Daewoo Doosan ADT MT25 MT26 MT31 MT36 MT41 Operation and Maintenance Manual MX519828 - PDF DOWNLOAD

MX519828 August 2014

ADT

Operation & Maintenance Manual MT25 / MT26 / MT31 / MT36 / MT41 MT25 / MT26 / MT31 - Serial Number 710655 and Up MT36 / MT41 - Serial Number 810109 and Up

Operation & Maintenance Manual MT25 / MT26 / MT31 /MT36 / MT41 ADT MT25 / MT26 / MT31 - Serial Number 710655 and Up MT36 / MT41 - Serial Number 810109 and Up

DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United States and various other countries around the world.

Copyright 2014 OperationDOOSAN and Maintenance Manual

MX519828 August 2014 Copyright Doosan 2011

1. Foreword

E

MT25/MT26/MT31 & MT36/MT41 OPERATING MAINTENANCE MANUAL MT25/MT26/MT31 Serial no. 710655 and up MT36/MT41 Serial no. 810109 and up

NOTE Operating & Maintenance Manuals are available in certain other languages. If other languages are required, please contact your local Moxy Dealer for

Manufacturer:

Dealer:

Moxy Engineering AS N - 6440 Elnesvågen - NORWAY Printed in Norway

Operating & Maintenance Manual

Part no.: 519828 1 2007 Edition: January

Table 1. ofForeword contents 1. Foreword .........................................................5-8 Foreword ..................................................................... 5 Safety information ....................................................... 6 Introduction ................................................................. 7

2. Safety Instructions ........................................... 9-40

Transmission oil list ..................................................... 131 Automatic Transmission Fluid (ATF) ........................... 132

7. Maintenance .............................................. 135 - 202 Maintenance precautions ............................................ 137 Maintenance table....................................................... 139 Initial 100 Hours Service ............................................. 142

3. Operating Controls ........................................ 41-80 Overview of the instrument panels and controls ......... 43 Instruments ................................................................. 44 Warning / indicator lights............................................. 49 Switches ..................................................................... 57 Controls ...................................................................... 65 Cab ventilation ............................................................ 71 Other cab equipment .................................................. 75

4. Running-in period ......................................... 81-86 1. Running-in operation ............................................. 83 2. Running-in services............................................... 84

5. Operating Instructions ................................. 87-120 Precautions on work sites ........................................... 89 Some simple rules to be observed prior to operation. 92 1. Starting the engine ................................................ 93 2. Operating the dump truck ...................................... 95 3. Parking the dump truck ......................................... 107 4. Stopping the engine .............................................. 107 5. Checks after stopping the engine .......................... 108 6. Loading and tipping ............................................... 108 7. Tyre handling ......................................................... 110 8. Cold weather ......................................................... 112 9. Long term storage ................................................. 113 10. Battery power assistance ...................................... 114 11. Towing the dump truck........................................... 115 12. Manual release of parking brake ........................... 115 13. Manual release of the tip valve............................. 116

Initial 500 Hours Service ............................................. 146 8 Hours / Daily Service ............................................... 149 40 Hours / Weekly Service .......................................... 159 500 Hours Service ...................................................... 162 1000 Hours Service .................................................... 178 2000 Hours Service .................................................... 191 4000 Hours Service .................................................... 197 Yearly recommended maintenance............................. 201

8. Technical Data .......................................... 203 - 220 Contents ..................................................................... 204 Measurements ............................................................ 205 Engine ......................................................................... 206 Transmission ............................................................... 206 Hydraulic system......................................................... 207 Tyre pressures ............................................................ 207 Electrical system ......................................................... 208 Metering conversion table ........................................... 209 Tool kit content (standard)........................................... 209 Tool kit content (optional) ............................................ 209 Performance chart ...................................................... 210 Engine and retarder brake capacity chart .................. 213 Torque limits for bolts .................................................. 216 Reference information................................................. 216 Consumeable parts..................................................... 216 Product signs .............................................................. 217 Periodic service........................................................... 219

9. Index ...........................................................221 - 226

14. Troubleshooting ..................................................... 117

6. Lubricants ................................................. 121 - 134 Lubrication schedule (MT25/26/31 Serial Number 710655 and up)................................... 123 Oil specification sheet (MT25/26/31 Serial Number 710655 and up)................................... 125 Filling capacities (MT25/26/31 Serial Number 710655 and up)................................... 126 Oil specification sheet (MT36/41 Serial Number 810053 and up)................................... 129 Filling capacities (MT36/41 Serial Number 810053 and up)................................... 130 2

Operating & Maintenance Manual

Table of contents

1. Foreword

Operating & Maintenance Manual

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1. Foreword

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Operating & Maintenance Manual

1. Foreword

Foreword This manual provides rules and guidelines which will help you use this dump truck safely and effectively.

This manual describes procedures for operating, handling, lubricating, maintenance, checking and adjustment.

It will help the operator to achieve peak performance through effective, economical and safe dump truck operation and maintenance.

• Keep this manual in the dump truck at all times and ensure that all personnel read it carefully before operating the dump truck.

• Continue studying the manual until proper operating are completely adopted as personal habit.

• This manual describes the basic techniques. The operator's skill will increase with correct knowledge of dump truck operation.

• Operation, inspection and maintenance should be carefully carried out, and safety must be given first prior ity.

If this manual has been lost or has become dirty and cannot be read, request a replacement manual from your local Moxy Dealer.

If you sell the dump truck, be sure to give this manual to the new owners.

Moxy Engineering AS cannot be held responsible for damage or injury caused through use of improper spare parts not specified by Moxy Engineering AS, improper handling, operation and utilisation of the dump truck in other ways than those described in this manual. Nor can Moxy Engineering AS be held responsible for unauthorised modifications or the non-adherence to local, national government or international regulations.

This Operating & Maintenance Manual may contain standard extra equipment and optional accessories that are not available in your area. Please consult your local Moxy Dealer for those items you may require.

Moxy Engineering AS aim to continuously improve the dump trucks and therefore retain the right to make design changes and improvements whenever we feel it will improve the efficiency of the dump truck.

Moxy Engineering AS also reserve the right to change data and equipment without prior notice, as well as amending instructions for maintenance and other service measures.

WARNING • This dump truck complies with EC directives 98/37/EC with amendments and 89/336/EC with amendments.

Dump trucks complying with the directives display the CE mark.

The dump truck must not be modified in such a way that it no longer complies with the EC directive.

• Improper operation and maintenance of this dump truck can be hazardous and could result in serious injury or death.

• Operators and maintenance personnel should read this manual thoroughly before operation or maintenance.

• Some actions involved in operation and maintenance of the dump truck can cause serious accidents, if they are not carried out in a manner described in this manual.

• The procedures and precautions given in this manual apply only to intended uses of the dump truck. If you use your dump truck for any unintended uses that are not specifically prohibited, you must be sure that it is safe for you and others. In no event should you or others engage in the prohibited uses or actions which are described in this manual.

• Moxy Engineering AS delivers dump trucks that comply with all applicable regulations and standards of the country to which it has been shipped. If this dump truck has been purchased in another country or purchase from someone in another country, it may lack certain safety devices and specifications that are necessary for use in your country. If there is any question about whether your product complies with the applicable standards and regulations of your country, consult your local Moxy Dealer before operating the dump truck.

• Safety descriptions are given in SAFETY INFORMATION on page 6 and in SAFETY INSTRUCTION,

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1. Foreword

Safety information Most accidents are caused by the failure to follow safety rules for the operation and maintenance of the dump truck. To avoid accidents, read, understand and follow all precautions and warnings in this manual and on the dump truck before operation and performing maintenance.

To identify safety messages in this manual, the following signal words are used:

NOTE

- This word is used for precautions that must be taken to avoid actions which could shorten the life of the dump truck.

CAUTION

- This word denotes safety messages for hazards which could result in minor or moderate injury if the hazard is not avoided. This word might also be used for hazards where the only result could be damage to the dump truck.

WARNING

- This word denotes safety messages where there is a potentially dangerous situation which could result in serious injury or death if the hazard is not avoided. These safety messages usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may also result in serious damage to the dump truck.

DANGER

- This word denotes safety messages where there is a high probability of serious injury or death if the hazard is not avoided. These safety messages usually describe precautions that must be taken to avoid the hazard. Failure to avoid this hazard may result in serious damage to the dump truck.

To identify labels on the dump truck, the following colours are used.

YELLOW & BLACK - These colours are used on safety labels where there is high/potential/moderate probability of death/injury if the hazard is not avoided.

GREEN & WHITE - These colours are used on information labels.

Know the capacity and limits of your dump truck!

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Operating & Maintenance Manual

1. Foreword

Introduction Intended use This Moxy articulated dump truck is designed to be used mainly for earth moving at sites, both on and off road conditions.

General description Moxy MT25, MT26, MT31, MT36 and MT41 are articulated, 6-wheel drive dump truck. The free-swinging rear tandem housing, and the special Moxy articulation system, provide excellent performance in soft and difficult terrain. The special body design ensures that a low centre of gravity is maintained and an even load distribution to front and rear wheels, for stability on uneven ground and for fast easy tipping. The Moxy dump truck is designed and manufactured to work under difficult conditions.

In addition, the wide range of optional equipment allows the dump truck to be used for several different applications.

Operators Dump body Engine bonnet

Head and side light

Hydraulic Tank

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1. Foreword

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Operating & Maintenance Manual

2. Safety Instructions

Safety Instructions

WARNING Read and follow all safety precautions. Failure to do so may result in serious injury or death.

This safety section also contains precautions for standard extra equipment and optional accessories.

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2. Safety Instructions

Content

2. Safety instructions ........................................... 9 - 40 1. Dump truck knowledge .................................. 11 2. General precautions ...................................... 11 3. Precautions before starting the engine.......... 16 4. When staring the engine ............................... 18 5. Do not go close to high-voltage cables.......... 18 6. Battery hazard prevention ............................. 19 7. Air conditioning system hazard prevention .... 20 8. Rules to follow when filling fuel or oil ............. 21 9. Expansion tank coolant level ......................... 21 10. Machine turning ............................................ 21 11.Emergency steering ...................................... 22 12. Travelling on slopes ....................................... 22 13. Operation of brakes ....................................... 22 14. Engine over speed (Emergency retarder) ..... 23 15. Wading .......................................................... 23 16.Dangerous loads (exhaust heated body) ...... 24 17. Welding on the dump truck ............................ 25 18. Top tailgate .................................................... 26 19. Engine bonnet ............................................... 27 20 Tiltable cab .................................................... 27 21. Body support ................................................. 29 22.Service position ............................................. 30 23. Wheel chocks ................................................ 30 24. Articulation lock ............................................. 31 25. Lifting/hoisting ............................................... 31 26. Dump truck transportation ............................. 32 27. High pressure ................................................ 32 28. Safety labels .................................................. 33

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Operating & Maintenance Manual

2. Safety Instructions

1. Dump truck knowledge Learn how to use the control devices, instruments and warning devices. Be sure you understand the meaning of the WARNING signs and other cautionary messages. Always know the dimension and performance limits of your dump truck.

Remember the check points and checking method of fluid levels.

2. General precautions, see also Precautions for Maintenance and Operating Instruction

2.1. Safety rules • ONLY trained and qualified personnel can operate and maintain the dump truck.

• Follow all safety rules, precautions and instructions when operating or performing maintenance on the dump truck.

• ALWAYS USE SEAT BELT DURING DRIVING! If there is instructor or passenger in the cab, be sure that they are seated on the instructor seat and are using their seat belt!

• Never operate the dump truck if you are under the influence of alcohol, medicines or other drugs.

• When working with other operators or persons on work site traffic duty, be sure all personnel understand all hand signals that are to be used.

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2. Safety Instructions

2.2. Clothing and personal protection items Avoid loose clothing, jewellery and loose long hair which may catch on controls or in moving parts and cause serious injury or death. Also, do not wear oily clothing because it is hazardous to your health and is flammable.

2.3. Unauthorised modification • Any modification made without authorisation from Moxy Engineering AS can create hazards.

• Before making a modification, consult your local Moxy Dealer. Moxy Engineering AS will not be responsible for any injury or damage caused by any unauthorised modification.

2.4. Getting on and off the dump truck • Always use handles and steps when entering and getting off the dump truck.

• Ensure safety, maintaining at least three-point contact of hands and feet with handles and steps.

• NEVER jump on or off the dump truck. NEVER get on or off a moving dump truck.

• Always clean off grease, oil, ice, snow and dirt to avoid slippery truck surfaces.

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2. Safety Instructions

2.5. Fire prevention for fuel and oil Fuel, oil and antifreeze can be ignited by a flame. Fuel is particularly FLAMMABLE and can be HAZARDOUS. • Keep flames away from flammable fluids.

• Stop the engine and do not smoke when refuelling.

• Tighten all fuel and oil caps securely.

• Refuelling and oiling should be carried out in well ventilated areas.

• Spilt fuel and oil must always be cleaned up immediately.

• Keep oil and fuel in a secure place and do not allow unauthorised persons to enter.

2.6. Precautions when handling at high temperatures I m m e d i a t e l y a f t e r o p e r a tions are stopped, the engine coolant, engine oil and hydraulic oil are at high temperatures, and are still under pressure. Attempting to remove the cap, drain the oil or coolant, or replace the filters may lead to serious burns.

Always wait for the temperature to fall, and follow the specified procedure when carrying out these operations.

• To prevent hot coolant from spurting out: 1. Turn engine off 2. Allow coolant to cool down.

3. Slowly loosen cap to relieve pressure before removing.

• To prevent hot oil from spurting out: 1. Turn engine off 2. Allow oil to cool down.

3. Slowly loosen cap to relieve pressure before removing.

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2. Safety Instructions

2.7. Fire extinguisher, first aid kit and warning triangle (optional equipment) • Know how to use the fire extinguisher (Distributor/ Dealer fitted).

