Page 1 Engine Ch 1 Tier-3 710655- page Chapter 1 Engine SHOP MANUAL MT26-31 - 06.2005...
Page 2: Table Of Contents
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 ......................7 Continuation next page SHOP MANUAL MT26-31 - 06.2005...
Page 3 Lubrication oilways ........................115 Oil pressure ..........................116 Oil cooler, engine ........................117 Oil cooler view ...........................118 Renewing seals .........................119 Oil filter ............................10 Centrifugal oil cleaner ............... 121 Dismantling and assembly ......................1 Cooling fan ..................126 Continuation next page SHOP MANUAL MT26-31 - 06.2005...
Page 4 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 SHOP MANUAL MT26-31 - 06.2005...
Page 5: Removal Of Engine Assembly
Place wheel chocks to the front wheel Take away the cab bolt, left and right hand side. Nv 46 mm Turn the direction valve on the pump in lifting up position. With the handle, pump and raise the cab. SHOP MANUAL MT26-31 - 06.2005...
Page 6 Disconnect the oil hose from engine brake cylinder and bracket disassemble the other end at left side on the magnetic valve Hook up the filter stand in lifting device. Screw off the fastening bolt for filter stand, left and right hand side SHOP MANUAL MT26-31 - 06.2005...
Page 7 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 8 Disconnect the outlet pipe bend from turbo, and the inlet water hose from the transmission cooler. Disconnect the retur hose. (Engine - ekspantionstank) (Quick release coupling) (Front of the engine, view from the right hand side) SHOP MANUAL MT26-31 - 06.2005...
Page 9 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 10 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. SHOP MANUAL MT26-31 - 06.2005...
Page 11: Lifting The Engine
- Fasten the lever block 8394 to the front lifting eye. With attention, lift the engine out from the frame Note: The lifting eyes are sized to cope with a maximum angle of 30°. SHOP MANUAL MT26-31 - 06.2005...
Page 12: Engine Identification
The actual output setting of the engine is indicated on the engine card. Application For general industrial use Variant 01-99 Type of regulator EMS engine management system with PDE and S6 © Scania Industrial & Marine Engines 2005-11:1 SHOP MANUAL MT26-31 - 06.2005...
Page 13: Fuel System
3 Fuel filter 4 Feed pump / hand pump 5 Shut-off cock 6 Oil hose water filter - feedpump 7 Water separating prefilter 8 Retur line Supply from tank 9 Drain valve Retur to tank SHOP MANUAL MT26-31 - 06.2005...
Page 14: General
There are three classes of so called environmentally favourable fuels (SS15 54 35). Class 1 is sulphur-free and class is low in sulphur. Compared with class 3 (normal fuel), these fuels are less dense and this reduces engine power output. SHOP MANUAL MT26-31 - 06.2005...
Page 15: Fuel Filter
Fuel filter, constituent parts Water separating prefilter Note: Close the shut-off cock when renewing the filter. The same intervals between changes apply as for those for an ordinary fuel filter. 1 Shut-off cock Drain valve SHOP MANUAL MT26-31 - 06.2005...
Page 16 - To prevent water in the fuel from freezing and forming ice, a maximum of 0.5-% alcohol (isopropanol) may be added. Drain fuel tanks and drain or change fuel fil- ters regularly. SHOP MANUAL MT26-31 - 06.2005...
Page 17: Feed Pump
Bleed the fuel system; refer to Bleeding the fuel system. Start the engine and check for leaks. 1 Feed pump Hand pump 3 Fuel filter 4 Fuel rail 5 Pressure relief valve 6 Bleeder nipple 7 ECU control unit SHOP MANUAL MT26-31 - 06.2005...
Page 18: Diagnostic Prosedure
4. Put in the USB key 5. Switch on the ignition key (If read the setting parameters) 6. Start the engine. (If controlling of the param- eters) 7. Start on Laptop the engine ECOM program. SHOP MANUAL MT26-31 - 06.2005...
Page 19 Contains two independent CANbus interfaces and han- dles data transfers between these buses Test port Connection point for engine diagnosis Laptop Handle WDB monitoring and alarm (CANbus connection) Handle histogram logging (In- formation for service) SHOP MANUAL MT26-31 - 06.2005...
Page 20: 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 21 . Start the logging by the start button 3. Select "Viev the list" to watch the values or - 4. Move text linr to section C 5. select the "Osciloscope" to view the graphical diagram 6. Stop logging to select new variable SHOP MANUAL MT26-31 - 06.2005...
Page 22 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 23 Go to the column for values, find the line for engine temp and change the value. Then go to the "button" ; write values and click on it, the value will now be change. Confirm your choise SHOP MANUAL MT26-31 - 06.2005...
Page 24: Ecom Standard Settings Code
0 = Not present 1 = From coordinator Reaction to low coolant level 0, 1, , 6 0 = Alarm only FD6D 1 = Torque limitation = Stop engine 6 = Stop engine with override option SHOP MANUAL MT26-31 - 06.2005...
Page 25 5100 5100 FD0B PTO mode 1, max torque 0 - 5100 5100 5100 FD0D PTO mode , max torque 0 - 5100 5100 5100 FD0F PTO mode 3, max torque 0 - 5100 5100 5100 SHOP MANUAL MT26-31 - 06.2005...
