    190
  - External Coolant Leakage
    191
  - Oil Pressed out Via Crankcase Ventilation
    191
  - Turbocharger Breakdown
    191
Chapter 2 2 Transmission Index

199
- Structure of the Repair Manual
  204
- Conversion Table
  205
- Denomination of Standard Dimensions
  205
- Torque Limits for Screws
  206
  - Table
    206
- Technical Data
  207
  - Description
    207
- Transmission Cross Section
  208
  - Oil Temperatures
    209
- Oil Grade
  210
  - Oil Level Check
    210
  - List of Lubricants
    211
  - Oil Change and Filter Replacement Interval
    214
  - Oil Level Check
    215
  - Oil Change and Oil Filling Capacity
    216
  - Filter Replacement
    216
  - Fine Filter
    217
  - Axle Insert „LK
    218
  - Oil Specification
    218
  - Oil Change
    218
- Controller
  220
  - Clutch Chart
    221
  - Circuit Diagram Controller
    222
  - Coding Controller
    222
  - Display
    223
- Operation
  226
- Testing System, ZF
  230
  - Safety Notice
    231
  - Diagnostic - Set
    232
  - Installation of Diagnostic Software --> Testman
    233
  - Start of Testman
    235
  - Produkt Menue Ergopower
    238
- AEB Starter
  239
  - AEB Calibration
    239
  - Automatic Calibration of the Shifting Elements
    239
  - Procedure to Start AEB
    240
  - AEB Code List
    243
  - Laptop - Start of AEB Via Testman
    244
- Installation View
  245
  - Inductive Transmitter
    248
  - Transmission Diagram
    249
- Oil Circuit Diagram
  250
  - Valve Block Controll Circuit
    250
- Measuring Points and Connections
  251
- Troubleshooting
  252
  - Prerequisites for the Troubleshooting
    252
  - Lay out 6WG-260
    253
  - Introduction
    254
  - ZF - Display
    254
  - Display During Operation
    255
  - Display During AEB-Mode
    256
  - Definition of Operating Modes
    257
  - Table of Fault Codes
    258
  - Measuring of Resistance at Actuator/Sensors and Cable
    286
- Electronic Control Unit EST-37A
  289
  - Important Parts Information
    289
  - Pin in Contact for the TCU
    290
  - Family Package of the EST-37A
    292
- Electro-Hydraulic Shift Control Unit
  293
  - Transmission Control
    293
  - Electro-Hydraulic Control Unit HSG-94
    294
  - Electro Hydr. Shift Control Valve, Cross Section
    295
  - Disassembly
    298
  - Assembly
    301
- WK-Valve
  309
  - WK Solenoid Shift Valve
    309
  - Disassembly
    310
- Retarder
  312
  - Function of a Retarder
    312
  - Retarder Reconditioning Tool
    313
  - Disassembly the Retarder
    314
  - Assembly
    319
  - Retarder Valve
    329
- Converter
  333
  - Function of the Converter
    333
  - Converter (WK)
    334
- Removal of Transmission, Ass'y
  336
  - Disassemble the Exhaust Parts
    338
  - Disassemble of the Hydraulic Hoses at the Transmission
    339
- Manual Transmission
  344
  - Disassembly
    344
  - Axle Disconnection
    352
- Interaxle Differential
  358
- Clutches, Powershift Transmission
  365
  - Multi-Disk Clutch
    366
  - Clutch Chart
    367
  - Plate Clearanse in the Single Multi-Disc Clutches
    368
  - Oil Circuit Diagram
    369
  - Disassemble Multi-Disc Clutches
    370
  - Dismantle Multi-Disc Clutch KR/K2
    377
  - Manual Transmission Assembly
    386
  - Multi-Disc Clutch-K3
    394
  - Multi-Disc Clutch-KR
    401
  - Multi-Disc Clutch-K2
    406
  - Clutch-KV
    414
  - Multi-Disc Clutch-K1
    419
  - Interaxle Differential Assembly
    428
  - Adjust Bearing Pre-Load of the Clutches
    439
  - Install Emergency Steering Pump
    446
  - Transmission Control. the Pump
    448
  - Hydraulic Pump
    450
  - Input Converter Bell
    464
- Inductive Transmitters and Speed Sensor
  472
  - Assembly and Settings
    472
  - Differential Carrier „LK
    478
  - Tools
    478
  - Disasembly
    479
  - Assembly
    486
  - Differential DL-2400, Interlock Value 45
    492
  - Mount Differential Carrier on the Transmission
    503
Table of Contents