If the fire extinguisher is missing, contact your local Moxy Dealer.

Location: Left hand side in the cab.

• If the first aid kit is present in the cab, keep it in its storage place.

Location: Left hand side in the cab, below the rear side window.

• If the warning triangle is present, keep it in its storage place.

Location: Toolbox in the right hand side fender.

• See also Safety equipment in chapter 3.

• Know what to do in case of fire. you

• Be sure you know the phone numbers of persons should contact in case of an emergency.

2.8. Precautions for optional accessories • When installing and using optional accessories, read the information related to the equipment in this manual.

• Do not use equipment or parts that are not authorised by Moxy Engineering AS. Use of unauthorised equipment or parts could create a safety problem and adversely affect the proper operation and useful life of the dump truck.

• Any injury, accidents, product failure resulting from the use of unauthorised attachments will not be the responsibility of Moxy Engineering AS.

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Operating & Maintenance Manual

2. Safety Instructions

2.9. Protection against falling objects and roll-over protection The cab on this dump truck is tested and approved to current ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) standards.

ISO 3471 ROPS ISO 3449 FOPS • This cab meets the requirements for objects falling onto the cab roof, and will protect the operator while he is remaining in the cab.

• This cab meets the requirements for roll-over protection.

A precondition for protection is that the operator USES THE SEAT BELT and remains in the cab. Therefore, hold onto the steering wheel if the dump truck should roll over.

DO NOT ATTEMPT TO JUMP CLEAR! • The approval sign for ROPS/FOPS is located on the fire wall underneath the bonnet.

• Structural damage, an overturn, modification, alteration or not permitted repair can affect the cab strength and there by void the certification • Consult Moxy Engineering AS or your Moxy Dealer to determine this structure’s limitations without voiding its certification.

2.10. Emergency exit • This dump truck is fitted with two emergency exits.

A

• Left door and front side window on right hand side.

• If door is blocked, you can get out through the front side window.

• Remove hammer (A) from storage location and break front side window.

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2. Safety Instructions

3. PRECAUTIONS before starting the engine

3.1. Safety at the work site • Before starting the engine, make sure that the bonnet is closed and thoroughly check the area for any unusual conditions that could be potentially dangerous.

• Before starting the engine, examine the terrain and soil conditions of work site. Determine the best and safest method of operation.

3.2. Fire prevention • Thoroughly remove wood chips, leaves, paper and other flammable material accumulated in the engine compartment, or other places on the dump truck.

THEY COULD CAUSE FIRE!.

• Marsh land, when dry, is highly flammable. Marsh land can self ignite even in low temperatures.

Always keep the engine and engine compartment clean!

• Check fuel, lubrication and hydraulic system for leaks.

Have any leaks repaired. Clean up any excess oil, fuel or other flammable fluids. (Check points - see daily maintenance "Walk around check") • Be sure that the fire extinguisher is present and working.

The fire extinguisher shall be located on left hand side in the cab.

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2. Safety Instructions

3.3. In operator's cab • Do not leave tools or spare parts laying around in the operator's cab. They may damage or break the control levers or switches.

They could also hit the operator and cause serious injury.

Always keep the tools in the tool box (in right hand side fender).

• Keep the cab floor, controls, steps and handrails free of oil, grease, ice, snow and dirt.

3.4. Ventilation for enclosed areas If it is necessary to start the engine within an enclosed area, provide adequate ventilation. Exhaust fumes from the engine can KILL.

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2. Safety Instructions

3.5. Precautions for mirrors, windows and lights • Remove all dirt from the surface of the windows and lights to ensure that you can see well.

• Adjust the rear view mirrors so that you can see clearly from the operator's seat, and always keep the surface of the mirrors clean. If any glass is broken, replace it with a new part.

• Check that the head lights, working lights and all other lights are installed to match the operating conditions. Check also that they light up properly.

4. When starting the engine • Walk around the dump truck just before you enter it, to check for people and objects that might be in the way.

• When starting the engine, sound the horn as alert.

• Fasten the seat belt and remain seated while in motion. Standing up is dangerous! Concentrate on and evaluate surroundings. Stop the dump truck if you are uncertain of how to operate safely.

• Slow driving is required to ensure hazard-free operation, especially on curves, narrow roads, hills/cliffs, bumpy or slippery ground. If the visibility is restricted and/or obstructed, designate a person to check and direct the work site traffic.

• Ensure that you keep a safe distance from other vehicles and nearby people.

Be sure that no persons or objects are situated in the articulation area or the overturn area (left and right hand side of the dump truck) before turning or driving.

Also make sure that no persons or objects are situated behind the dump truck before reversing or when tipping the load.

5. Do not go close to high-voltage cables • Going close to high-voltage cables can cause electric shock. Do not raise the body near high-voltage cables.

The following actions are effective in preventing accidents: • Wear shoes with rubber or leather soles.

• Use a signalman to give warning if the dump truck approaches too close to the electric cable.

• If the body should touch the electric cable, the operator should not leave the operator's cab.

The operator should remain in the cab until it has been confirmed that the electricity has been shut off.

• When carrying out operation near high-voltage cables, do not let anyone come close to the dump truck.

• Check with the electricity company about the safety zone and voltage of the cables before starting operations.

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Operating & Maintenance Manual

2. Safety Instructions

6. Battery hazard prevention • Battery electrolyte contains sulphuric acid and can quickly burn the skin and eat holes in clothing. If you spill acid on yourself,immediately flush the area with water.

• Battery acid could cause blindness if splashed into the eyes. If acid gets into the eyes, flush them immediately with large quantities of water and see a doctor at once.

• If you accidentally drink acid, drink a large quantity of water or milk, beaten egg or vegetable oil. Call a doctor or hospital immediately.

• When working with batteries ALWAYS wear safety glasses or goggles.

• Batteries generate hydrogen gas. Hydrogen gas is very EXPLOSIVE, and is easily ignited with a small spark or flame.

• Before working with batteries, turn the starter switch to the OFF position, and the battery main switch must be turned OFF. • Avoid short-circuiting the battery terminals through accidental contact with metallic objects, such as tools, across the terminals.

• When removing or installing, check which is the positive (+) and negative (-) terminal.

Removing the batteries (see figure): 1. Disconnect (-) terminal connected to the earth point.

2. Disconnect the battery cable between the batteries.

3. Disconnect (+) terminal connected to the starter.

When installing the batteries, carry out the procedure in the opposite order, 3 - 2 - 1.

• Tighten the battery caps securely.

• When removing any battery cap, wear rubber gloves to prevent electrolyte contact with the skin.

Battery main switch (OFF) (MT36/41)

1

• Tighten the battery terminals securely, check that the terminals are not loose by trying to move the battery cables by hand.

Loosened terminals can generate sparks and lead to an explosion.

3 2

Battery main switch (OFF) (MT25/26/31)

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2. Safety Instructions

7. Air conditioning system hazard prevention • The air conditioning system is filled with refrigerant (R134a).

• Always use safety glasses or goggles, gloves, boiler suit and protective footwear when inspecting, servicing and repairing the air conditioning system.

• Refrigerant R134a has a property that can cause frostbite if it comes into contact with bare skin or eyes.

• Always work on the air conditioning system in well ventilated places.

• High concentration of the refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst un consciousness. Very high concentration of the gas can even cause cardiac insufficiency.

Do not smoke when servicing the air conditioning system!

Worker protection rules, refrigerant The following worker protection actions must be taken if there is any contact with escaping refrigerant: • Refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst unconsciousness.

Very high concentration of the gas can even cause cardiac insufficiency. In all cases, get into fresh air and move the affected person from the risk zone. Contact a doctor.

• If larger quantities of fluid refrigerant come into contact with skin (frostbite), the injured area should be carefully warmed with luke warm running water and covered with a sterile compress. Contact a doctor.

• If fluid refrigerant comes into contact with a person's eyes (frostbite), rinse the eyes with lukewarm running water, min. 10 min. Contact a doctor.

• If fluid refrigerant is accidentally swallowed, there can be serious frostbite in the mouth and gullet. Rinse the mouth with water.

DO NOT INDUCE VOMITING. Contact a doctor.

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2. Safety Instructions

8. Rules to follow when filling fuel or oil • Spilt fuel and oil may cause you to slip, so always clean up immediately.

• Slowly loosen the caps to relieve pressure before removing the caps.

• Always check fuel/oil specifications (chapter 6, lubricants) before refilling.

• Always refill fuel and oil in a well-ventilated place.

• Always tighten the cap of fuel and oil fillers securely.

• Never use fuel for washing any parts.

9. Expansion tank coolant level 1. If it is necessary to refill coolant to the expansion tank, stop the engine and allow the engine and the expansion tank to cool down before refilling coolant.

2. Slowly loosen the caps to relieve pressure before removing the caps.

3. Always refill using pre-mixed coolant.

(See chapter 7, maintenance)

10. Machine turning This articulated dump truck has two frames and the design allows unrestricted turning between front and rear chassis.

Overturn of one frame while the other remains level is possible.

It is possible that the operator will not receive warning signs of an overturn, therefore: • Avoid high speed turning and hard braking in curves.

• Reduce speed, avoid sudden turning if travelling across slopes.

• T h e r e a r c h a s s i s ty decreases when tipping. Be alert

Operating & Maintenance Manual

s t a b i l i when body

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2. Safety Instructions

11. Emergency steering The emergency steering pump will be activated if the engine stops. It is possible to steer the dump truck when it is in motion, but the steering speed will be slower.

If the emergency steering light illuminates at truck speeds above approx.. 5 km/h: • Stop as soon as possible and park in a safe place!

Continued driving may result in uncontrollable steering.

• Correct the fault before operating the dump truck again.

If necessary, contact your Moxy Dealer.

12. Travelling on slopes • Travelling on hills, banks or slopes that are steep, can result in the dump truck starting to slide/slip or roll over.

• Always check ground conditions before travelling on slopes.

• Always travel straight up or down on slopes.

• Do not turn on slopes or travel across slopes.

Always go down to a flat place to perform these operations.

• Keep travel speed very low.

WARNING Ground conditions, gradients, friction, available traction and type of load is of vital importance for safe operation and stability on slopes.

13. Operation of brakes The service brakes must never be applied for long periods due to danger of fading (loss of braking effect due to overheating).

To avoid fading, depress the pedal firmly and release it after the speed is reduced.

Select a gear and adjust the speed in a downhill slope so that the speed can be controlled with the engine brake or engine and retarder brake, without the use of the service brake to hold the speed. Never use the service brake for long periods. Avoid racing the engine. See also Operating Instructions.

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2. Safety Instructions

14. Engine over speed (Emergency retarder) When the operator releases there foot off the accelerator, the exhaust brake is automatically engaged. Driving downhill with the accelerator pedal released, the engine rpm’s will increase, when the engine rpm's reach 2,200 the transmission retarder is activated, this will disengage when rpm’s drop to 1,800, the exhaust brake will continue to operate.

It’s called emergency retarder because the cooling capacity is not designed for continuous operation.

If the truck is on a downhill slope and the operator does not release there foot off the accelerator pedal, the exhaust brake is activated at 2,450 rpm’s to override the operator error. The transmission emergency retarder brake will be activated at 2,500 rpm.

To prevent engine damage due to the over-speed situation, the transmission control unit (TCU) will perform an automatic up-shift to the next gear, if engine reach's 2,700 rpm’s.

15. Wading Never drive into water (river beds, ponds, flooded pits, ditches etc.) without knowing the ground surface and depth. The bottom can be slippery, obstacles such as rocks/holes and other dangerous areas can be difficult to determine, and the force of a river current can be substantial. If it is found to be safe, drive slowly to avoid splashing. Do not stop unless absolutely necessary.

Be aware of reduced braking effect when brakes are wet.

The brake linings must be checked/replaced more often when driving in wet and swampy areas, because wear of the linings will increase (see 500 hours service for procedure).

The maximum wading depth is: MT25/MT26/MT31 - 780mm, i.e. up to the front fenders MT31 - 1100mm, i.e. up to the front fenders MT41 - 1250mm, i.e. up to the front fenders

NOTE Under no circumstances let water flow through the grill!

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2. Safety Instructions

16. Dangerous loads If the body is exhaust heated, dangerous loads such as explosives or inflammable materials like petrol's, oils etc. must not be transported.

In some countries there may be special national regulations for transportation of dangerous loads.

To blank off the exhaust heating, do as follows: • Always allow the dump truck to cool down before changing exhaust direction.

1. Remove the clamps on both the vertical exhaust pipe and the pipe which goes to the body.

2. Remove the plate which gives heating to the body (in the vertical exhaust pipe).

3. Remove the ring from the pipe which goes to the body and install it into the vertical exhaust pipe.

4. Install the plate which will blank the exhaust to the body (in the pipe which goes to the body) 5. Refit the clamps.

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2. Safety Instructions

17. Welding on the dump truck The transmission and the engine are equipped with electronic control units. Before welding on the dump truck: 1. Disconnect batteries.

2. Unplug the connectors on the electronic control units for the engine and the transmission. The units are located behind the cover on the back wall (behind the instructor seat back rest, if that is fitted).

3. Earth point should be less than 1 m from welding point.

4. There should not be sealings and bearings between the welding point and the earth point.

OFF

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2. Safety Instructions

18. Top tailgate For safe tipping: See Operating Instructions.

If top hinged tailgate is fitted to this dump truck, particular attention should be paid to the material handled in the interest of both safety and efficiency.

The top tailgate is suitable for materials which are both well fragmented and free floating, such as dry earth, gravel, sand, coal, etc. In such instances, discharge should be continuous during the whole cycle of tipping.