Page 26 Torque limit 3, extra torque curve for customer use. Breakpoints for software version 53: 1000, 1100, FD15 0 - 5100 array x 1 Nm 1 x 5100 100, 1400, 1600, 1800, 1900, 000, 100, 00, 300, 400 rpm SHOP MANUAL MT26-31 - 06.2005...
Page 27: Engine Control Unit, Ecu
How to read fault codes from the ECU control unit, for a description of how to read off flashing codes. See the section Flash codes tables for a list of flashing codes for the control unit and ECU Control unit SHOP MANUAL MT26-31 - 06.2005...
Page 28: Wiring And Cable Duct
(kick down switch). The idle safety switch tells the control unit whether the accelerator is released or activated. This is primarily a safety feature to check that the potentiometer is working as it should. SHOP MANUAL MT26-31 - 06.2005...
Page 29 Sensor for charge air temperature and 3. Coolant temperature sensor pressure 4. Engine speed sensor () Engine speed sensor (2) Coolant level monitor (located in the expansion tank) 2005-11:1 © Scania Industrial & Marine Engines SHOP MANUAL MT26-31 - 06.2005...
Page 30 Ch 1 Engine Tier-3 710655- page SHOP MANUAL MT26-31 - 06.2005...
Page 31: Diagnostic Lamp And Switch
Push the upper side and read the blink code for the Push upper ECU. side for ECU Push the lower side and read the blink code for the Push lower Coo. side for Coo Double switch SHOP MANUAL MT26-31 - 06.2005...
Page 32: Fault Codes
• How often the fault occurs • If the diagnostics lamp lit up when the fault occurred • If the diagnostics lamp went out by itself when the fault ceased • If the fault codes have been erased SHOP MANUAL MT26-31 - 06.2005...
Page 33: How To Read Fault Codes From The Ecu Control Unit
5 The PC-based diagnostics tool must to be used to gain further information on the fault code. 6 A single, very long flash (4 s) means that there are no fault codes stored in the memory. = 4 s SHOP MANUAL MT26-31 - 06.2005...
Page 34 3 Start the engine and check that the diagnostics lamp goes out. 4 Press the diagnostics switch. The fault code memory should be empty; only one long flash should be seen. SHOP MANUAL MT26-31 - 06.2005...
Page 35: Flash Codes Tables
Incorrect voltage supply to one of the sensors. coordinator. PDE in cylinder 1: The solenoid valve does not Internal hardware fault in the processor (TPU). work correctly. PDE in cylinder 2: The solenoid valve does not work correctly. SHOP MANUAL MT26-31 - 06.2005...
Page 36 3 Hold the diagnostic switch down for between 3 and 10 seconds. 4 This erases the passive fault codes. The active codes must be rectified to make them passive. They can then be erased. SHOP MANUAL MT26-31 - 06.2005...
Page 37: Overview Of Flash Codes For Coordinator
Different versions of ECU does not have the same the communications Replace the coordinator version of the communication protocol between the with a matching unit. protocol as the coordinator. coordinator and EMS. Continued next page SHOP MANUAL MT26-31 - 06.2005...
Page 38 Short circuit in the signal cable to the coolant temperature warrning lamp Short circuit in the signal cable to the charge indicator lamp Incorrect signal from the Fixed speed switches Fault in CAN communication SHOP MANUAL MT26-31 - 06.2005...
Page 39: Renewing The Control Unit
Plug in the connectors on the control unit. Do the necessary programming with ECOM. Start the engine. Check the fault codes and then delete them in accordance with the routine in troubleshooting booklet or with the PC-tool ECOM if it is available. SHOP MANUAL MT26-31 - 06.2005...
Page 40: Removing The Ecu Wiring
Remove the cable clamps as well. Note: Handle the engine speed sensors with care. They are magnetic and are sensitive to impacts. Remove engine speed sensor 1 and its clamps. Remove engine speed sensor and its clamps. SHOP MANUAL MT26-31 - 06.2005...
Page 41 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. SHOP MANUAL MT26-31 - 06.2005...
Page 42 Check that you have run the right cable to 1 and 6 each unit injector by testing the cables with and 7 a multimeter as shown in the tables. 4 and 9 1 and 6 and 7 4 and 9 SHOP MANUAL MT26-31 - 06.2005...
Page 43 Plug the connectors into the control unit. Fit the upper rocker covers and tighten the screws to 18 ± 3 Nm. Fit the inlet pipe between the turbocharger and the air cleaner. Top up with coolant in accordance with the SHOP MANUAL MT26-31 - 06.2005...
Page 44: Cylinder Head
5160 Drift 5161 Handle 5157 Drift 5166 Pilot tap 512260 5159 Drift 512266 512258 5158 Drift 512257 512261 512259 516 Guide 5165 Valve seat cutter 5163 Setting tool 5164 Setting tool 512262 512265 512263 512264 SHOP MANUAL MT26-31 - 06.2005...
Page 45: Cylinder Head, Parts View
5. Rocker arm 40. Rocker cover gasket 1. Valve spring collar 6. Core plug 13. Valve spring 7. Unit injector 14. Rivet plug 8. Cylinder head 15. Tight-fit screw 9. Pin 16. Shaft 30. Rivet plug SHOP MANUAL MT26-31 - 06.2005...
Page 46: Valve Mechanism
The effort required for gas flow is reduced and engine ef- ficiency is improved. This in turn leads to a reduction in fuel consumption. The injector can be located centrally, which improves com- bustion and results in reduced emissions and lower fuel consumption. SHOP MANUAL MT26-31 - 06.2005...