886
- Environmental Protection
  887
- Explanation of Symbols Used
  887
- Introduction
  887
- Service
  887
- User's Responsibility
  887
- Appropriate Use
  888
- General Safety Instructions
  888
- Installation
  888
- Misuse
  888
  - Exclusion of Liability
    888
  - Disposal
    888
- Operation, Maintenance and Repair
  888
- Regulations of Prevention of Accidents
  888
- Safety Instructions
  888
- Pump Models
  889
- Identification Code VDC
  891
- Description
  892
- P223
  892
- P223 Without Datalogger
  892
  - Control P.C.b. MF00
    892
- P233
  892
- Quicklub Centralized Lubrication Pumps
  892
- Control Unit
  893
  - Datamemory
    893
  - Operating States
    894
- P233 with Datalogger
  893
  - Control P.C.b. MDF00
    893
  - Datalogger Module
    893
- Mode of Operation
  894
- Pump Elements with Fixed Lubrication Output
  894
  - Pump Element B7 with Bypass Check Valve
    895
  - Check Valve
    896
  - Arrangement of the Pump Elements
    896
- Pump Elements with Adjustable Output
  896
- Pressure Relief Valve
  898
  - Without Grease Return
    898
  - With Grease Return (Optional)
    898
- Control P.C.b. with or Without Data Memory
  899
  - Pause Time
    900
  - Operating Time
    900
  - Monitoring Time
    900
- Return Line Connection
  899
- Display of the Membrane Keypad
  901
- Membrane Keypad
  901
- Operator Keys of the Membrane Keypad
  902
- Monitoring Relay
  903
- Low-Level Control for Grease
  904
  - When the Reservoir Is Filled
    904
  - When the Reservoir Is Empty
    905
  - Magnetic Switch
    905
- Reading of the Data Memory "Quickdata" (Only P233)
  904
- Contact Protection Measures
  905
- External Triggering of an Additional Lubrication Cycle
  906
- Factory Settings
  906
- Operator Keys
  906
- Setting an Operation
  906
- Display Mode
  907
- Programming Mode
  909
- Operating Mode
  912
- Maintenance
  915
  - Pump Filling
    915
- Maintenance, Repair and Tests
  915
- Repair
  916
  - Pump
    916
  - Replace Pump Element
    916
  - Control P.C.b
    916
- Tests
  917
  - Operational Test
    917
  - Triggering an Additional Lubrication Cycle
    917
  - Check the Pressure Relief Valve
    917
- Troubleshooting
  918
- Pressure Relief Valve
  920
- Pump
  920
- Technical Data
  920
- Torsion Torques
  920
- Weight
  920
- Electrical Data
  921
  - Input
    921
  - Output
    921
  - Emc
    921
  - Motor
    921
  - Time Setting
    921
  - Operation with Bayonet Plug
    921
- Electrical Connection VDC
  922
- Dimensions
  923
- Attaching Boreholes of the 2L, 4L, and 8L Pump
  928
- Lubricants
  928
- Quicklub List of Lubricants
  929
- Declaration by the Manufacturer
  931

Moxy MT 31 Manual (170 pages)