However, if the material is poorly fragmented or adhesive, such as clay, bulky boulders etc., it is imperative that a top tailgate is NOT fitted. Such materials do not have an even discharge and problems could arise during the tipping cycle when the material comes in contact with the top tailgate. Cases have been reported where the tailgate restriction has caused the front wheels of the dump truck to leave the ground. Such a situation creates instability of the front of the dump truck, and results in reduction of operator safety.

WARNING Moxy Engineering AS cannot be held responsible for any damage that may occur through improper use of the top hinged tailgate.

DANGER It is hazardous to work/stand underneath the tailgate while the body is raised!

The tailgate must be removed if any work is to be done inside the body while the body is raised.

Removal of the top tailgate: 1. Attach wire or chain to the lifting points. The tailgate shall be disassembled in three parts, tailgate arms (left and right) and the rear tailgate plate.

Be sure that wire or chain are attached to all three tailgate parts before disassembling.

2. Remove all screws (see arrows) on the tailgate (both sides) and lift off the tailgate parts.

Approx. weight: 1500 kg.

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2. Safety Instructions

19. Engine bonnet Do not open the bonnet when the engine is running. The bonnet is fitted with lockable bonnet opener on left hand side. The bonnet must always be closed and secured with the lock when operating the dump truck.

When the bonnet is open, make sure that the bonnet catcher for open position (on left hand side) secures the bonnet from falling down.

• To open the bonnet: 1. Depress the button on the handle grip on left hand side.

2. Lift the bonnet catcher.

3. Push up the bonnet.

4. Check that the bonnet catcher engages.

• To close the bonnet: 1. Push the bonnet forward.

2. Lift the bonnet catcher.

3. Push down the bonnet and see to that the lock engages.

DANGER It is hazardous to work/stand underneath the bonnet without applying the bonnet catcher!

Do not operate the dump truck with a raised and secured bonnet!

20. Tiltable cab Always secure the tilted cab with the support before service/inspection and other work/stand underneath the cab. The cab must always be closed and secured with the locks when operating the dump truck.

Before tilting the cab, check that there are no loose objects in the cab.

When the cab is tilted, make sure that the support secures the cab from falling down. To tilt the cab.

• To tilt the cab: 1. Lift the body and secure it with the body support (see item 21).

2. Stop the engine.

3 Open the bonnet and apply the bonnet catcher (see item 19).

4. Put a plastic bag or similar around the brake fluid reservoirs before the cab is tilted. To prevent brake fluid spillage.

5. The cab has two tilted positions: • Service position - Must be secured with the safety support, see below (item 8)

Operating & Maintenance Manual

27

2. Safety Instructions

• Top position - The cover behind the hydraulic tank has to be removed before tilting the cab to top position.

- If exhaust heating is fitted, this must also be removed.

- The cab must be fastened to a crane or similar when tilted for safety reason.

6. Remove one bolt on each side of the cab.

Spanner: 46 mm 7. Push up the cab by using the hydraulic pump (a) on left hand side. If hydraulic pump is not installed, crane has to be used.

• Make sure that the handle for up-and down pushing (b) is in the up-position (the illustration shows the down position).

8. In service position: Fasten the safety support (c) to the anchorage point at the cab and front frame, by using the bolts removed in item 6.

The safety support is to be found in the toolbox.

• To lower the cab: 1. Unscrew the safety support (c). Put it back to its storage place in the tool box.

a

2. Lower the cab by using the hydraulic pump (a) on left hand side. If hydraulic pump is not installed, crane has to be used.

• Make sure that the handle for up-and down pushing (b) is in the down-position (the illustration shows the down position).

3. Refit the bolt on each side of the cab.

4. Remove the plastic bags on the brake fluid reservoirs.

5. Close the bonnet.

6. Lower the body.

b

7. Refit the cover behind the hydraulic tank and the exhaust heating, if this was removed.

DANGER It is hazardous to work/stand underneath the cab without applying the safety support!

Do not enter the cab while it is tilted!

Do not operate the dump truck with a tilted and secured cab!

c

28

Operating & Maintenance Manual

2. Safety Instructions

21. Body support Always secure the raised body with the body support before service/inspection and other work underneath the body. The body support device is intended for empty body only!

• Engagement of the support device: 1. Raise the body.

2. Make sure that the parking brake is on (locked) before leaving the cab.

3. Lift the body support in top position.

4. Slowly lower the body towards the support device until firmly positioned.

5. Return the tip control lever to hold position.

6. Stop the engine and remove the starter switch key.

• Disengagement of the support device: 1. Start the engine.

2. Lift the body slightly.

3. Return the tip control lever to hold position when the body is off the body support.

4. Make sure that the parking brake is on (locked) before leaving the cab.

5. Lower the body support.

6. Lower the body.

DANGER It is hazardous to work/standunderneath the body without applying the body support device!

Do not operate the dump truck with a raised and secured body!

Operating & Maintenance Manual

29

2. Safety Instructions

22. Service position Prepare the dump truck before service, maintenance and other work on the dump truck. Take every precaution for safe work. If more than one person shall perform work, one person should supervise to maintain the safety.

1. Park on a level ground and apply the parking brake.

2. Apply the articulation lock (see item 24).

Block the wheels (see item 23).

3. Stop the engine and remove starter switch key if not necessary for the work. Disconnect the main switch on the front fender (left hand side).

4. Secure the dump truck from being operated by accident or by persons unauthorised by attaching a warning label to the steering wheel. Do not allow persons to approach the area unnecessarily.

5. Be aware of hot fluids and components.

6. Block up all lifted components to prevent them from falling during work/stand underneath.

Before starting up after work, make sure the dump truck is in good operating condition.

23. Wheel chocks Always place wheel chocks under the wheels to avoid spontaneous rolling: • when parking • during maintenance and other work • during transportation of dump truck.

30

Operating & Maintenance Manual

2. Safety Instructions

24. Articulation lock The lock prevents the dump truck turning when applied.

• Apply the lock: 1. Take out the spring cotter, lift the pin and swing the linkage forward into the hinge ear.

2. Insert the pin through linkage and ear and refit the spring cotter.

• Release the lock: 1. Take out the spring cotter, and remove the pin through the linkage and ear.

2. Swing the linkage backwards, insert the pin through the link age and ear, and refit the spring cotter.

The lock must always be applied: • During maintenance, greasing and other work.

• When lifting or hoisting the truck, see item 25.

• During dump truck transportation, see item 26.

25. Lifting / hoisting 1. Apply the articulation lock (see item 24).

2. Open and secure (see item 19) the bonnet.

3. Fit suitable lifting wires or chains to the hoisting points at both sides of the body and engine, and use a suitable lifting beam as shown.

Machine net weight: MT25: approx. 22,500 kg MT26 : approx. 23,500 kg MT31: approx. 25,150 kg MT36: approx. 28,800 kg MT41: approx. 29,200 kg incl. tailgate

WARNING Never lift or hoist a loaded truck, the points are intended for an empty dump truck only!

Operating & Maintenance Manual

31

2. Safety Instructions

26. Dump truck transportation 1. Apply the parking brake.

2. Apply the articulation lock.

3. Apply wheel chocks.

Fit suitable wires or chains to the tie down points as shown and tighten them up.

CAUTION Always transport the truck without load in the body!

27. High pressure Be aware of high pressure in the hydraulic system (with running engine and operated service brakes) and tyres. Do not strike or bend pressure hoses or tubes. Do not use bare hands for checking leaks, use shield as protection to avoid personal injury. Even a pin-hole size leak can penetrate the skin. Always release pressure before maintenance or servicing: Hydraulic: Accumulators contain oil under high pressure!

Always empty the accumulators before working on or opening the hydraulic system.

Procedure: • Stop the engine.

• Operate the brake pedal repeatedly until the accumulators are empty.

Accumulators can also be emptied through the accumulator test connectors.

Be aware that the accumulators will be recharged with oil when the engine is re-started.

Tyres: Release the pressure through the rim nipple before attempting to remove any embedded objects or removing tyre/rim assembly from the machine. The pressure inside the tyres is substantial and an explosion can cause damage and serious personal injury. Never heat or weld on rims or surrounding areas when the tyre is inflated. Stand behind the tread when inflating a tyre.

32

Operating & Maintenance Manual

2. Safety Instructions

28. Safety labels The following labels are related to safety and should always be present and easy to read. Do not cover labels with paint or similar: Cab certification.

The cab has been approved to current ROPS/FOPS standards. Structural damage, an overturn, modification, alteration or not permitted repair can affect the cab strength and thereby void the certification. Consult your Moxy Dealer to determine this structure’s limitations without voiding its certification.

Warning - use of top tailgate • Top tailgate is fitted on this dump truck.

• Pay particular attention to the material handled by dump truck with top tailgate.

• Wrong material and improper use of top tailgate can cause a DANGEROUS situation and reduce the operator's safety.

• Read the operating manual (safety instructions, item 18)

Warning - dangerous loads Warning - never coast in neutral • N e v e r c o a s t with the gear selector in the neutral position.

Operating & Maintenance Manual

• Explosive or inflammable loads must not be transport if the body is exhaust heated.

• Read the operating manual (safety instructions, item 16)

33

2. Safety Instructions

Warning - operation, inspection and maintenance • Improper operation and maintenance can cause serious injury or death.

Emergency exit • T h e e m e r g e n cy exit can be used by removing the hammer from the storage location and break front side window.

• Read the operating manual (safety instructions, item 2.10) before operation.

34

Operating & Maintenance Manual

• Read the manual and labels before operation and maintenance. Follow instructions and warnings in the manual and on labels on the dump truck.

• Always keep the manual in the cab. If this manual is lost, please contact your Moxy Dealer for a replacement.

2. Safety Instructions

Fire extinguisher • The fire extinguisher is located on the left hand side in the cab.

• Read

the

operat-

Warning - accumulators contain oil under high pressure • Always empty the accumulators before working on or opening the hydraulic system • Read the operating manual (safety instructions, item 27 and chapter 7, maintenance) before servicing

Warning - air conditioner • Refrigerant R 134a under high pressure.

• Read the operating manual (safety instructions, item 7 and chapter 7, maintenance) before servicing

Warning - welding precaution • Disconnect the batteries and unplug the connectors on the electronic control units before welding.

• Read the operation manual (safety instructions, item 17) before welding.

Operating & Maintenance Manual

35

2. Safety Instructions

First aid kit • The first aid kit (if fitted) is located o n t h e l e f t hand side in the cab, below the rear side window.

36

Operating & Maintenance Manual

2. Safety Instructions

Warning - limited visibility • Keep out of this area when the engine is running, the operator has limited visibility.

• To prevent serious injury or death carry out the following before moving the dump truck: • Be sure no one is on or near the dump truck.

• Sound horn to alert people

Warning - engine is running • Never open the bonnet with the engine running.

• To prevent serious injury stop the engine before opening the engine bonnet.

• Wait until all engine parts have completely stopped before touching them.

• Do not touch hot surfaces!

Fingers or hands can be

Note - sling and/or tie down point • Read the operating manual (safety instruction, item 25 and 26)for correct use of the s l i n g a n d / o r t i e d ow n

Warning - pinch danger • Keep clear, pinch danger in the articulation area.

• To prevent serious injury or death carry out the following before moving/turning the dump truck: • Be sure no one is on or near the dump truck.

• Sound horn to alert people nearby.

• Always use the articulation lock when servicing!

• Read the operating manual (safety instructions, item 24).

Operating & Maintenance Manual

37

2. Safety Instructions

Warning - body support • Do not stand underneath the body without applying the body support device.

• Always use the body support when working underneath the body.

• Empty body before body support is used.

• Read also the operating manual ( s a f e ty instructions, item 21) before Note - sling and/or tie down point • Read the operating manual (safety instruction, item 25 and 26) for correct use of the

Warning - accumulators contain oil under high pressure • Always empty the accumulators before working on or opening the hydraulic system • Read the operating manual (safety instructions, item 27 and chapter 7,maintenance) be-

MT25/MT26/MT31/MT36/MT41

ROPS/FOPS approval cab • Read the operating manual (safety instructions, item Note - sling and/or tie down point • Read the operating manual (safety instr uction, item 25 and 26)

38

Operating & Maintenance Manual

-

2. Safety Instructions

Note - check oil specification • Always check oil specifications before refilling.

• Read the operating manual (chapter 6, lubricants) before

Note - use correct type of grease • Always check grease specifications before refilling.

• Read the operating manual (chapter 6, lubricants) before

Warning - hot coolant can spurt out

• The exhaust pipes and nearby area may be hot. Fingers and hands can be burnt!

• If it is necessary to refill coolant to the expansion tank, stop the engine and allow the engine and the expansion tank to cool down.

• Use gloves when checking the transmission oil level or filling oil.

• Slowly loosen the cap to relieve pressure before removing the cap.

Warning - hot area!

Operating & Maintenance Manual

39

2. Safety Instructions

(Behind the hydr. tank)

(Behind the

Note - transmission

Note - fuel tank

Note - hydraulic tank

• Read the operating manual (safety instructions, item 2.5 and 8) before refilling oil.

• Read the operating manual (safety instr uctions, item 2.5 and 8) before refilling fuel.

• Read the operating manual (safety instructions, item 2.5 and 8) before refilling oil.

• Always check fuel specification (chapter 6, lubricants ) before refilling.

• Always check fuel specification (chapter 6, lubricants ) before

(Inside battery compartment)

(Inside battery compartment)

Warning - battery acid and gases

Warning - welding precaution • Disconnect the batteries and unplug the connectors on the electronic control units before welding.

• Read the operation manual (safety instructions, item 17) before welding.

• Always check oil specification (chapter 6, lubricants) before refilling.

Note - sling and/or tie down point • Read the operating manual (safety instruction,item 25 and 26) for correct use of the sling and/ or tie down point.