Page 47 Clean the rocker cover and the surrounding area. Remove the top part of the rocker cover. Relieve the pressure on the valves by undoing the bolts on the rocker arm shaft alternately. SHOP MANUAL MT26-31 - 06.2005...
Page 48 Remove the pushrods. Note: The pushrod for the unit injector is secured with a retaining ring. Jiggle and pull carefully on the pushrod to loosen it. Remove the valve bridges. Remove the lower rocker cover. SHOP MANUAL MT26-31 - 06.2005...
Page 49 Note: If the slide hammer is placed directly under the solenoid valve, there is a risk of breaking the solenoid valve. Place the slide hammer as indicated by the arrow. SHOP MANUAL MT26-31 - 06.2005...
Page 50 Detach the intake manifold, fuel manifold, ventilation pipe for the cooling system and the exhaust manifold. Remove the cylinder head. Mark the cylinder heads if more than one is being removed at the same time. SHOP MANUAL MT26-31 - 06.2005...
Page 51: Dismantling
Renewing the valve stem seal Remove the valve. Remove the valve stem seal with a pair of pliers. 8407 Fit the valve. 4. Tap in a new valve stem seal carefully using tool 8407 and a hammer. SHOP MANUAL MT26-31 - 06.2005...
Page 52: Replacement Of Valve Seats
There is a risk of frost injuries. Oversize valve seat inserts can be fitted if the valve seat insert position has been damaged. If this is the case, the seat must be machined using valve seat cutter 5165. SHOP MANUAL MT26-31 - 06.2005...
Page 53: Machining The Valve Seats Insert
Check that the contact surface and the magnetic base are smooth and clean. Clean the valve bushings. Select the largest spindle which slides easily into the valve guide.Insert the guide spindle and turn the feed screw to its uppermost position. SHOP MANUAL MT26-31 - 06.2005...
Page 54 1 mm. Centre the tool precisely. Connect the magnetic base (position 1). Apply the quick-action lock. Make sure the crank can be turned easily. If not, redo the centering. SHOP MANUAL MT26-31 - 06.2005...
Page 55: Renewing The Valve Guides
Press out the valve guides using drift 5159. 5159 Press in the new valve guides using drift 5158 Press the guide down as far as the drift allows, i.e. until it makes contact with the spring seat in the cylinder head. 5158 SHOP MANUAL MT26-31 - 06.2005...
Page 56: Renewing Pde Unit Injector Sleeves
Degrease the new injector sleeve and apply a thin film of sealing agent 351161-- on the sleeve and cylinder head contact surfaces. 512561 Press in the sleeve with drift 51561 and 512262 guide 516 SHOP MANUAL MT26-31 - 06.2005...
Page 57: Assembly
• Finally, tighten all bolts a further 90° • Make a mark with a centre punch on the head of the bolt. Fit the lower part of the rocker cover and tighten the bolts to 6 Nm. SHOP MANUAL MT26-31 - 06.2005...
Page 58: Pde Injectors
Bolt for fork on unit injector. 0 Nm + 75° Bearing bracket and rocker arm shaft 105 Nm Screws for cable connections on unit injector +/- 0. Nm Special tools Number Description Illustration 5156 Torque screwdriver SHOP MANUAL MT26-31 - 06.2005...
Page 59 A rubber insert will keep the seal in place on the unit injector. WARNING! Check that there is no fuel left in the cylinder. If fuel runs into the combustion chamber, it must be removed immediately using a pump. SHOP MANUAL MT26-31 - 06.2005...
Page 60 Press down the unit injector by hand as far as possible. Torque tighten the bolt to 0 Nm and then a further 75°. There are two marks on the rocker cover with a 75° angle between them. SHOP MANUAL MT26-31 - 06.2005...
Page 61 Reconnect the cables on the unit injectors. Their relative position is not important. Use torque screwdriver 588 179 to tighten the screws to Nm. SHOP MANUAL MT26-31 - 06.2005...
Page 62: Adjusting Unit Injectors
NOTE ! Machine 710656 ( Tier 3) - : Dimension A = PDE3: 69.9 +/- 0.1 mm Dimension B = PDE3: 38,5 mm Tightening torques Lock nut on rocker arm: 39 Nm SHOP MANUAL MT26-31 - 06.2005...
Page 63 Measure the distance between plane a and the top of the valve spring collar using a digital sliding caliper. Adjust the rocker posi- tion by means of the adjusting screw until the dimension is 69.9 +/- 0.1 mm. Tighten the lock nut to 39 Nm. SHOP MANUAL MT26-31 - 06.2005...
Page 64: Adjusting The Valve Clearance And Unit Injectors
The intake valves are actuated by the short rocker arms and the exhaust valves by the long rocker arms. Make sure the valve bridge is resting correctly against the valves. See the table next page. SHOP MANUAL MT26-31 - 06.2005...
Page 65: Checking, Adjusting The Pde3 Injector Rocker Arms (I)
If the value is e.g. 0,8-1,0 mm, then check the position of engine. Start the adjusting prosedure again and follow the table be- low. Valve Adjust the Adjust unit overlap on valves on injector rocker cylinder cylinder arm on cylinder TDC Up (0°) SHOP MANUAL MT26-31 - 06.2005...
Page 66 It is a good idea to mark the rocker arm with a pen after adjustment to keep track of what has already been adjusted. Torque tighten the lock nut to 39 Nm after adjusting. SHOP MANUAL MT26-31 - 06.2005...