Brand: Moxy | Category: Trucks | Size: 8.81 MB

Table of Contents
2
Removal of Engine Assembly
5
Lifting the Engine
11
Engine Identification
12
Fuel System
13
Schematic Diagram of the Fuel System
13
Overflow Valve
13
General
14
Fuel
14
Fuel Filter
15
Water Separating Prefilter
15
Feed Pump
17
Diagnostic Prosedure
18
Use of Diagnostic Kit, Machine
18
Measurement
20
Ecom Standard Settings Code
24
Engine Control Unit, ECU
27
Wiring and Cable Duct
28
Throttle Position Sensor
28
Diagnostic Lamp and Switch
31
Fault Codes
32
How to Read Fault Codes from the ECU Control Unit
33
Flash Codes Tables
35
Overview of Flash Codes for Coordinator
37
Renewing the Control Unit
39
Removing the ECU Wiring
40
Cylinder Head
44
Special Tools
44
Cylinder Head, Parts View
45
Valve Mechanism
46
Dismantling
51
Renewing the Valve Stem Seal
51
Replacement of Valve Seats
52
Machining the Valve Seats Insert
53
Renewing the Valve Guides
55
Renewing PDE Unit Injector Sleeves
56
Assembly
57
Fitting
57
PDE Injectors
58
Fitting the PDE Injector
58
Adjusting Unit Injectors
62
Adjusting the Valve Clearance and Unit Injectors
64
Checking, Adjusting the PDE3 Injector Rocker Arms (I)
65
Turbocharger
67
General
68
Special Tools
69
Measuring Radial Clearance and Axial Clearance
70
Renewing the Turbocharger
72
Pistons and Cylinder Liners
73
Special Tools
74
Connecting Rods
75
Removing and Dismantling Connecting Rods and Pistons
76
Renewal of Bearing Bushing in Connecting Rod
78
Pistons
80
Assembling Piston and Connecting Rod
82
Cylinderblock
83
Cylinder Liner
83
Removing the Cylinder Liners
85
Measuring the Cylinder Liner Height
86
Fitting the Cylinder Liners
87
Fitting the Piston and Connecting Rod
88
Flywheel and Flywheel Housing
90
Special Tools
91
Removing the Flywheel
91
Renewing the Rear Crankshaft Seal
93
Removing the Flywheel Housing
93
Fitting Flywheel Housing
94
Fitting the Flywheel
96
Timing Gears
97
Gear Drive
97
Belt Drive Collant Pump, Generator and AC Compressor
98
Renewing the Seal in the Front Cover
99
Crankshaft Damper
100
Timing Gear, View Exploded
101
Special Tools
102
Crankshaft Seal
103
Timing Gear Cover
105
Intermediate Gear
107
Crankshaft Gear
108
Camshaft Gear
109
Camshaft
110
Crankshaft
112
Lubrication System
114
Oil Pump
114
Lubrication Oilways
115
Oil Pressure
116
Oil Cooler, Engine
117
Oil Cooler View
118
Renewing Seals
119
Oil Filter
120
Centrifugal Oil Cleaner
121
Dismantling and Assembly
122
Cooling Fan
126
Cooling System
127
View of the Cooling System
127
Circulation
128
View of the Radiator System
128
Disassemble the Cooling Unit
129
Thermostat and Thermostat Housing
131
Thermostat
132
Coolant Pump
133
External Cleaning
137
Internal Cleaning
137
Specifications
138
General Information
138
Cylinder Head
140
Turbocharger
142
Pistons and Cylinder Liners
142
Connecting Rods
143
Flywheel and Flywheel Housing
143
Timing Gear
144
Lubrication System
145
Troubleshooting Tables
146
White Smoke
146
White Smoke, Water Vapour
146
Black Smoke When Running/Under Load
147
Black Smoke on Starting
148
Blue Smoke
148
Fuel in the Oil
148
Oil in Coolant
149
Coolant/Water in Oil
150
Low Oil Pressure
151
High Oil Pressure (Engine Warmed Up)
153
Abnormal Wear (Liner, Piston Rings, Etc.)
153
Vibration, no Driven Components Engaged
154
Delivery Pipe Fractures
155
External Corrosion on Cylinder Liner
155
Engine Difficult to Start
155
Fluid Stroke
156
Knocking Noise
156
High Oil Consumption
158
High Fuel Consumption
159
Low Compression
159
Low Engine Output
159
Hot Engine
161
Cold Engine
162
Coolant Loss
162
Engine Heater
163
High Oil Temperature
163
High Exhaust Temperature
164
Low Charge Air Pressure
164
Low Fuel Pressure
165
Low System Voltage
165
High System Voltage
165
External Oil Leakage
166
External Fuel Leakage
166
External Coolant Leakage
167
Oil Pressed out Via Crankcase Ventilation
167
Turbocharger Breakdown
167

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Chapter 1 Index

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