• Battery electrolyte contains sulphuric acid and can quickly burn the skin and eat holes in clothing. Flush the area with water if you have spilt acid on yourself.

• Batteries generate hydrogen gas.

Hydrogen gas is very explosive, and is easily ignited with a small spark or flame.

• Read the operating manual

40

Operating & Maintenance Manual

3. Operating controls

Operating Controls

Operating & Maintenance Manual

41

3. Operating Controls

Contents

3. Operating controls .......................................... 41-80 Overview of the instruments and controls .......... 43 Instruments ........................................................ 44 Warning / indicator lights .................................... 51 Switches ............................................................. 57 Controls .............................................................. 63 Cab ventilation .................................................... 71 Other cab equipment .......................................... 75

* Numbers refer to positions on the electrical circuit diagram 42

Operating & Maintenance Manual

3. Operating controls

Overview of the instrument panels and controls

WARNING Do not drive the dump truck until you are well acquainted with the location and function of instruments and controls. Read the following carefully, together with the chapter about operation.

• Check the instruments now and again. When abnormal values are discovered in time, precautions can be taken to prevent the occurrence of major damage.

• If red lamps light up, stop the dump truck as soon as possible at a safe place and take necessary precautions.

If you don't, safety could be endangered or the dump truck could be damaged.

• To be able to check the function of instruments and controls, the battery main switch must be connected and the starting switch key must be in position 1. See item 87.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

43

3. Operating Controls

Instruments Standard extra equipment and optional accessories are also shown and described.

1

2

Pos 1 2 3 4 5

3

4

Description Fuel gauge Engine revolution counter and hour meter Gear display Speedometer Transmission oil temperature gauge

5

Page 45 45 45 48 48

* Numbers refer to positions on the electrical circuit diagram 44

Operating & Maintenance Manual

Remarks

3. Operating controls

Instruments 1. Fuel gauge 30*

1

The gauge indicates fuel tank level from empty to full.

Tank capacity: MT25, approx. 290litres MT26, approx. 320 litres MT31, approx. 350 litres MT36, approx. 425 litres MT41, approx. 490 litres Fill up with diesel when necessary, and at the end of the

2

2. Engine revolution counter and hour meter 2* The counter indicates the engine rpm.

Normal revolution: • Low idle: 650 rpm ± 50 • Max. economic area: 1500 - 1900 rpm • High idle:

2430 rpm ± 50

• Max. allowed rpm:

2600 rpm

The electronic display can show four different screens, these are explained below, you depress button (A) to access these screens.

A

C 2.1 B Depress button A once D 2.2 E Depress button A once 2.3 Depress button A once 2.4

2.1. This display shows the clock (B) and the amount of hours the dump truck has been operating (C). (This screen will return to the last adjustment display selected when the dump truck is first switched on) 2.2. This displays the total distance travelled by the dump truck (D) and the distance travelled in the current measured journey (E).

To reset Trip counter: Hold button (A) for 3 seconds.

2.3. This displays the wet disc brake error codes. This display will automatically appear if the following error codes are reported: WDB 1: Temperature warning WDB 2: Temperature alarm WDB 3: Temperature sensor fault WDB 4: Reservoir low level warning WDB 5: Can Bus fault 2.4. This displays the engine water temperature. This display will automatically appear if temperature reaches 95°C, but will disappear when temperature drops to 93°C.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

45

3. Operating Controls

Instruments 3. Gear display 250* A. Shows gear ranges: Manual, 1st gear Manual, 2nd gear Manual, 3rd gear Manual, 4th - 6th gear Automatic mode, 1st - 6th gear • The bars will flash when the lock-up is disengaged.

B. Shows engaged gear 1,2,...etc. (In forward and reverse direction). When the pre-selected gear and the engaged gear are different, the digit will flash.

C. Shows driving-direction ("F" for Forward, "R" for Reverse, "N" for Neutral). When preselected driving direction gear is not engaged the digit will flash.

D. Starts flashing if error has been detected.

The main warning light for transmission failure (30) will also light.

If this wrench starts flashing: 1. Stop the dump truck on a safe place.

2. Select neutral gear position and apply the parking brake.

3. Check and note the error codes on the display, which will be shown at pos B and C when the gear selector is in neutral position. If more than one error has been detected, each error code will be shown for about 1 second.

4. Contact your Moxy Dealer (a short explanation of the codes is listed under troubleshooting, chapter 5).

NOTE

• •

•

If error codes are shown on the display, contact your Moxy Dealer in all cases.

All error codes (also the special features) shown on the display, if the wrench is flashing, will be stored in the memory of the transmission controller.

Error codes will only be shown when the gear selector is in neutral position.

* Numbers refer to positions on the electrical circuit diagram 46

Operating & Maintenance Manual

3. Operating controls

Instruments Gear display continued ...........

Special features: "NN" - shown on the display, means "waiting for gear selector neutral position" (Not Neutral). This will be shown if the starter switch is turned on while the gear selector is out of neutral position.

"EE" - will be shown if the display has a time-out, i.e.gets no data from the EST.Main reason:EST is in aTOTAL RESET MODE (due to output disconnection or external power supply at lines to the gear-solenoid valves) or is without power or data wire is not properly connected. "

"- will be shown on the display if the oil temperature is below -12°C. The transmission controller will not release any gear before the oil has been warmed up.

Keep the engine rpm above 1200 rpm and the gear selector in neutral position during the warm-up pe-

riod.

"BA"- will be shown on the display (flashes between BA and the actual gear position) if the transmission filters are clogged and need maintenance. The filter elements must be replaced immediately.

See 1000 hours service for procedure.

"WS"- will be shown on the display (flashes between WS and the actual gear position) if the oil temperature in the transmission sump (after the oil coolers) is too high.

Stop the dump truck immediately, select neutral gear position and run engine at mid-range speed for a while to cool down the oil temperature.

"WR"- will be shown on the display (flashes between WR and the actual gear position) if the oil temperature on the output of the retarder (before the oil coolers) is too high.

Stop the dump truck immediately, select neutral gear position and run engine at mid-range speed for a while to cool down the oil temperature.

"WT"- will be shown on the display (flashes between WT and the actual gear position) if the oil temperature on the torque converter is too high. Stop the dump truck immediately, select neutral gear position and run engine at mid-range speed for a while to cool down the oil temperature.

"WE"- will be shown on the display (flashes between WE and the actual gear position) if the engine rpm is too high, i.e. WE starts flashing if the engine rpm reaches 2500 rpm.

The main warning light (30) will also illuminate, and the emergency retarder will automatically engage.

The engine speed must be reduced immediately!

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

47

3. Operating Controls

Instruments 4. Speedometer 10* 4

The gauge indicates the dump truck travel speed in kilometres per hour (km/h) and miles per hour (mph).

5. Transmission oil temperature gauge 28* The gauge indicates the oil temperature in the transmission.

Normal range is 50 - 105°C, max. permitted for a short period 120°C. Normal operation temperature during retarder brake operation is up to 140°C, max. permitted for a short period 150°C. If the oil temperature in the transmission is too high during operation, the following warnings will show up: the main warning light (30),the wrench on the gear display (3) will flash and the display will show the letters WS, WR or WT (see explanation under item 3, gear display).

Stop the dump truck immediately, select neutral gear, and run engine at mid-range speed for a while to cool down the oil.

One reason for the high temperature could be use of a too high gear range.

* Numbers refer to positions on the electrical circuit diagram 48

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights Standard extra equipment and optional accessories are also shown and described.

21

22

30 31

13 14 15 23 24

25

33 34 35 43 44 45

12 20 10 11

Pos 10 11 12 12 13 14 15 20 21 22 23 24 25 25

Description Page Spare space 50 Spare space 50 Spare space 50 Wet disc brakes alarm (MT36/41 only) 50 (S/N. 810053 and up) Brake system warning light 50 Emergency steering warning light 50 Parking brake indicator 50 Engine coolant temperature warning 51 light Engine oil pressure warning light 51 Main warning light, engine failure 51 Battery charge warning light 51 Air filter warning light 51 Warning light, engine failure, 51 co-ordinator (S/N. -810035) Spare space (S/N. 810036 and up) 51

Pos 30 31 32 33 34 35 40 41 42 43 44 45

32 40 41 42

Description Page Main warning light, transmission failure 52 Spare space 52 Spare space 52 Spare space 52 Spare space 52 Lock-up indicator 52 High beam indicator 53 Engine brake indicator 53 Inter axle differential lock indicator 53 Direction light indicator 53 Retarder brake indicator 53 Automatic central lubrication indicator 53

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

49

3. Operating Controls

Warning / indicator lights

10

11

12

10. Spare space

11. Spare space

12. Spare space

12. Wet disc brakes (MT36/41 S/N. 810053 and up)

13

14

15

When wet disc brake failure occurs this lamp will illuminate.

See engine revolution counter for error code.

A warning buzzer will sound when error code is detected.

13. Brake system warning light, red 6-A2* When brake system hydraulic pressure is abnormal, this lamp will illuminate.

Can also light when the starter switch is turned on, switches off when the fluid pressure is at a normal level. If the light does not switch off, check for leakage.

A warning buzzer will sound if the pressure is too low on the supply line.

WARNING Do not drive a dump truck with the low brake pressure warning lamp illuminated.

14. Emergency steering warning light, red 6-B2* Lights if the emergency steering is activated.

It shall also light when the dump truck is stationary and during slow driving (indicates low oil supply from the emergency steering pump).

15. Parking brake indicator, red 6-C2* Lights when the parking brake (77) is engaged.

The light will flash and a buzzer will sound if a gear is selected while the parking brake is on.

* Numbers refer to positions on the electrical circuit diagram 50

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

20

21

22

20. Spare space

21. Spare space

22. Main warning light, engine failure, red 7-C1* Lights and flashes if there is an engine /engine controller failure.

23

24

25

Stop the engine (possible fault) immediately and contact your Moxy Dealer.

23. Battery charge warning light, red 7-A2* Lights if the battery charging voltage is too low (less than 24 volts). Check alternator, multi-groove belt and regulator.

24. Air filter warning light, red 7-B2* Lights if the engine air filter is clogged and needs maintenance. See 1000 hours service for procedure.

25. Spare space (S/N. 810036 and up)

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

51

3. Operating Controls

Warning / indicator lights

30

31

32

30. Main warning light, transmission failure, red 8-A1* Lights if there is an transmission / transmission controller failure. Check the gear display (3) for error codes and contact your Moxy Dealer.

A short explanation of the error codes are listed under troubleshooting, chapter 5.

31. Spare space

33

34

35 32. Spare space

33. Spare space.

34. Spare space

35. Lock-up indicator, green 8-C2* Lights when the automatic lock-up clutch for transmission is connected.

* Numbers refer to positions on the electrical circuit diagram 52

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights 40. High beam indicator, blue 9-A1*

40

41

42

Lights when high beam (switch 80B) on the headlights are activated.

41. Engine brake indicator, orange 9-B1* Lights when the engine brake is engaged (throttle pedal released).

43

44

45 42. Inter-axle differential lock indicator, orange 9-C1* Lights when the inter-axle differential lock is engaged (switch 76)

43. Direction light indicator, green 9-A2* Flashes when direction indicator (switch 80 E/F) or hazard light (switch 63) is activated.

• Will flash fast if an external direction indicator bulb is burnt out.

(Accumulators to market demand).

44. Retarder brake indicator, orange 9-B2* Lights when the retarder brake is engaged (switch 62)

45. Automatic central lubrication indicator (Lincoln lubrication system), yellow 9-C2* Lights if there is a failure in the system, blink codes for the indicator, see next page.

Lights also when the starter switch is turned on. Switches off when the automatically test cycle is done.

The system performs all operation automatically. After the starter switch is turned on or is in operation the pump will at 30 minutes interval supply measured quantities of grease to all the lubrication points.

NOTE If there is a failure in the system, it is only possible to run the dump truck in 2nd gear until the failure is corrected. continued overleaf * Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

53

3. Operating Controls

Troubleshooting for Lincoln lubrication system Fault

Possible Cause Power supply interrupter, segment display for On/h is not lit

The pump motor does not run stirring paddle does not turn

Remedy Check the power supply (connection, lines) and fuses.

If necessary rectify the fault and / or replace the fuses.

Check the line leading from the fuses to the Power supply from control p.c.b pump plug. to motor interrupted electric motor Check the power supply to the motor. If necesdefective. sary replace the motor.

Defective control printed board

Replace the control p.c.b

Defective operator key of the membrane keypad.

*EP* display is lit. Replace housing and membrane keypad.

Defective piston detector (initiator)

Remove main line towards the monitored divider valve.

Unscrew the piston detector.

Pump motor does not stop dispensing (30 minutes monitoring time)

Blockage in the system

Check the piston detector by introducing an iron pin into the borehole of the detector, maintain it there for more than 2 seconds and pull out again. If then the pump switches off a blockage may exist. If the pump does not switch off, check cable connections towards the pump.

Cable connections from the piston Check cable connections towards pump. detector towards the pump interIf necessary, replace piston detector with conrupted. necting plug.

Defective control p.c.b

Replace the control p.c.b

Reservoir empty. *LL* displays on Fill up the reservoir with clean grease. Let the the membrane keypad is flashing. pump run (trigger additional lubrication cycle, see next page 55) until lubricant shows at all lube points.

NOTE: Depending on the ambient temperature Pump does not deliver lubricant and/or sort of lubricant it may take 10 minutes of and *Er* display on the memoperation before the pump elements reach their brane keypad is flashing full lubricant output. Therefore, trigger several additional lube cycles.

The pump does not deliver lubricant

Air bubbles in the lubricant

Trigger an additional lubrication cycle (see next page 55). Loosen the outlet fitting or the main line on the pressure relief valve. The lubricant must penetrate without air bubbles.

