doosan mt26 mt31 articulated dump truck service repair manual

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  • Shop Manual MT 26/31

    Part no 512967

    Moxy articulated dump trucks are manufactured by MOXY ENGENEERING AS, Elnesvågen, Norway. Tel. +47 71 26 85 00 Fax +47 71 26 85 50

    www.moxy.no

    Edition: Dec. 2004

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    Contents

    Shop Manual MT26/MT31

    Chapter 0 General

    Chapter 1 Engine Group

    Chapter 2 Transmission

    Chapter 3 Drive Line and Brakes

    Chapter 4 Air System

    Chapter 5 Hydraulic System

    Chapter 6 Electrical System

    Chapter 7 Front Wagon

    Chapter 8 Rear Wagon

    Chapter 9 Optional Equipment

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    0 General .................................................................................................................. 4 0.1 Introduction .........................................................................................................................4 0.1.1 Important information on Industrial Safety .......................................................................4 0.2.1 Incidents are warning signals ...........................................................................................5

    0.2 Workshop Safety ............................................................................................... 5 0.2.2 Vibrations ........................................................................................................................6 0.2.3 Injurious Noise .................................................................................................................6 0.2.4 Organic Solvents ..............................................................................................................7 0.2.5 Coolant .............................................................................................................................8 0.2.6 Refrigerant .......................................................................................................................8 0.2.7 Air Pollution ......................................................................................................................9 0.2.7 Liquid Or Gas Under High Pressure ..............................................................................10 0.2.8 Fire And Explosion Risks ...............................................................................................11 0.2.9 Asbestos ........................................................................................................................12 0.2.10 Lead .............................................................................................................................12 0.2.11 Jacked Up Vehicle Or Bodywork ..................................................................................13 0.2.12 Heavy Objects ..............................................................................................................13 0.2.13 Protection Against Damage And Injury .......................................................................13 0.2.13 More than one person working on the same Vehicle ...................................................14 0.2.14 Involuntary Start of Electric Equipment ........................................................................14 0.2.15 Rotating Parts ..............................................................................................................14 0.2.16 Splinters, Flying Object When Using Certain Tools ......................................................15 0.2.17 Springs Under Load .....................................................................................................15 0.2.18 Tyres and Wheels .........................................................................................................15 0.2.19 Precautions for Disassembly and Assembly Operations ..............................................16 0.2.19.1 Types of sealing-/locking Compounds and Lubricants used during Assembly ..........17 0.2.19.2 Torque limits for screws ............................................................................................18 0.2.20 Handling of Oil Seals ...................................................................................................19 0.2.21 Handling of Gaskets .....................................................................................................19 0.2.22 Handling of O-ring Seals ..............................................................................................20 0.2.23 Handling of Bearings ....................................................................................................20 0.3 Precaution before any Maintenance Operation .................................................................21 0.4 Location of Main Components ..........................................................................................22 0.5 Location of Drive Line Main Components .........................................................................23

    Chapter 0 General

    Index

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    This Shop Manual is an aid for planning and performing quality repairs of your dumper truck, and giving the service personnel information to obtain good overall knowledge on the dumper truck. This manual will also serve as a useful reference for other personnel involved in the service of the dump truck. Study, and make sure that you understand the manual and use it at every maintenance task you are going to accomplish. When using this manual, always have the Operation and Maintenance Manual at hand for references, and be familiar with both manuals

    Generally, the persons maintaining MOXY products are responsible for their own safety. The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding damage to persons and to the product during maintenance and repair works. Persons performing repair works must familiarize themselves with these regulations. The proper repair of MOXY-products requires the employment of suitably trained and skilled personnel. The mechanic is obliged to perform the training.

    WARNING!_______________________

    Symbols like this followed by a written warning serves as an attention to special working procedures where care must be taken not to cause injury to people, or damage to equipment !

    Caution Illustrations do not always represent the original equipment, just the working procedure is shown. The illustrations are not always drawn to scale, and conclusions regarding size and weight must not be drawn (not even within one representation). The tasks must be performed according to the description.

    0.1 Introduction

    0 General

    0.1.1 Important information on Industrial Safety

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

    Follow the workshop manual This shop manual provides instructions for work methods and equipment that reduces the risk of accidents.

    Mechanical skill This is a very important factor. The Moxy-mechanic is skilled and well trained for his job. Without these qualities, risks are much greater and more difficult to anticipate.

    Common sense This characteristic should form the basis of activities in the workshop. Negligence and carelessness cannot be allowed.

    Work with a safety margin Always expect that something can go wrong during the work. Always work with a safety margin where there are risks.

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

    Warnings (parts or packages) Always read and follow warnings and instructions. Do not trust your own knowledge of the risks. The properties of a part or the chemical composition of a product could have been changed during transit.

    You have to know where the risks are In this way you can avoid them. In many cases, risks are so obvious that you do not have to search for them, e.g. carbon monoxide - true it is invisible, but you know that it is lethal. Therefore protect yourself.

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

    The three demands of safety

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

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

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

    0.2.1 Incidents are warning signals

    An incident is an unforeseen event without injury or damage. The next time the consequence of the same event may be worse. An incident demonstrates that there is a risk. Every incident must be taken as a warning signal - exactly as if there had been an accident or someone had been taken ill. Look out Do not trust others to point out the hazards. It is difficult to remember all

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