doosan mt40b articulated dump truck service repair manual

Download Doosan MT40B Articulated Dump Truck Service Repair Manual

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  • 1.1.1STRUCTURE & FUNCTION

    SHOP MANUAL MT40B - 06.99

    Chapter 1 Engine

    Main Index

    Chapter 1.1 Structure Function ..............................................................3

    Chapter 12 Testing & Adjusting..............................................................33

    Chapter 1.3 Disassembly & Assembly...................................................57

    Chapter 1.5 Trouble shooting..................................................................163

  • 1.1.3STRUCTURE & FUNCTION

    SHOP MANUAL MT40B - 06.99

    Engine 1.1 Structure & Function

    Index

    Cylinder block ........................................................................................4 Cylinder liner ............................................................................................................................... 4

    Pistons ....................................................................................................6 Piston rings ................................................................................................................................. 7

    Connecting rods ....................................................................................8 Gear drive ..................................................................................................................................12 Belt drive ...................................................................................................................................13 Oil pump ....................................................................................................................................14 Oil cleaner ..................................................................................................................................15 Oil cooler ...................................................................................................................................16 Lubrication oilways .....................................................................................................................16 Turbo filter ..................................................................................................................................17 Cooling system ..........................................................................................................................20 Circulation ..................................................................................................................................21 Charge air cooler ........................................................................................................................21 Thermostat and thermostat housing ...........................................................................................22 Coolant pump .............................................................................................................................23

    Scania Digital Engine Control system (DEC2) ................................ 24 General ......................................................................................................................................24 Basic features ............................................................................................................................24 Emissions ..................................................................................................................................24 Engine protection .......................................................................................................................24 Important information: ................................................................................................................24 Diagnostics ................................................................................................................................25 Fault finding ...............................................................................................................................25

    Control unit .......................................................................................... 26 LED functions during normal operation ......................................... 27

    CONTROL STATUS ....................................................................................................................27 SHUTDOWN ..............................................................................................................................27 STARTING .................................................................................................................................27 RUNNING ...................................................................................................................................27 TORQUE LIMIT ..........................................................................................................................27 BOOST LIMIT ............................................................................................................................27 POWER- ....................................................................................................................................27 POWER+ ...................................................................................................................................27

    Sensors ................................................................................................ 28 Note! ..........................................................................................................................................28 Engine speed .............................................................................................................................28 Charge air temperature ...............................................................................................................28 Charge air pressure ....................................................................................................................28 Coolant temperature ...................................................................................................................28 Oil pressure ...............................................................................................................................28 Junction box ..............................................................................................................................28

    Sensor location ................................................................................... 29 Electronically controlled actuator ................................................................................................30 Control rack sensor ....................................................................................................................30 Fuel shut-off valve .....................................................................................................................31 Throttle position sensor ..............................................................................................................31

  • SHOP MANUAL MT40B - 06.99

    STRUCTURE & FUNCTION1.1.4

    Cylinder block

    1. Cylinder liner 2. Cylinder block 3. Cylinder head gasket 4. Shim

    Cylinder liner The cylinder liners are of “wet” type, i.e. they are surrounded by coolant. At the top of the cylinder liners is a loose scraper ring which removes residual carbon from the edge of the piston crown and reduces the risk of cylinder liner wear.

    The cylinder liners and scraper rings are replaceable. To ensure a good seal, the edge of the cylinder liner stands 0.3 mm proud of the surface of the cylinder block. As a result, the cylinder head gasket is pressed against the cylinder head. The cylinder liner is adjusted to the correct height by means of a shim.

    The cylinder block is a one-piece casting with 8 cylinders arranged in two rows at 90° to each other in a Vee configuration. There is a separate cylinder head for each cylinder. A steel gasket seals between cylinder block and cylinder head. Seals are bonded in place at the oil and coolant passages.

  • 1.1.5STRUCTURE & FUNCTION

    SHOP MANUAL MT40B - 06.99

    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 ensure that the oil needed for lubrication between piston rings and liner remains on the wall of the liner. The design of the pattern is of major importance for ensuring low oil consumption in the engine.

    The lower part of the cylinder liner is to some extent movable to allow for thermal expansion. Three sealing rings, 1 - 3, seal the lower part of the liner at different levels. An overflow hole which discharges in the side of the cylinder block is provided between the two bottom rings. Leakage in any of the sealing rings will result in oil or coolant coming out of the overflow hole.

    The V configuration of the cylinders means that the main bearings are also exposed to lateral stress. For this reason, the main bearing caps are attached with both vertical and horizontal bolts.

    1. Seal for coolant 2. Seal for coolant 3. Seal for oil 4. Overflow hole

  • SHOP MANUAL MT40B - 06.99

    STRUCTURE & FUNCTION1.1.6

    Pistons

    The pistons are made of high-strength aluminium alloy characterized by low weight and good thermal dissipation.

    For the piston to resist the high pressure and high temperature prevailing in the combustion chamber, the material is thicker at the piston crown and piston ring grooves than in the remainder of the piston.

  • 1.1.7STRUCTURE & FUNCTION

    SHOP MANUAL MT40B - 06.99

    Piston rings For the piston to travel freely, a gap i