NOTE: When push-in type fittings are used, the high-pressure hose, which is under pressure, cannot be easily disconnected from the pressure relief valve. For this purpose, loosen the pressure relief valve or, if exists, the filling nipple on the pressure relief valve in order to relieve the high-pressure hose.

Unsuitable lubricant has been used

Renew the lubricant (for list of correct lubricants see section 6 - Lubricants

Suction hole of the pump element clogged

Remove pump element. Check suction hole for foreign particles. If there are any , remove them.

Pump piston worn Check valve in the pump element defective or clogged

Replace pump element

* Numbers refer to positions on the electrical circuit diagram 54

Operating & Maintenance Manual

3. Operating controls

Located under the cover

Test

• In order to check the system a single lubrication cycle can be performed.

1. Starter switch turned on.

2. Depress the test button (1) (on the membrane keypad located on the lubrication pump) for 2 seconds. The system will run a single lubrication cycle test.

1

45. Automatic central lubrication indicator (Groeneveld lubrication system), yellow 9-C2* Lights if there is a failure in the system, blink codes for the indicator, see next page.

Lights also when the starter switch is turned on. Switches off automatically when the test cycle is done.

The system perfor ms all operations automatically. After the starter switch is turned on or is in operation the pump will at 30 minutes interval supply measured quantities of grease to all the lubrication points.

NOTE If there is a failure in the system, it is only possible to run the dump truck in 2nd gear until the failure is corrected.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

55

3. Operating Controls

Warning / indicator lights Blink codes for the automatic central lubrication indicator: Blink codes

Cause/Meaning

The light flashes 4 times once (0.5s on/0.5s off) The automatic central lubrication is activated. as soon as the starter switch has been turned on: The light does not flash when the starter switch 1. The system is not powered. Check fuses and is turned on: connection to earth and replace if necessary.

2. Lamp or wiring to lamp could be defective.

Check lamp and wiring and replace if necessary.

Minimum grease level in the reservoir has been reached. Refill the reservoir as soon as possible, see 40 hours service.

The light flashing for 2 minutes (0.5s on/0.5s off) at the beginning of each cycle:

The light continuously light for 2 minutes at the Insufficient grease pressure. Contact your Moxy end of the pumping phase: Dealer.

The light continuously light after starter switch has been turned on:

System out of order! Immediate action is required.

Possible causes: • Insufficient grease pressure during 10 consecutive cycles (or 10 consecutive times in the same main pipe channel). Check cause and reset by depress-ing the test button (on the reservoir) for at least one second while the starter switch is turned on.

• Reservoir empty; refill the reservoir and after that depress the test button (on the reservoir) for at least one second while the starter switch is turned on.

The light flashing during one complete cycle (2.0s on/2.0s off):

Single test run being executed (see "test")

The light flashing continuously (0.2s on/0.2s off):

Continuous cycle test run being executed (see "test")

Located under the cover

Test

• In order to check the system a single lubrication cycle can be performed.

1. Starter switch turned on.

2. Depress the test button (on the reservoir) for 3 to 5 seconds. The system will run a single cycle test. During this test the light will flash (2.0s on/2.0s off).

Test button

• I n o r d e r t o p r o v i d e a d ditional grease to all lubrication points (i.e after cleaning the dump truck) or to vent the system, a continuous lubrication cycle run can be performed.

1. Starter switch turned on.

2. Depress the test button (on the reservoir) for more than 6 seconds.

The system will perform a continuous lubrication cycle run.

During this run the light will flash (0.2s on/0.2s off). The continuous test cycle ends after the starter switch has been

* Numbers refer to positions on the electrical circuit diagram 56

Operating & Maintenance Manual

3. Operating controls

Switches Standard extra equipment and optional accessories are also shown and described.

50

51

52

53

54

55

63

60

76

64

61

77

65 62 70

71

72

Pos 50 51 52 53 54 55 60 61 62 63 64 65 70 71

72 73 74 75 76 77

73

74

75

Description Main light switch Cab light Rotating beacon switch Working light and extra high beam Spare space Working and back-up lights Spare space Spare space Retarder brake switch Hazard light switch Spare space Test switch for brake warning light Mirror heating switch Electrically heated driver's seat switch (MT25/26/31 S/N.- 710707) (MT36/41 S/N. -810127) Spare space Spare space Spare space Engine controller switch for code reading Inter-axle differential lock Parking brake switch

Page 56 56 56 56 56 56 57 57 57 57 57 57 58 58

Remarks

Optional Optional Optional

Optional Optional

58 58 58 58 59 59

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

57

3. Operating Controls

Switches

50

51

50. Main light switch 90*

52

1st position, Side lights.

When the switch is set to 1st position, the side/licence plate lights illuminates.

2nd position, Headlights.

When the switch is set to 2nd position the headlights (high or low beam according to position of column switch (80)) will also illuminate. Built-in light.

51. Cab light 93* Push the switch to light the cab.

Turn off during operation. Built-in light.

52. Rotating beacon switch 92* Push switch to activate the rotating beacon on top of the cab roof. Built-in light.

53

54

53. Working lights and extra high beam 20*

55

I

I

0

0

II

II

Push the switch to activate the lights.

Will only be activated if the main light switch (50) is switched on to 2nd. position.

Built-in light.

The switch has three positions: I. The extra high beam will light when the high beam on the column switch (80) is switched on.

0. Neutral, the lights are switched off.

II. The working lights will light.

54. Spare space

55. Working and back-up lights 38* Push the switch to activate the lights.

Will only be activated if the main light switch (50) is switched on.

Built-in light.

The switch has three positions: I. The back-up light will light when the reverse gear is engaged.

0. Neutral, the lights are switched off.

II. The working lights will light. * Numbers refer to positions on the electrical circuit diagram 58

Operating & Maintenance Manual

3. Operating controls

Switches

60

61

62

60. Spare space

61. Spare space

62. Retarder brake switch 47* When the operator releases there foot off the accelerator, the exhaust brake is automatically engaged. Driving downhill with the accelerator pedal released, the engine rpm’s will increase, when the engine rpm's reach 2,200 the transmission retarder is activated, this will disengage when rpm’s drop to 1,800, the exhaust brake will continue to operate.

It’s called emergency retarder because the cooling capacity is not designed for continuous operation.

If the truck is on a downhill slope and the operator does not release there foot off the accelerator pedal, the exhaust brake is activated at 2,450 rpm’s to override the operator error. The transmission emergency retarder brake will be activated at 2,500 rpm.

To prevent engine damage due to the over-speed situation, the transmission control unit (TCU) will perform an automatic up-shift to the next gear, if engine reach's 2,700 rpm’s.

An engine/transmission over-speed will be indicated as a warning to the operator in the gear display. If the overspeed situation is not reduced but increased, the TCU will store an over speed error situation at 2,600 rpm's.

Push the switch to engage the retarder brake.

The retarder brake will only engage if the throttle pedal is fully released, lock-up connected and a gear is selected.

Built-in light.

Indicator light (44) will light when the retarder brake is engaged.

63

64

65

63. Hazard light switch 89* Push switch to activate the hazard light, all direction indicators will flash at the same time. An indicator light (43) on the instrument panel will flash concurrently. Built-in light.

64. Spare space

65. Test switch for brake warning light 5* Push the switch and check that the warning light for brake fluid circuit failure (13) lights up.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

59

3. Operating Controls

Switches

70

71

70. Mirror heating switch 94*

72

Push the switch to heat the external mirrors for ice and condensation removal. Built-in light.

Engage only when necessary!

71. Electrically heated driver's seat switch 205* (MT25/26/31 S/N. -710707) (MT36/41 S/N. -810127) Push the switch to activate the heating of driver's seat.

Built-in light.

72. Spare space

73

74

73. Spare space

75

ECU "0"

74. Spare space

Coo 75. Engine controller switch for code reading (S/N. - 810034) Push the upper side to pos "ECU" to read the codes for the engine controller. Push the lower side to pos "Coo" to read the codes for the co-ordinator.

The symbol you see on this picture is not like the actual symbol

75. Engine controller switch for code reading (S/N. 810035 -) Push the lower side to read error codes for "ECU" (engine controller) and "Coo" (co-ordinator).

* Numbers refer to positions on the electrical circuit diagram 60

Operating & Maintenance Manual

3. Operating controls

Switches

76. Inter-axle differential lock 77* Push the switch to engage the inter-axle differential lock.

To engage the inter-axle differential lock, the dump truck must be stationary and the gear selector must be set to neutral (N) position.

An indicator light (42) will light when the lock is engaged.

Built in light.

NOTE Engage only: • when the dump truck is stationary.

• when necessary!

77. Parking brake switch

77

0

Lock device

I

The parking brake is on (locked) when the switch is in the backward position. An indicator light (15) will light when the parking brake is on.

Push the lock device to release the parking brake.

In the forward position the parking brake is off (released).

The parking brake must not be applied when the dump truck in motion unless in an emergency situation. Indicator light (15) and a buzzer will sound if a gear is selected while the parking brake is on (locked).

CAUTION Do not drive the dump truck if the fluid pressure is below normal pressure (indicator light 13 and buzzer). The parking brake will not be fully released, and the service brakes may not have max. braking effect.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

61

3. Operating Controls

* Numbers refer to positions on the electrical circuit diagram 62

Operating & Maintenance Manual

3. Operating controls

Controls Standard extra equipment and optional accessories are also shown and described.

89

80

81

82

86

85

90

88 87 83

Pos 80 81 82 83 84 85 86 87 88 89 90

84

Description Column switch Steering wheel Steering column Brake pedal Throttle pedal (accelerator) Gear selector Tip control lever Starter switch Cigarette lighter Emergency exit Cab ventilation

Page 62 64 65 65 66 67 67 67 68 69

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

63

3. Operating Controls

Controls

80. Column switch 16* B C

The column switch is a multi-function switch for main lights, horn, direction indicators and windscreen wiper/washer.

Main lights (A, B, C):

A

A. Low beam (when switch 50 is in position 2) B. High beam (when switch 50 is in position 2), indicator 40 will light.

C. High beam flash. Automatic return.

D. Horn, centre button automatic return.

D

E. Right turn, all right direction indicators flash.

Indicator light 43 flashes correspondingly.

E

F. Left turn. All left direction indicators flash.

Indicator light 43 flashes correspondingly.

F

* Numbers refer to position on the electrical circuit diagram 64

Operating & Maintenance Manual

3. Operating controls

Controls

G. Windscreen wiper. Turn handle. Positions: 0 OFF G

J interval I low speed II high speed

H

H. Windscreen washer, push outer ring to activate the washer monitor. At the same time, the wiper wipes some times after releasing the ring.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

65

3. Operating Controls

Controls 82. Steering column The steering wheel is fitted on an adjustable column for comfortable reach and easy operation.

• Height adjustment - lift lever up to unlock.

• Tilt adjustment - push lever down to unlock.

• Confirm that the steering column is fixed before operating the truck.

WARNING Do not adjust position while driving!

* Numbers refer to position on the electrical circuit diagram 66

Operating & Maintenance Manual

3. Operating controls

Controls 83. Brake pedal The pedal controls the main brake (service brake). When depressing the pedal, the rear stop light will light. Braking effect depends on pedal position. Depress pedal gradually, and learn to associate braking requirements for loaded and unladen dump truck.

Do not use the pedal for long period retardations, i.e. loaded downhill. This will overheat and damage the disc brake.

CAUTION If warning for brake system failure lights up (warning light 13), stop the dump truck immediately!

84. Throttle pedal (accelerator) The pedal controls the engine speed electronically.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

67

3. Operating Controls

Controls

85. Gear selector 236* The dump truck is equipped with a fully automatic transmission with 6 forward and 3 reverse speeds. Gear shift pattern is speed and engine load dependent. Preselection of gears is possible. The gear display (3) on the dashboard will always show the engaged gear position.

Pos N: Neutral gear position

Depress the knob on top of the gear selector when shifting from neutral to forward or reverse position.

Also, always depress the knob when shifting directly between forward and reverse direction.

Pos V: Forward drive position.

Automatic gear shift between 1st-6th gear according to speed and engine load.

For preselection of gear, push the selector to the right (+) for upshifting or to the left (-) for downshifting.The selected gear will then be engaged when the speed matches the set points.

If the gear selector is pushed either to the left or right, manual gear shifting will take place.

The gear selector must then be pushed in order to change gear.

Manual gear shifting will also take place if the knob on the top of the gear selector is depressed while driving in automatic. To return to automatic gear shifting while driving in manual, depress the knob on top of the gear selector.

Pos R: Reverse drive position:

Manual gear shift between 1st-3th gear according to speed and engine load.

The transmission will always select the 1st reverse when the gear selector is set to "R".The selected gear is engaged directly if the dump truck is stationary.

The gear selector has to be pushed in order to change gear.

For preselection of gear, push the selector to the right (+) for upshifting or to the left (-) for downshifting.

See also chapter 5, Operating Instructions

NOTE The knob on top of the gear selector has three functions: 1. Depress the knob when shifting from neutral to forward or reverse position.

2. Depress the knob when shifting directly between forward and reverse direction.

3. Depress the knob to change between automatic and manual gear shifting.

* Numbers refer to position on the electrical circuit diagram 68

Operating & Maintenance Manual

3. Operating controls

Controls 86. Tip control lever

1

The lever controls the body lifting and lowering.

The lever has 3 positions:

2 3

1. Lower (body down/power down).

2. Hold (hold and floating position).

3. Lift (body up).

The lever are electronically locked in the lower position, and have spring return from lower to hold.

Always keep the lever in hold position during loading and driving.

Check that the body is resting on the frame rubber pad during loading and driving.

A warning light (32) will light when the body is lifted (i.e. when the body is not resting on the frame rubber pads).