Page 67: Turbocharger
The shaft is mounted in two bushings which rotate freely in the bearing housing. The bearing hous- ing seals for the turbine and compressor consist of seals which are similar to piston rings. SHOP MANUAL MT26-31 - 06.2005...
Page 68: 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 69: Special Tools
4. Straight union 5. Seal 6. Straight union 7. Gasket 8. Lubrication oil return pipe 9. Hose 10. Hose clamp 11. Bolt 1. Bracket 13. Bolt 14. Clamp 15. Clamp 16. Bolt 17. Gasket 18. Turbocharger SHOP MANUAL MT26-31 - 06.2005...
Page 70: Measuring Radial Clearance And Axial Clearance
8 and measuring stand 809 If any wheel rubs against the housing, despite radial clearance being within tolerance, the turbocharger should be changed. Measuring compressor wheel radial clearanse with deflection gauge 8 and measuring stand 809 SHOP MANUAL MT26-31 - 06.2005...
Page 71 Check that the air filter is not blocked and that there are no other reasons for the abnormal increase of vacuum in the intake system. Check that engine output is correct. Excessively high output reduces the life of the turbo. SHOP MANUAL MT26-31 - 06.2005...
Page 72: Renewing The Turbocharger
(fuel shut-off) and turn the engine over with the starter motor for at least 30 seconds so that the lubricating oil will reach the turbocharger. Start the engine and check that there is no leakage. SHOP MANUAL MT26-31 - 06.2005...
Page 73: Pistons And Cylinder Liners
6. Compression ring 7. Compression ring 8. Oil scraper ring 9. Circlip 10. Steel piston 1. Gudgeon pin 13. Circlip 14. Bearing bushing 15. Connecting rod 16. Crankshaft 17. Bearing shell 18. Bearing cap 19. Flange bolt SHOP MANUAL MT26-31 - 06.2005...
Page 74: Special Tools
Dial gauge 84 Piston ring compressor 808 Pressing tool 8036 Hydraulic cylinder 815 Puller for cylinder liner 8049 Impact drift 8401 Dismantling tool 8409 Assembly tool 8390 Test apparatus for connecting rods 8395 Piston ring expander SHOP MANUAL MT26-31 - 06.2005...
Page 75: Connecting Rods
The upper part of the connecting rod is wedge shaped. This al- lows a larger journal surface on the underside of the gudgeon pin where load is greatest during combustion. SHOP MANUAL MT26-31 - 06.2005...
Page 76: Removing And Dismantling Connecting Rods And Pistons
However, new pistons should be washed carefully using white spirit or the like. Note: Always inspect the connecting rod in cylinders which have seized, been filled with water or where the valve has broken. Bent connecting rods must not be straightened. SHOP MANUAL MT26-31 - 06.2005...
Page 77 - Turn the connecting rod around and measure the corresponding distance. Important! The difference must not exceed 0.6 mm. Checking whether the connecting rod is bent into an S shape SHOP MANUAL MT26-31 - 06.2005...
Page 78: Renewal Of Bearing Bushing In Connecting Rod
Turn the press drift with the smaller diameter against the bearing bushing and press it out. Turn over the press drift and mount a new bearing bushing onto it. Press in the bearing bushing. SHOP MANUAL MT26-31 - 06.2005...
Page 79 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 80: 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 81 In the oil scraper ring is a coil spring which presses it against the cylinder wall. The design and quality of the pistons and piston rings are ex- tremely important for the reliability and lubrication of the engine as well as oil and fuel consumption. SHOP MANUAL MT26-31 - 06.2005...
Page 82: Assembling Piston And Connecting Rod
Turn the piston and connecting rod as illustrated. The arrow mark should point forward on the engine. Insert the gudgeon pin using tool 8005 and fit the second retaining ring for the gudgeon pin. 8005 SHOP MANUAL MT26-31 - 06.2005...
Page 83: Cylinderblock
To ensure a good seal, the edge of the cylinder liner protrudes slightly above the surface of the cylinder block. This ensures that the cylinder head gasket is pressed against the cylinder head. SHOP MANUAL MT26-31 - 06.2005...
Page 84 Leakage at any of the sealing surfaces will result in oil or coolant coming out of the overflow hole. 1. Seal for coolant . Support point for liner SHOP MANUAL MT26-31 - 06.2005...
Page 85: Removing The Cylinder Liners
99 066 and hydraulic cylinder 8036. Fit spacers under the support lugs to avoid damaging the surface of the block. Remove the sealing ring in the cylinder block. 8215 Cylinder liner extractor with hy- draulic cylinder SHOP MANUAL MT26-31 - 06.2005...
Page 86: Measuring The Cylinder Liner Height
- The difference between the two measurements on the same liner must not exceed 0.0 mm. - The height of the cylinder liner D (=A-B) above the block should be 0.0 – 0.30 mm. SHOP MANUAL MT26-31 - 06.2005...
Page 87: Fitting The Cylinder Liners
Fit the scraper ring in place after the piston Fit the scraper ring in place after the piston has been fitted. has been fitted. SHOP MANUAL MT26-31 - 06.2005...
Page 88: Fitting The Piston And Connecting Rod
Insert the connecting rod and piston. On aluminium pistons the arrow mark on the piston should point forward. Clamp piston ring compressor 98 1 round the piston and push the piston down into the cylinder. SHOP MANUAL MT26-31 - 06.2005...