87. Starter switch 50* The starter switch is key operated, and has 4 positions.

P = Park (key removable) 0 = Power off (key removable) I = Power on (drive position).

II = Starting position (key returns back to pos. I when released).

WARNING Do not turn the key to off position if you do not intend to stop the engine. The engine has a key stop and requires neutral position on the gear selector to start again.

88. Cigarette lighter 51* Push in to activate the heating function. Automatic return when hot.

Can also be utilised as a 24 Volt / 10 amp power source.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

69

3. Operating Controls

Controls

A

89. Emergency exit • This dump truck is fitted with two emergency exits.

• Left door and front side window on right hand side.

• If the door is blocked, you can get out through the front side window.

• Remove hammer (A) from storage location and break front side window.

* Numbers refer to position on the electrical circuit diagram 70

Operating & Maintenance Manual

3. Operating controls

Cab ventilation

90. Cab ventilation

1

2

3

4

1. Ventilation fan switch 55* Turn switch to operate the 3-speed cab fan.

The fan must be used together with both the heater unit and the air conditioner. The fan must be on (1st, 2nd or 3rd speed) to operate the air conditioner.

2. Air flow regulator 55* Selects direction of the air flow, either towards the driver's feet or towards the windows (front windscreen, side windows and back window).

Turning counter clockwise to increase the air flow towards the driver's feet.

Turning clockwise to increase the air flow towards the windows.

3. Heater regulator 55* Adjust air heating with the knob. The air is heated by the engine coolant. Turning clockwise increases heating.

4. Air conditioner switch 55* Push the switch to activate the air conditioner system.

A compressor (engine mounted) and a cooling element cools the air when the engine is running and this air conditioner switch is set to on.

The intake air is filtered before it enters the cab. All nozzles, except nozzles for the front windscreen, are adjustable, and air may be directed in the desired direction. It is also possible to close the nozzles.

General about heat and ventilation

• Keep the door and window shut.

• Always open the nozzles when operating the dump truck.

• Direct the air flow so that it does not blow straight on uncovered skin.

• Always turn the fan on (1st, 2nd or 3rd speed) when operating the dumptruck and adjust fan speed until it feels comfortable in the cab.

• When using air conditioner, do not direct the air flow directly towards the windows, it can cause steamy windows.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

71

3. Operating Controls

Cab ventilation Setting heat and ventilation

1

2

3

4

Without air conditioning How to get...... ......maximum heat:

• • • •

All nozzles fully open.

Heater regulator (90.3) on max., i.e right position Fan switch (90.1) on max, i.e. speed 3.

Air flow regulator (90.2) to driver's feet i.e. left position.

If condensation forms, see "......remove condensation from all widows.

1

2

3

4 ...... pleasant working temperature:

• All nozzles fully open.

• Heater regulator (90.3) on max., i.e. right position • When the correct temperature has been obtained, turn heater regulator (90.3) (left) until you maintain the desired temperature.

• Air flow regulator (90.2) turned to the position which feels most comfortable.

• Fan switch (90.1) set to speed 1 or 2.

1

2

3

4 ......fresh air in cab:

• All nozzles fully open.

• Heater regulator (90.3) on min., i.e. left position • Air flow regulator (90.2) on max. air flow towards the driver's feet, i.e. left position.

• Fan switch (90.1) on max, i.e. speed 3.

* Numbers refer to position on the electrical circuit diagram 72

Operating & Maintenance Manual

3. Operating controls

Cab ventilation Setting heat and ventilation

1

2

3

4 Without air conditioning How to get...... ......rid of condensation and ice on all windows:

• Nozzles towards the windows fully open.

• Heater regulator (90.3) on max., i.e. right position • Air flow regulator (90.2) on max. air flow towards the windows, i.e. right position.

• Fan switch (90.1) on max, i.e. speed 3.

This instruction is a basic recommendation, and each driver should learn to set and regulate the heating/ventilation unit, to give the correct temperature without draft and achieve best working environment.

CAUTION Ensure good ventilation!

Do not operate the dump truck without ventilation, or with the cab entirely closed, unless the fan is on.

Poor ventilation can cause drowsiness (lack of oxygen).

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

73

3. Operating Controls

Cab ventilation

1

2

3

4

Air conditioner How to get...... ......a pleasant temperature quickly:

• Nozzles towards the driver's feet fully open.

• Heater regulator (90.3) on min., i.e. left position • Air flow regulator (90.2) on max. air flow towards the driver's feet, i.e. left position.

• Fan switch (90.1) on max, i.e. speed 3.

• Switch (90.4) pressed down, i.e. air conditioner engaged.

1

2

3

4 When the temperature has been lowered to the level you want:

• • •

1

2

3

Turn the fan switch (90.1) to the position which maintains the desired temperature.

Turn the air flow regulator (90.2) to the position which feels most comfortable.

Adjust the nozzles towards the driver to a comfortable position.

4 ...... rid of air humidity in the cab:

• All nozzles fully open.

• Heater regulator (90.3) on max., i.e right position • Air flow regulator (90.2) on max. air flow towards the windows, i.e. right position.

• Fan switch (90.1) on max., i.e speed 3.

• Switch (90.4) pressed down, i.e air conditioner engaged.

• In very cold countries, use of the air conditioner will retain humidity in cab air which may become too dry through heating.

This instruction is a basic recommendation, and each driver should learn to set and regulate the air conditioning unit, to give the correct temperature without draughts and achieve best working environment. * Numbers refer to position on the electrical circuit diagram 74

Operating & Maintenance Manual

3. Operating controls

Other cab equipment Driver's seat The seat is air-sprung with a separate air compressor and adjustable in height, tilt, back support and lengthwise position.

Adjust the seat to the desired position. Always use the safety belt when operating the dump truck.

Seat adjustment.

A. Backrest angle adjustment B. Armrest angle adjustment Can be lifted for easy access, and the inclination of the arm rests are adjustable for comfortable operating position.

C. Fore and aft slide adjustment Lift lever up and slide the seat to a suitable position release lever.

D. Thigh support adjustment (3 positions) E. Seat heater (MT25/26/31 S/N. 710708-) (MT36/41 S/N. 810128-) The seat can be heated by pushing the switch.

F. Headrest fore and aft adjustment G. Adjustable damper control

WARNING For one seated occupant. Do not adjust seat when vehicle is in operation. Keep clear of all moving parts. Installation and maintenance should be carried out by authorised and competent personnel.

71.

70

71

72

Electrically heated seat.

(MT25/26/31 S/N. -710707) (MT36/41 S/N. -810127) The seat can be heated by pushing the switch.

Refer to item 71 in this chapter.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

75

3. Operating Controls

Other cab equipment

Instructor seat There is one seat for instructor, on the left side of the driver seat. The seat cushions are spring-loaded and will return to upright position when released. The seat are fitted with safety belt which is recommended for use during driving, both for safety and comfort.

Internal door opener • Push up handle to open the door.

External door opener/lock The door is fitted with lockable door opener.

• Depress the button on the handle grip to open the door.

• The door can be locked from outside by using the door

* Numbers refer to position on the electrical circuit diagram 76

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Side window There are 4 different opening positions by two locking mechanisms at the upper edge of the top windows.

• To open the window: Lift both lock arms to a suitable position.

• To close the window: Push window completely upward and check that the window locks are in the locked position.

Safety equipment If the safety equipment is present, always keep it on its storage place and make sure that it is in order: • First aid kit (optional equipment)

• Fire extinguisher, 2 kg, ABE class II powder. (Distributor / Dealer fitted)

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

77

3. Operating Controls

Other cab equipment

• Warning triangle (located in right hand side fender).

(Optional equipment)

Ashtray

Retractable roller sun blind on front windscreen

Cab light The cab light switch has three positions: • On • Off • Door activated (or switch on the instrument panel)

* Numbers refer to position on the electrical circuit diagram 78

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Radio/CD player 201,212* The radio has following security features: Detachable panel, security warning sticker and identification number.

If any of the security features are missing, contact your local Moxy Dealer.

1.

Detachable panel Take the detachable panel with you when leaving the dump truck. Keep it in its protective cover. Always replace the detachable panel before starting to drive.

• Remove the panel by depressing button 2.

2

• Replace the panel starting with the left-hand side of the radio. Then push the panel until it clicks into position.

2.

Security warning stickers • This "security" warning sticker shall be fitted on your dump truck window.

3.

Identification number • This radio has a unique identification number (printed on the "security card"). This card is required as proof of ownership if the radio is stolen, if the detachable panel is lost or if requesting service.

• The "security card" shall be removed before installing the detachable panel.

Do not keep the "security card" in your dump truck.

4.

Operating Manual for the Radio/Cassette player

For operation of the radio, see separate Operating Manual.

If the Operating Manual for the radio is missing, contact your local Moxy Dealer.

* Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

79

3. Operating Controls

* Numbers refer to position on the electrical circuit diagram 80

Operating & Maintenance Manual

4. Running-in period

Running-in period

Operating & Maintenance Manual

81

4. Running-in period

Content

4. Running-in period ............................................ 81 - 86 1. Running-in operation ..................................... 83 2. Running-in service ........................................ 84

82

Operating & Maintenance Manual

4. Running-in period

1. Running-in operation Each new dump truck requires careful operation the first 100 hours (refer to hour meter) to break in (run-in) all moving parts.

Follow instructions below during this period: 1. Start engine as described in "Operating Instructions"(chapter 5) . Run engine at low idle speed until pressure in the various circuits is normal (i.e. brake system warning light switched off, also see chapter 3).

2. Warm up by operating the dump truck at low load and reduced rpm until all gauges show normal range.

Extend the warming up period in the winter (cold season).

3. During operation do not drive with constant high engine rpm and load, avoid heavy-duty work and high speed travelling.

4. Drive carefully and avoid sudden starts and stops, abrupt acceleration and turns.

5. Carefully perform the running-in services, see next page.

Take special care for the following points: • A warming up period until gauges show normal range is important - also after the dump truck has been run in.

• Operating up to the limit of the dump truck's capacity during the running-in period, may prematurely reduce the performance potential.

Operating & Maintenance Manual

83

4. Running-in period

2. Running-in services Running-in service is to be carried out after operating the dump truck the first 8, 100 and 500 hours.

These services are most important for running in a new dump truck.

This is the owner’s responsibility.

2.1 First 8 hours: 1. Wheel nuts.

• Torque setting:

Check tightening of nuts.

450 Nm. Spanner: 32 mm

2. Lubricating.

Grease all lubricating points.

3. Battery:

Checking electrolyte level in the batteries, see 500 hours service, item 1.5.

Checking battery charge, see 1000 hours service, item 2.3.

4. Multi-groove belt:

Checking multi-groove belt condition, see 1000 hours service, item 2.4.

5. Carry on with the normal 8 hours service, listed in chapter 7, maintenance.

Since these points are important for the dump truck to work satisfactorily right from the start they are also listed below.

All items below refer to 8 hours / daily service in chapter 7.

1. General • Walk around check, before start Item 1.1 • Check driver's seat, before start Item 1.2 2. Engine • General condition check - look for leakages remedy as necessary Item 2.1 • Drain the water separating fuel filter 4* Item 2.2 • Check oil level, before start 1* Item 2.3 • Check coolant level, before start 5* Item 2.4 Coolant should be filled up when the engine is stopped after first stop.

It is recommended to fill up with the same mixture as filled from the producer 40% glycol / 60% water, see also 2000 hours service, item 1.2 check the coolant.

• Check fuel level, before start 13* Item 2.5 • Function check of the centrifugal cleaner, after operation 2* Item 2.6 3. Transmission • Check oil level, before operation 20* Item 3.1 4. Hydraulic system • Check oil level, before start 40* Item 4.1 6. Brake system • Parking brake, check braking (holding) capacity, before operation Item 6.1 • Service brake (main brake), check braking (holding) capacity, before operation Item 6.2 • Service brake (main brake), Check function, before operation Item 6.3 • Accumulators, check the oil pressure, before operation Item 6.4 7. Steering • Check function, before operation Item 7.1 8. Engine brake • Check function, before operation Item 8.1 9. Engine and retarder brake • Check function, before operation Item 9.1 2.2 First 100 hours: 1. Change transmission oil.

20* See 1000 hours service, item 3.1.

2. Replace transmission filter.21* See 1000 hours service, item 3.1.

3. Clean strainer.

22* See 1000 hours service, item 3.1.

4. Replace hydraulic filter.

43* See 1000 hours service, item 4.2.

5. Run the AEB-Tester See Initial 500 hours service, item 2.1.

6. Multi-groove belt: Checking multi-groove belt condition, see 1000 hours service, item 2.4.

7. Expander bolts: Checking torque setting on expander bolts on tip- and steering cylinders, see 500 hours service, item 5.1 8. Retorque window wiper spindle nuts.

• Torque setting: 35 Nm (M10), 18 Nm (M8) 9. Lubricating. Grease all lubricating points.

* Numbers refers to position on lubrication schedule, chapter 6 84

Operating & Maintenance Manual

4. Running-in period

2.3 First 500 hours: 1. Change oil in: • Front differential.

• Rear differential.

• Tandem housings.

• Reduct. gears, front.

2. Check/adjust: • PDE injector rocker arms • Valve clearance • Hydraulic oil pressure.

30* 31* 32* 33*

See 1000 hours service, item 5.1.

See 1000 hours service, item 6.1.

See initial 500 hours service, item 3.1.

See 1000 hours service, item 8.1.

See initial 500 hours service, item 1.1 See 2000 hours service, item 1.1.

Contact your local Moxy dealer.

3. Run the AEB-Tester. Procedure described in initial 500 hours service, item 2.1.

4. Lubricating. Grease all lubricating points.

5. Carry on with the normal 500 hours service, listed in chapter 7, maintenance.

• Change oil, engine ........................................ item 1.1.

• Clean centrifugal cleaner .............................. item 1.2.

• Replace oil filter ............................................. item 1.3.

• External cleaning of the radiator ................... item 1.4.

• Check batteries ............................................. item 1.5.

• Check battery terminals ................................ item 1.6.

• Check oil levels ............................................. item 2.1.

• Check brake lining thickness ......................... item 3.1.

• Check wheel nuts torque ............................... item 4.1.

• Check expander bolts, tip- and steering cyl... item 5.1.

• Air conditioner system, test operation ........... item 6.1.

• Check cab ventilation filter element............... item 6.2.

• Check the automatic central lubrication ........ system ....................................................... item 7.1.

See chapter 7 for procedures and chapter 6 for fluid specifications.

* Numbers in brackets refer to position on lubrication schedule, chapter 6 Operating & Maintenance Manual

85

4. Running-in period

86

Operating & Maintenance Manual

5. Operating Instructions

Operating Instructions

Operating & Maintenance Manual

87

5. Operating Instructions

Content

5. Operating instructions ..................................... 87 - 120 Precautions on work sites .................................. 89 Some simple rules to be observed prior to operation ............................................................ 92 1. Starting the engine ........................................ 93 2. Operating the dump truck .............................. 95 3. Parking the dump truck ................................. 107 4. Stopping the engine ...................................... 107 5. Checks after stopping the engine .................. 108 6. Loading and tipping ....................................... 108 7. Tyre handling ................................................. 110 8. Cold weather ................................................. 112 9. Long term storage ......................................... 113 10. Battery power assistance .............................. 114 11.Towing the dump truck .................................. 115 12. Manual release of parking brake ................... 115 13. Manual release of the tip valve ...................... 116 14. Troubleshooting ............................................. 117

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Precautions on work sites There are many different types of work sites, some of them could be: • Dusty areas • Rocky areas • Wet, swampy or muddy areas • Seashore or salty areas

• Altitude above 1000 m • Steep driving • Extremely hot areas

• Underground areas (mines) • Transit, long distance drive-away (more than 3 km) • Extremely cold areas

Rules and guidelines are listed below to increase the lifetime of the dump truck. Pay attention to these guidelines and let the safety always get first priority.

General • On work sites where extra heavy-duty operations are occurring, reduce the maintenance intervals and carry out greasing more frequently.

• Clean the machine regularly. Keep grease fittings, breathers and oil level gauges clean and avoid dirt to enter these items.

Dusty areas/Underground areas (mines) • When working in dusty/sandy work sites or work sites where the service brake (foot brake) is frequently used, check the brake lining more often, at least every 250 hours (see 500 hours service for procedure).

• Watch the air filter warning light, to see whether the engine air filter is clogged. Clean/replace the engine air filter at shorter intervals than specified, clean as often as necessary (see 1000 hours service for procedure).

Extremely dusty applications may require to clean the air filter every day!

• Clean the radiator core frequently, every week if necessary, to avoid clogging (see 500 hours service for procedure).

• Clean and replace the fuel filters frequently (see 1000 hours service for procedure).

• Check daily the cab ventilation filter and pre-filter. These filters will very soon be clogged in dusty areas, therefore it is necessary to clean and replace the cab ventilation filter and pre-filter more frequently than usual (see 40 and 500 hours service for procedure).

Never remove a filter element/pre-filter without replacing it with a new one!

• Clean electrical components, especially the starting motor and alternator, to avoid accumulation of dust.

Rocky areas • Inspect the pinion bearings more often when working in rocky areas (see 1000 hours service for procedure), and replace the bearings as often as necessary, i.e. if the bearings shows signs of wear, cracks or damages.

• Check for damage to the undercarriage and for looseness, flaws, wear and damage in wheel bolts and nuts.

• Check tyres for damage and wear. Remove foreign object from the threads as soon as possible, these will sooner or later penetrate into the tyre. Also protect the tyres from falling stones during loading.

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5. Operating Instructions

Wet, swampy or muddy areas (see also chapter 2, item 15 - Wading) • Be aware of that the braking effect will be reduced when the brakes are wet.

• The brake linings must be checked more often, at least every 250 hours, when driving in wet or swampy areas (see 500 hours service for procedure), the wear of the lining will increase.

• The wear of the sealings will also increase when driving in wet or swampy areas, check and replace sealings as often as necessary.

• If mud sticks to the callipers or discs, and the brakes are left in that condition, the wear of the lining will increase, therefore always wash the area well with water after operations. E.g. when clay is dried up it is hard as concrete, this will cause breakage and wear of the machine.

• Do not let the water flow through the grill or into the different breathers and air filters.

• Do not operate the dump truck in water/rivers permanently for a long period.

And do not under no circumstances let the water flow through the grill.

Seashore or salty areas • Before start working, check plugs and valves for tightness.

• Spray exposed areas with anti-corrosive.

• Check the brake linings more often (see 500 hours service for procedure). When driving in wet salty/sandy areas the wear of the lining will increase.

• Check also the sealings more often, the wear will increase in salty/sandy areas.

• Lubricate components more frequently than usual.

• Do not operate the dump truck in water permanently for a long period.

And do not under no circumstances let the water flow through the grill.

• It is important to wash the machine immediately after the work to protect the components for rusting and to remove dirt and sand.

See also item above "Wet, swampy or muddy areas" High altitude (above 2000 m) • Be aware of that the engine power and torque will be reduced due to low air density.

Contact your Dealer for possible remedy.

• Do not remove the air filter!

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Steep driving • Always when driving downhill and loaded, use only the exhaust and retarder brake for retarding. The service brake (foot brake) must only be used for complete stop. (see also chapter 2, item 13 - Operation of brakes and chapter 5, item 2.12 Up, down and cross gradient travel) • See also engine and retarder brake capacity chart at chapter 8.

Extremely hot areas • Watch the engine coolant temperature gauge, the engine coolant temperature warning light and the transmission oil temperature gauge. If the temperatures are at the limit, check the engine radiator for clogging (see 500 hours service) • Watch the air filter warning light, to see whether the engine air filter is clogged. Clean/replace the engine air filter at shorter intervals than specified, clean as often as necessary (see 1000 hours service for procedure).

Extremely cold areas (see also chapter 5, item 7 - Cold weather) • Use engine heater • Check that the correct oils are used (see oil specification sheet, chapter 6) • Check that there is enough glycol in the coolant (see 2000 hours service for freezing point and correct coolant)

Transit, long distance drive-away (more than 3 km) • Check and adjust the tyre pressure on cold tyres before starting. Do not reduce pressure during driving.

• Generally replace the mineral based oil with fully synthetic oil.

A mineral based oil have a rapid break down of lubrication ability and cooling ability when operated at high temperatures (120OC).

Replacing mineral based oil with a synthetic oil will improve the cooling capacity by 15%.

• Make sure that the interaxle differential is disconnected when driving, as the 50/50 torque split will generate a lot of heat.

• Drive only without load.

• Drive 2 hours and stop for minimum 30 min. Drive another 2 hours and stop for minimum 1 hour. Repeat.

• Upper speed limit for this operation: 2000 rpm at 6. gear.

Must not be exceeded!

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Some simple rules to be observed prior to operation.

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• Read and understand this Operating & Maintenance Manual before you begin to operate the dump truck.

• When the dump truck is operated, the door should be shut.

• Never operate the dump truck if you are under the influence of alcohol, m e d i c i n e s o r o t h e r

• Check that the seat is adjusted for comfortable and safe operation of controls before operation.

• You must wear personal safety equipment, for safe operation.

• Check that the steering column is adjusted for comfortable op eration, and confirm that it is fixed before operation. DO NOT ADJUST POSITION OF THE STEERING WHEEL WHILE DRIVING!

• Use helmet to increase protection of your head.

• Always use the seat belt during driving!

If there is an instructor or passenger in the cab, be sure that they are seated on the instructor seat and are using seat belts!

• When you climb up or down from the dump truck, always climb with your face towards the dump truck and use steps and handles. Always use two hands and one foot, or one hand and two feet.

DO NOT JUMP!

• If instructor seat is not fitted, instructor o r p a s s e n g e r may not stay in the cab during driving.

• Do not climb on surfaces which are not intended for this, always use the surfaces which are provided with anti-slip coatings.

• Check that the brake system warning light is not lighted before driving.

• The cab is the driver's protection a n d c o n fo r m s t o the requirements for roll over protection (ROPS) and falling objects (FOPS), specified in the standard for these.

The precondition for providing protection is that the driver uses the seat belt and remains in the cab.

Therefore, hold on to the steering wheel if the dump truck should roll

• The cab has two exits, one door and the front side window on the right hand side as emergency exit.

The emergency exit can be used by removing the hammer from the storage location and break front side window.

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5. Operating Instructions

1. Starting the engine Before starting the engine in the morning, perform the Daily Service, see chapter 7.

Remember to connect the battery main switch on the left hand side of the front fender (if disconnected) otherwise there will be no power supply.

ON

1.1. Confirm that parking brake is ON

1.2. Confirm that gear selector is in neutral position

1.3. Turn the starter switch ON, pos 1

Check warning lights before starting: • engine oil pressure • charging light • parking brake • brake system - could light up if the fluid pressure is too low.

If the light does not switch off, check for possible fault.

• emergency steering warning light - switches off above 5 km/h.

• automatic central lubrication - switches off when the automatically test cycle is done.

• seat belt - fasten the seat belt.

• depress the test switch for brake warning light to check that the warning light is okay.

If any of these lights do not light up, either the lamp is broken or there is a fault in the electrical system. This should be checked and fixed before starting, if necessary.

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5. Operating Instructions

1.4. Start the engine 1. Turn the starter switch key to the right, pos. II to engage the starter.

2. Hold until engine starts (Max. 30 sec).

3. Check that warning lights for engine oil pressure and battery charge switch off.

1.5. If engine does not start: 1. Turn starter switch OFF, and wait until engine has stopped completely before attempting to start again.

2. In cold weather, wait 2 minutes before restart.

2 min.

1.6. Starting in cold weather / at low temperatures Start aids, engine heater should be used to avoid starting problems and white smoke.

Below -10 °C it can be absolutely necessary to use engine heater to avoid starting difficulties.

• If an engine heater is equipped, an external power supply is needed (AC 220 V - 50 Hz).

• See also item 7, Cold weather in this chapter.

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2. Operating the dump truck 2.1. Before operation When the engine is running properly and the fluid pressures are within operating range:

1. Clean/defrost the windows before driving.

6. Sound the horn as alert.

2. Fasten the seat belt before driving.

7. Depress the brake pedal.

3. Check that gauges and warning lights do not indicate any abnormalities.

OFF

8. Release the parking brake and confirm that the indicator light goes off.

4. Confirm low idle speed.

9. Select a suitable gear position at low idle (see item 2.3, Gear shifting).

5. Check that there are no persons or objects in front of the dump truck, or in the articulation area, before you drive off.

10. Release the brake pedal and increase the engine speed by pressing the throttle pedal downwards.

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5. Operating Instructions

2.2. Warming up period When driving off with a cold dump truck, operate the dump truck gently with reduced engine load and rpm to warm up until all gauges indicate operating range. This is important to avoid reduction of the dump truck’s performance potential.

2.3. Gear shifting The transmission has automatic gear shift to match the travel speed. The shifting is electronically controlled and a lock-up clutch is fitted in the transmission to increase efficiency in all gears. Connection/disconnection is auto matic but speed and engine load related.

Gear position N: Neutral gear position The engine will not start if the gear selector is out of neutral position.

When the gear selector is in neutral position it is always necessary to depress the knob on top of the selector to shift to forward or reverse position.

Also, always depress the knob when shifting directly between forward and reverse direction.

Gear position V: Forward drive position.

Automatic gear shift

The transmission shifts automatically between 1st and 6th gear, according to dump truck speed and engine load.

The transmission will normally start in 2nd gear, if the conditions are heavy, it will automatically shift down to 1st gear.

Gear shift program: The gear shift program is decided automatically by the dump trucks computer, the computer chooses the gear shift program that is most relevant to the throttle pedals position.

Shifting at low rpm happens when the pedal is partially depressed. If the throttle pedal is further depressed, the gear shift will take place at higher rpm. With the throttle pedal fully depressed, the gear shift will either be prevented or close to the maximum engine rpm.

When the throttle pedal is released and the engine brake or the engine and retarder brake is engaged, the down shift will take place at high rpm.

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Preselection of gears.

The gears can be preselected by the driver as follows: Push the gear selector to the right (+) for upshifting or to the left (-) for downshifting.

When a gear is preselected and the gear selector is pushed either to the left or right, the gear system will switch to manual gear shifting.

The gear selector must then be pushed in order to change gear.

When the selected gear is engaged, the transmission will only operate in this gear until the selector is pushed to another position or changed back to automatic gear shift by depressing the knob on top of the gear selector.

When a gear is preselected and not engaged, the digits on the gear display will flash.

Manual gear shifting Manual gear shift

To avoid repeated up and down shifting when driving in heavy conditions it is an advantage to use manual gear shift. When changing from automatic gear shift to manual gear shift, push the gear selector either to the left for downshift or to the right for upshift, or manual gear shift can be obtained by depressing the knob on top of the gear selector while driving in automatic.

In manual gear shift mode the selector must be pushed in order to change gear. Preselection of gears is also possible in manual gear shift.

When the selected gear is engaged the transmission will only operate in this gear until the selector is pushed to another position. If the dump truck is stationary, the selected gear will be engaged directly.

To return to automatic gear shift while driving in manual, depress the knob on top of the gear selector.

CAUTION With the dump truck stationary, do not engage a gear at high engine speed.

Engine and retarder brake mode When the engine brake or the engine and retarder brake is engaged, the transmission will not shift to a higher gear if the speed increases at downhill driving, unless the engine RPM speed is too high, then the auto-upshift function will engage at 2,600 rpm's.