Page 89 Damaged nozzles must not be re-aligned, renew them instead. Fit the oil sump and tighten the bolts to 30 Nm. Fit the cylinder head. Tighten the cylinder head bolts as described in the section Cylinder head. SHOP MANUAL MT26-31 - 06.2005...
Page 90: Flywheel And Flywheel Housing
10. Flange bolt 23. Timing gear plate, 36. Washer 11. Cover engines with PDE unit injectors 37. Guide sleeve 1. Lifting eye 4. Stud 38. Crankshaft 13. Hexagon nut 5. Pin 14. Washer 6. Flange bolt SHOP MANUAL MT26-31 - 06.2005...
Page 91: Special Tools
Removing the flywheel 8006 Remove the engine speed sensor(s) in the flywheel housing. Remove the bolts for the flywheel. 14” flywheel: Also remove the washer. Pull off the flywheel from the crankshaft using puller bolts 8006 SHOP MANUAL MT26-31 - 06.2005...
Page 92 Make sure the ring gear is securely against the flywheel. If necessary, knock down the ring gear with a plastic hammer. The ring gear must not be cooled rapidly but be left to cool in the open air. SHOP MANUAL MT26-31 - 06.2005...
Page 93: Renewing The Rear Crankshaft Seal
Place the crankshaft seal on the tool and fasten the tool with the bolts. Turn the tool clockwise until is stops in order to attain the correct crankshaft seal position. Removing the flywheel housing Remove the starter motor. Remove flywheel housing. SHOP MANUAL MT26-31 - 06.2005...
Page 94: Fitting Flywheel Housing
M10 bolts to 50 Nm. Apply the sealing agent on the timing gear Fit the starter motor housing side against the transmission plate. Apply the sealing agent around the screw holes marked with arrows. SHOP MANUAL MT26-31 - 06.2005...
Page 95 Engine Ch 1 Tier-3 710655- page SHOP MANUAL MT26-31 - 06.2005...
Page 96: Fitting The Flywheel
Always use new bolts and washer . 512563 99 411 Lock the flywheel using tool: - 51563 for engines with unit injector. Torque tighten the bolts alternately to 130 Nm and then a further 90°. Fit the engine speed sensors). SHOP MANUAL MT26-31 - 06.2005...
Page 97: Timing Gears
To facilitate correct assembly of the timing gears, the gears are marked on a tooth or in the space between two teeth. The injection pump gear has an oval hole for setting the injec- tion timing (the a angle). SHOP MANUAL MT26-31 - 06.2005...
Page 98: Belt Drive Collant Pump, Generator And Ac Compressor
An automatic belt tensioner is used to obtain the correct belt tension. Spacing sleeve Roller Roller Belt tensioner Poly V belt 10 Alternator 11 Coolant pump 1 A/C compressor 13 Pulley SHOP MANUAL MT26-31 - 06.2005...
Page 99: Renewing The Seal In The Front Cover
Bolt the driver to the crankshaft flange and tighten the flange bolts to 135 Nm. Bolt the crankshaft damper and possibly the 8421 belt pulley to the hub and tighten to 110 Nm. Fit the belt(s), fan ring and fan. SHOP MANUAL MT26-31 - 06.2005...
Page 100: Crankshaft Damper
There is a heavy oil between the housing and ring which damps the relative movement between the two. The oscillation at the front of the crankshaft is damped by the ring striving to rotate with even speed. 1 SHOP MANUAL MT26-31 - 06.2005...
Page 101: Timing Gear, View Exploded
35. Key 10. Flange bolt 23. Crankshaft gear 36. Camshaft 11. Flange bolt 24. Injection pump gear 37. Tappet 12. Flange bolt 25. Bolt 38. Retaining ring 13. Flange bolt 26. Washer 39. Pushrod 40. Bushing SHOP MANUAL MT26-31 - 06.2005...
Page 102: Special Tools
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 SHOP MANUAL MT26-31 - 06.2005...
Page 103: Crankshaft Seal
T hen unscrew the bolt a few turns and tap the hub in to loosen the cone. 6. Pull the hub off altogether. 7. R emove the seal using slide hammer 87 596. Protect the end of the crankshaft against scratches. SHOP MANUAL MT26-31 - 06.2005...
Page 104 (60°) using slogging wrench 99 059. 6. Fit the oscillation damper and, if fitted, the belt pulley. T ighten the bolts to 110 Nm. 7. R efit the components that were removed ear- lier because they were in the way. SHOP MANUAL MT26-31 - 06.2005...
Page 105: Timing Gear Cover
9. E ngine equipped with compressor: R emove the coolant manifold between the coolant pump and compressor. 10. Undo the three compressor retaining bolts in the timing gear housing. E xtract the compres- sor and gear. SHOP MANUAL MT26-31 - 06.2005...
Page 106 300 Nm and then a further sixth of a turn (60°) using slogging wrench 99 059. 7. Fit the oil sump with a new gasket. 8. R efit the components that were removed ear- lier because they were in the way. SHOP MANUAL MT26-31 - 06.2005...
Page 107: Intermediate Gear
2. Fit the washer and tighten the bolts to a torque of 39 Nm. 3. Fit the oil catcher on the end of the crankshaft. 4. Fit the timing gear cover. See Timing gear cover: F itting. SHOP MANUAL MT26-31 - 06.2005...
Page 108: Crankshaft Gear
3. Fit the intermediate gear. See Intermediate gear: F itting, points 1-2. 4. Fit the oil pump. 5. Fit oil catcher on end of crankshaft. 6. Fit the timing gear cover. See Timing gear cover: F itting. SHOP MANUAL MT26-31 - 06.2005...
Page 109: Camshaft Gear
4. Check that the gear has cooled down. Secure the flywheel. T ighten the camshaft nut to a torque of 600 Nm. 5. Fit oil catcher on end of crankshaft. 6. Fit the timing gear cover. See Timing gear cover: F itting. SHOP MANUAL MT26-31 - 06.2005...
Page 110: Camshaft
Camshaft gear: F itting, points 1-4. 5. L ubricate the camshaft cams. Fit the side cov- ers with a new gasket. 6. L ubricate pushrods and rocker arms with motor oil and fit them in place. SHOP MANUAL MT26-31 - 06.2005...
Page 111 T DC position is reached again. 6. R ead the two dial gauges and compare the results with the values given below: Intake valve lifting height 0.55-1.65 mm E xhaust valve lifting height 0.50-1.50 mm SHOP MANUAL MT26-31 - 06.2005...
Page 112: Crankshaft
It is important that the fillet radius of the pivot pins is correct. A fter grinding the pivot pins, the oil hole ori- fices at the bearing surfaces should be rounded and polished. SHOP MANUAL MT26-31 - 06.2005...
Page 113 6. Fit pistons, connecting rods and oil pump. 7. Fit the fan bearing and fan, oil sump, timing gear housing and intermediate gear. 8. Fit the flywheel and flywheel housing. 9. Fit the cylinder heads and pushrods. SHOP MANUAL MT26-31 - 06.2005...
Page 114: Lubrication System
6. Strainer 7. Ring NOTE! 8. Flange bolt In the case of leakage or fault in the 9. Pipe oil pump, it should not be recondi- 10. Seal tioned but should be renewed as a unit. SHOP MANUAL MT26-31 - 06.2005...
Page 115: Lubrication Oilways
The oil is led to the roller tappet shafts via grooves in the camshaft bearing. The roller tappet shafts have drilled channels to lubricate the roller tappets. 1. Oil pump . Oil cooler 3. Oil cleaner centrifuge 4. Piston cooling nozzle 5. Oil filter 6. Oil sump SHOP MANUAL MT26-31 - 06.2005...
Page 116: Oil Pressure
Oil is sprayed up under the piston crown through special nozzles, one for each cylinder. Since piston cooling is not needed at low engine rpm, an oil pressure valve in the oil cooler hous- ing opens at 3 bar. See the next page. SHOP MANUAL MT26-31 - 06.2005...
Page 117: Oil Cooler, Engine
(idling). See also under Lubrication oilways. Oil from oil pump Heat exchanger assembly Oil from filter into engine Cooled oil to paper filter Delivery valve for piston cooling Partial flow to centrifugal cleaner SHOP MANUAL MT26-31 - 06.2005...
Page 118: 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. Plug 8. Core plug SHOP MANUAL MT26-31 - 06.2005...
Page 119: Renewing Seals
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. Bolt the side cover to the block. SHOP MANUAL MT26-31 - 06.2005...
Page 120: Oil Filter
Operating & Maintenance Manual. 1. Filter head . Gasket 3. Seal 4. Straight union 5. Gasket 6. Flange bolt 7. O-ring 8. Pressure censor 9. Union 10. Overflow valve 11. Oil filter 1. Adapter 13. Screw SHOP MANUAL MT26-31 - 06.2005...
Page 121: Centrifugal Oil Cleaner
10. Rotor 11. Strainer 1. O-ring (change when cleaning) 13. Rotorbowl 14. Nut 15. Snap ring 16. O-ring (change when cleaning) 17. Cover 18. Lifting eye 19. O-ring 0. Lock nut 1. Nipple . Gasket SHOP MANUAL MT26-31 - 06.2005...
Page 122: Dismantling And Assembly
Turn the rotor counterclockwise 1,5 turns by hand, or if this does not help, use M0 screw and nut as shovn at the figure SHOP MANUAL MT26-31 - 06.2005...
Page 123 Inspect the two nozzles on the rotor. Make sure they are not blocked or damaged. Renew with new rotor if any damaged on the nozzles. Make sure the bearings are not damaged. Renew with new rotor if any damaged on the bearing SHOP MANUAL MT26-31 - 06.2005...
Page 124 Ti behöver hylsnyckeln 98 41 modifieras med en mutter: -Borra ur gängorna i en M0-mutter så att den passar på hylsnyckelns fyrkantsfäste. -Svetsa fast muttern. Obs! Hylsnyckeln passar fortfarande för den gamla centrifugaloljerenaren efter ombearbetningen. SHOP MANUAL MT26-31 - 06.2005...
Page 125 Refit the rotor and spin it by hand to make sure it rotates easily. Inspect the O-ring on the cleaner housing cover and fit it with a lock nut. Tighten the lock nut to 15 Nm. SHOP MANUAL MT26-31 - 06.2005...
Page 126: 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 127: 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 128: Circulation
The pressure of the air, in the air charge system, to the cylinders is approx 1 - bar, depend on the engine’s rpm. View of the radiator system Engine Air condition cooler Thermostat condenser housing Charge air cooler Transmission Radiator cooler shield SHOP MANUAL MT26-31 - 06.2005...
Page 129: Disassemble The Cooling Unit
(2 on left and side 2 on the right side). this can be doing with to operate the brake pedal sev- eral times. (Approx 15-20 times) SHOP MANUAL MT26-31 - 06.2005...
Page 130 Check that all cooling pipes and hoses are disassembled Disassemble the upper bracket between engine and fan bracket, (3 screws). Disassemble lower fastening screws (left and right hand side) Carefully lift the cooler unit out from the frame. SHOP MANUAL MT26-31 - 06.2005...
Page 131: Thermostat And Thermostat Housing
Closed thermostat - Open thermostat - return to coolant pump trough full flow to radiator by-pass channel 1. Coolant from the engine 2. By-pass channel (back to the coolant pump) 3. Outlet to the radiator SHOP MANUAL MT26-31 - 06.2005...
Page 132: Thermostat
Fill the system with coolant. See OPERATING & MAINTENANCE MANUAL chapter 7 for the composition of the coolant. Start the engine and check that there are no leaks.Check the coolant level and top up as necessary. SHOP MANUAL MT26-31 - 06.2005...
Page 133: Coolant Pump
The pump shaft bearing is sealed against the ingress of coolant by an elastic axial seal. Circulation through coolant pump Outlet to engine By-pass channel Static line Return from charge air cooler Coolant from radiator SHOP MANUAL MT26-31 - 06.2005...
Page 134 Fit the fan. Fill the cooling system. See booklet 00:03-01 for the composition of the coolant. Start the engine and check that no leakage occurs. Check the level of the coolant and top up as necessary. SHOP MANUAL MT26-31 - 06.2005...
Page 135 Fit puller 501354 using two M 8 x 65 mm bolts and drift 501349. Pull off the impeller. 501349 Split the carbon ring on the seal and remove the debris. The impeller is removed SHOP MANUAL MT26-31 - 06.2005...
Page 136 Puller for pulley 501348 Drift for pulley 501349 Puller for impeller 501354 Drift for pressing in A = 13,3 - 13,7 mm The clearance is measured sealing ring and for impeller 501351 SHOP MANUAL MT26-31 - 06.2005...
Page 137: External Cleaning
Refill the system with hot water and run the engine for approximately through an authorized 0-30 minutes. waste disposal contractor. Drain the water from the system. Refit the thermostat. Fill up with new coolant according to the specification on page 33. SHOP MANUAL MT26-31 - 06.2005...
Page 138: Specifications
(kp/cm 3 - 6 Min. oil pressure: hot engine under 1000 rpm bar (kp/cm hot engine above 1000 rpm Oil volume, see page 27 Crankcase pressure with closed -55 - +20 crankcase ventilation mm VP SHOP MANUAL MT26-31 - 06.2005...
Page 139 1.0 m radiator (litres) ELECTRICAL SYSTEM System voltage Alternator, current 80 or 100 Starter motor output kW (hp) 5.5 (7.5) Monitors, threshold values: oil pressure monitor bar (kp/cm 1,0 0,15 temperature monitor °C Programmed in S6 SHOP MANUAL MT26-31 - 06.2005...
Page 140: Cylinder Head
Seat for valve seat insert, diameter ....... 46.00 - 46.16 mm Cooling temperature when fitting valve seat insert ....approx. -80°C SHOP MANUAL MT26-31 - 06.2005...
Page 141 Fully open at........... . 95°C SHOP MANUAL MT26-31 - 06.2005...
Page 142: Turbocharger
Max. clearance in groove........0.5 mm SHOP MANUAL MT26-31 - 06.2005...
Page 143: Connecting Rods
........M1 : 90 Nm SHOP MANUAL MT26-31 - 06.2005...
Page 144: Timing Gear
Bolts for timing gear plate ........63 Nm SHOP MANUAL MT26-31 - 06.2005...
Page 145: Lubrication System
Bolts for oil cooler insert......... 6 Nm SHOP MANUAL MT26-31 - 06.2005...
Page 146: Troubleshooting Tables
If the fault is hard to trace: Cracked cylinder head Change all cylinder heads for exchange cylinder heads. (not cracks between valve (Or test pressurizing all cylinder heads. Heat the cylin- seats) der heads before pressurizing them.) Crack in cylinder liner SHOP MANUAL MT26-31 - 06.2005...
Page 147: Black Smoke When Running/Under Load
Nozzle tip jams bustion temperatures More than 1 washer under injector Check charge air pres- Fault in turbo sure Clogged air filter High exhaust counter- See page 48 pressure Worn intake valves Clogged intake port SHOP MANUAL MT26-31 - 06.2005...
Page 148: Black Smoke On Starting
Correct value for new engine: 0 - +10 mm wc (flow rate 60 - 100 l/min.) Frequent cold starts Closed crankcase ventilation: -50 - +0 mm wc Worn engine Intake valve not open- SHOP MANUAL MT26-31 - 06.2005...
Page 149: Oil In Coolant
If the fault is hard to trace: Change all cylinder heads for exchange cylinder Crack in cylinder head heads. (not cracks between (Or test pressurize all cylinder heads. Heat the cyl- valve seats). inder heads before pressurizing them.) SHOP MANUAL MT26-31 - 06.2005...
Page 150: Coolant/Water In Oil
As a rule it is possible (Coolant runs down via to see which cylinder the oil duct for rocker head or heads are arm lubrication.) leaking. Leakage in charge air Test pressure (air cooler core 0.5 bar, liquid 4 bar) SHOP MANUAL MT26-31 - 06.2005...
Page 151: Low Oil Pressure
Max. oil pressure bar Check/remedy Broken spring in oil at 000 r/min relief valve relief valve The piston in the oil re- lief valve has jammed in open position Continue next page SHOP MANUAL MT26-31 - 06.2005...
Page 152 3 bar SHOP MANUAL MT26-31 - 06.2005...
Page 153: High Oil Pressure (Engine Warmed Up)
Short service life ture (cold engine) Change the fuel Change to oil with a Excessive sulphur con- higher base number. tent in fuel Shorter oil change intervals Defective injector (causes oil film to be washed off) SHOP MANUAL MT26-31 - 06.2005...
Page 154: Vibration, No Driven Components Engaged
Only when compressed with excessive counter- air compressor is pressure (e.g. clogged charging, worst at piping/air dryer) or about 1000 r/min, see excessively high safety also page xx valve opening pressure Check engine align- Alignment fault ment SHOP MANUAL MT26-31 - 06.2005...
Page 155: Delivery Pipe Fractures
Starting aids are not normally needed at Ambient temperature temperatures above too low -15 °C Oil viscosity too high Paraffin precipitation in the fuel Blocked intake or ex- haust system No fuel Wrong injection timing Faulty injector SHOP MANUAL MT26-31 - 06.2005...
Page 156: Fluid Stroke
Loosened big end Tighten to the torque The piston strikes the cap (wrong tightening specified in the Shop cylinder head torque after repair) manual Foreign objects in the piston crown Continue next page SHOP MANUAL MT26-31 - 06.2005...
Page 157 Fuel leakage in flame Check whether it leaks. (Take out the flame start and start run the engine with fuel pipe connected) Loosened big end cap Check the injection timing Melting damage on piston crown Incorrectly adjusted injector SHOP MANUAL MT26-31 - 06.2005...
Page 158: High Oil Consumption
Clogged air filter Excessive vacuum in Measure the vacuum the air intake before (max. 500 mm wc) the turbocharger Check the air filter Oil viscosity too low Deformed/incorrectly directed piston cooling nozzles SHOP MANUAL MT26-31 - 06.2005...
Page 159: High Fuel Consumption
Low fuel supply pres- Look for leakage in the suction pipe between tank sure (below 0.3 bar) and feed pump Clogged fuel filter/Paraffin precipitation in fuel Faulty injector Continue next page SHOP MANUAL MT26-31 - 06.2005...
Page 160 48 Incorrectly adjusted Check in a pump test injection pump bench Blocked fuel consump- tion gauge Injector’s nozzle nut Binding injector tightened too hard Exhaust brake/white smoke limiter throttle in closed position SHOP MANUAL MT26-31 - 06.2005...
Page 161: Hot Engine
Excessive pressure Check with forcibly opened thermostats drop in the external cooling system Clogged radiator Circulation of cooling Check by taking temperature readings Cavitation damaged impeller in coolant pump Leakage in charge air cooler SHOP MANUAL MT26-31 - 06.2005...
Page 162: Cold Engine
Polluted coolant Effect Cause Troubleshooting Action Faulty inhibitor Clean the cooling system and fill it with coolant as described in the mainte- Overdosed corrosion nance instructions inhibitor SHOP MANUAL MT26-31 - 06.2005...
Page 163: Engine Heater
= 40 - 60 °C High oil temperature Effect Cause Troubleshooting Action Defective sensor/in- Check with separate strument instrument Instrument indicates too high temperature Poor water flow in oil cooler SHOP MANUAL MT26-31 - 06.2005...
Page 164: High Exhaust Temperature
Clogged air filter max. 500 mm wc Take a reading, recommended counterpressure: High exhaust counter- 500 mm wc, max. 1000 mm wc pressure Check silencer, spark arrester, length and inside diameter of exhaust pipe High fuel temperature SHOP MANUAL MT26-31 - 06.2005...
Page 165: Low Fuel Pressure
Batteries in poor condi- voltage: 7 - 8 V tion Alternator fault Voltage regulator fault Battery charger fault High system voltage Effect Cause Troubleshooting Action Voltage regulator fault Normal charging voltage: 7 - 8 V Battery charger fault SHOP MANUAL MT26-31 - 06.2005...
Page 166: External Oil Leakage
Leakage in manifold Low load joint External fuel leakage Effect Cause Troubleshooting Action Damaged injector and injection pump connec- tions/gaskets Defective pulsation damper Leakage at high Blocked overflow valve engine speed and low power output SHOP MANUAL MT26-31 - 06.2005...
Page 167: External Coolant Leakage
Oil seepage via pistons - liner Oil seepage in air com- pressor Turbocharger breakdown Effect Cause Troubleshooting Action Excessive bearing play in turbocharger Loss of power Lubrication piping between turbocharger Check the connections and filter incorrectly connected SHOP MANUAL MT26-31 - 06.2005...
Page 168 Ch 1 Engine Tier-3 710655- page SHOP MANUAL MT26-31 - 06.2005...
Page 169 Engine Ch 1 Tier-3 710655- page Note SHOP MANUAL MT26-31 - 06.2005...
Page 170 Ch 1 Engine Tier-3 710655- page Note SHOP MANUAL MT26-31 - 06.2005...

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