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5. Operating Instructions

Operating hints Different types of terrain require different operating techniques.

Automatic gear shift

• Use automatic gear shift, for normal travel.

• The knob on top of the gear selector is used for: • Shifting from neutral to forward or reverse position.

• Shifting directly between forward and reverse direction.

Manual gear shift

• Changing between automatic and manual gear shift.

• In terrain, before uphill/

downhill driving, manually select a suitable position for the estimated speed in the area, avoid repeated up and down shift in hilly terrain.

• When selecting a gear from the neutral position and when shifting between forward and reverse gears:

N

OFF

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• In manual gear shift mode, always drive allowing the lockup clutch to connect.

• Stop the truck and release the throttle pedal completely.

• Neutral position must not be selected during driving.

• Depress the knob on the top of the gear selector, select the desired gear and wait until the gear is engaged before increasing the engine speed.

• The starter switch must NEVER be turned off (position 0) during driving, if you do not intendto stop the engine!

The engine has key stop and requires neutral position on gear selector to restart.

• Do not operate the gear selector with the throttle pedal depressed.

This will cause a big shock, and will also reduce the life of the dump truck.

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5. Operating Instructions

2.4. Reversing (back-up) operations 1. Before reversing, make sure that no persons or objects are behind the dump truck or in the articulation area.

2. Stop the dump truck completely before selecting the reverse gear.

3. Depress the knob on top of the gear selector and place the gear selector in position R with engine running at low idle. The transmission will always select 1st reverse.

4. Increase the engine speed.

The reverse drive position has only manual gear shift between 1st, 2nd and 3th gear. The selector must be pushed in order to change gear. When a gear is engaged, the transmission will only operate in this gear until the selector is pushed to another position.

WARNING •

Be careful when reversing, the rear visibility is limited!

2.5. Normal operation Always operate the dump truck with caution. Careful driving is recommended for safe and comfortable operation.

Regulate dump truck speed in accordance with the ground conditions and surrounding environments.

In manual gear shift mode, always drive allowing the lock-up clutch to connect.

If abnormal noise, vibration, smoke or odours occur during operation, check for possible faults and remedy.

Check at regular intervals that all gauges are indicating normal values, and that no warning lights are on.

• Transm. oil temp.:

50 - 105°C, max 120°C a short period

• Transm. oil temp. at retarder brake operation: up to 140°C, max 150°C a short period

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2.6. Brakes There are four different brake systems on the dump truck. Check the brakes every day to ensure function.

Service brake (main brake) All hydraulic operated dry single disc brake on each wheel.

There are two separate circuits. If a fault occurs in one of the circuits, the dump truck can still brake with the intact circuit.

Self adjusting system.

Engine brake Hydraulic operated, speed dependent brake which restricts exhaust flow.

Efficient only when lock-up clutch is connected.

Retarder brake Infinitely variable, hydrodynamic, wear resistant and speed dependent oil retarder fitted before transmission torque converter.

The braking effect of the retarder brake depends on the engine rpm. High engine rpm gives high retarder braking effect.

Parking brake Spring actuated, hydraulic released single disc brake on the rear prop. shaft. Self-adjusting system.

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2.7. Engine and retarder brake operation When the operator releases there foot off the accelerator, the exhaust brake is automatically engaged. Driving downhill with the accelerator pedal released, the engine rpm’s will increase, when the engine rpm's reach 2,200 the transmission retarder is activated, this will disengage when rpm’s drop to 1,800, the exhaust brake will continue to operate.

If engine rpm’s continue to increase, the emergency retarder will be engaged at 2,500 rpm and increase transmission retarder braking to between 90-100%.

It’s called emergency retarder because the cooling capacity is not designed for continuous operation.

If the dash switch for transmission retarder brake is applied, both exhaust and transmission retarder will be applied when accelerator pedal is released.

If the truck is on a downhill slope and the operator does not release there foot off the accelerator pedal, the exhaust brake is activated at 2,450 rpm’s to override the operator error.

The transmission emergency retarder brake will be activated at 2,500 rpm.

To prevent engine damage due to the over-speed situation, the transmission control unit (TCU) will perform an automatic up-shift to the next gear, if engine reach's 2,700 rpm’s.

An engine/transmission over-speed will be indicated as a warning to the operator in the gear display when reaching 2,500 rpm. If the overspeed situation is not reduced but increased, the TCU will store an over-speed error situation at 2,700 rpm.

If the engine speed reaches 3,000 rpm’s, the engine will go into shutdown mode. This over-speed error will be stored in the ECU.

NOTE •

Always use the engine brake or engine and the retarder brake when driving downhill for constant retardation.

•

Both the engine brake and the retarder brake will automatically disconnect if the turbine rpm falls lower than 1200 rpm and will connect again when the turbine rpm rises above 1300 rpm.

•

To avoid over speed of the engine, the retarder brake will automatically engage if the engine speed exceeds 2700 rpm.

This will happen regardless to the throttle pedal an switch position.

Reduce the engine speed immediately!

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2.8. Braking/stopping the dump truck Learn to associate the braking requirements for loaded and unloaded machine.

See also chapter 2. Safety Instructions 1. Release the throttle pedal.

2. Apply the engine brake or the engine and retarder brake.

3. Depress the brake pedal gradually, until desired deceleration is obtained.

4. When the dump truck is completely stopped, move the gear selector to neutral.

5. Apply the parking brake.

• Hint: Always use the engine brake or the engine and retarder brake, this will result in increased lifetime of the service brake linings.

2.9. Emergency braking If braking effect is lost in both brake circuits, the dump truck can be braked as follows: 1. Release the throttle pedal.

2. Apply the engine and retarder brake.

3. Set the parking brake to locked (on) position.

4. Move the gear selector to 1st gear manually as quickly as possible.

5. When the dump truck has stopped, immediately put wheel chocks under the wheels.

WARNING After an emergency stop: DO NOT CONTINUE! The parking brake MUST be checked as well as the reason for the service brake failure!

Consult your Moxy Dealer.

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2.10. Steering • The dump truck has 2 frames. The steering movement is created by articulation of the frames in relation to each other. The steering is fully hydraulically controlled and there are no mechanical links between the steering column and the steering cylinders.

The steering circuit has priority over the tipping circuit, ensuring hydraulic oil available to the steering at any time.

• The dump truck is equipped with an emergency steering system, which will deliver oil when the dump truck is in motion due to a ground-driven pump. It will then be possible to steer the dump truck if the engine stops. The steering movement will then be slower and the warning light for emergency steering will light.

Repair the fault before operating the dump truck again!

NOTE Mechanical endstops are fitted in the steering cylinders.

Steering movement that will “hammer” these endstops must be avoided. Continuance of the steering actions against the endstops causes maximum pressure in the system - this must be avoided!

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5. Operating Instructions

2.11. Differentials The dump truck has permanent 6-wheel drive with 3 differentials.

1. Front differential, automatic differential. brake (limited slip type) Fitted to the transmission. Transfers the power to left and right front wheels.

1

The differential will automatically provide highest torque to the wheel which has best grip. The locking ratio is 45%, i.e. the differential is capable of compensating for a 1:2.64 difference in friction between left and right wheels.

2. Inter axle differential, 100% lockable torque divider Integrated in the transmission. Transfers the torque by 1/3 to the front axle and 2/3 to the rear axle.

The differential lock can improve dump truck performance and should be used to avoid wheel spinning in severe conditions, i.e. slippery surfaces.

Engage the differential lock before entering an area with a slippery surface, soft ground, or if the dump truck is stuck in the terrain.

The differential lock must not be used when driving on firm ground!

2

3

CAUTION Use the inter-axle differential lock to avoid spinning on front and rear axle.

3. Rear differential, automatic diff. brake (limited slip type) Fitted in the rear axle housing. Transfers the power to left and right tandem drive.

The differential will automatically provide highest torque to the wheel which has best grip. The locking ratio is 45%, i.e. the differential is capable of compensating for a 1:2.64 difference in friction between left and right wheels.

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2.12. Up, down and cross gradient travel

• When travelling on gradients, consider the ground condition, and maintain a safe speed according to the grade of the path, the surface, degree of

• Operate the dump truck sensibly and avoid cross gradient travel. Select a low speed and negotiate the terrain without exaggerated steering movements and sudden braking.

• Before starting downhill, release the throttle pedal and slow down the dump truck to a safe speed for the downhill slope. Move the gear selector to a suitable position (1st, 2nd or 3rd).

R u l e : S e l e c t t h e same gear for operating downhill as you would for operating

• Do not under any circumstances drive the dump truck with raised body.

• Always use the engine brake o r t h e e n g i n e and retarder brake for constant retardation. Long time e n g a g e m e n t and unnecessary use of the service brakes can cause excessive wear and a possibility of loss

• K e e p e n g i n e speed at the upper area, 1500 - 1900 rpm in heavy conditions and for hill travel.

Select a manual gear position

• If use of the engine brake or engine and retarder brake is insufficient to keep the dump truck within a safe speed, reduce the speed by depressing the brake pedal.

The travel must then continue in a lower gear with the engine brake or the engine and retarder brake applied.

• Do not park or leave the dump truck on grades or slopes, the risk for spontaneous rolling is high!

• Pay attention to the transmission oil temperature when the retarder brake is applied.

• ALWAYS keep the engine speed below max. allowed rpm when travelling downhill!

T h e r e t a r d er brake (emergency retarder) will be automatically engaged if the engine speed reaches 2500 rpm, this will also increase transmission retarder braking to between 90 - 100%,to avoid over speed

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2.13. Important operating instructions

• The dump truck must not coast with gear selector in neutral position.

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• E n g i n e s p e e d within 1500 1900 rpm with engaged lockup is recommended

• Engine speed must be reduced, and the dump truck must be stopped completely before changing between reverse and forward gears.

• T h e r e t a r d er brake (emergency retarder) will be automatically engaged if the engine speed reaches 2500 rpm, this will a l s o i n c r e a s e transmission retarder braking to between 90 - 100%, to avoid over speed

• Do not keep turning against the mechanical endstops, or force it into this point when making maximum turns.

• Do not continue to operate the dump truck if a warning lamp lights, a gauge shows abnormal value, or if the warning buzzer sounds.

• There is no braking effect from transmission when the engine is stopped.

• Always operate the dump truck within the rated limits and carry out maintenance according to the scheduled program. Overloading and lack of maintenance reduces safety and the life time of the dump truck is reduced.

• Select neutral gear and apply the parking brake when leaving the dump truck.

Never leave the dump truck with a gear engaged!

• In case of problems with the dump truck, stop the vehicle and contact your local Moxy

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3. Parking the dump truck 1. Avoid parking with loaded body.

2. Do not park on grades or slopes.

3. Park on a safe ground, where it will not freeze in place, sink down, etc. A change of weather may affect the ground.

4. Move the gear selector to neutral position.

5. Apply the parking brake.

6. Lower the body completely.

7. Neutralise all operating controls.

8. Secure the dump truck from spontaneous rolling by adding wheel chocks under the wheels before leaving the dump truck.

4. Stopping the engine 1. Stop the dump truck.

2. Run the engine at low idle for a few minutes to allow it to gradually cool down if the dump truck has been driven with a heavy load for a long period of time.

If engine is stopped suddenly before it cools down, engine life maybe shortened.

Never stop the engine immediately after driving except in case of emergency.

3. Before stopping the engine, check that the main warning lights for engine failure is not on or flashing.

See chapter 3, Operating Controls for procedure if the warning lights are on or flashing.

4. Turn the key in starter switch to OFF position.

5. Remove the key from starter switch.

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5. Operating Instructions

5. Checks after stopping the engine 1. Lock the sliding windows and the cab door.

2. Turn off the battery main switch.

3. Check for leakage of oil or water.

4. Fill up the fuel tank.

Make sure that the filler cap and the area around the filler opening is clean to avoid contamination of the fuel 5. Remove any waste paper or other flammable material which may cause fire in the engine compartment.

6. Remove any mud stuck to the chassis.

6. Loading and tipping 6.1. Loading • The body must be lowered completely before loading materials.

The tip control lever shall stay in hold (float) position. with

• When loading large rocks, cover the body bottom gravel or start with the smallest stones first.

• During loading, the parking brake should be applied and gear selector should stay in neutral position.

• Before driving off, check that no danger can occur during travel. Maintain an even load distribution, avoid unbalanced loads.

• Never overload the dump truck. The operator's safety will be considerably reduced and lifetime of the dump truck will drop.

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6.2. Tipping 1. Place the dump truck on a level ground.

Check that the tipping may take place safely.

2. The gear selector must be in neutral position, and the parking brake must be applied.

3. Move the tip control lever to body "up" position and increase the engine speed. The body will raise, and the top tailgate, if fitted, opens automatically.

The tipping speed is proportional with the engine speed.

4. Reduce the engine speed before the body reaches the top position (check that the top tailgate, if fitted, opens).

5. To stop the tipping movement, release the tip control lever.

It will then automatically return to hold position.

6. Move the tip control lever to "down", and the body will go down. The top tailgate, if fitted, will then automatically close when the body is completely down.

The tipping cylinders are double acting. The lowering speed is proportional with the engine speed.

7. The tip control lever shall stay in hold (float) position when not operated.

NOTE For safety reasons, the tipping system is equipped with an automatic tip stop, to prevent the loaded body from tipping over.

Vibrations caused by the automatic tip stop may help to loosen material from the body.

WARNING • • • • • •

Reduce tipping speed when dumping large rocks!

Do not load material into the body if the body is raised!

Do not drive a empty or loaded truck with a raised body!

Do not raise body near electrical power lines!

See Chapter 2. SAFETY INSTRUCTIONS Avoid tipping on cross-gradients!

Utilisation of top tailgate has safety restrictions!

See Chapter 2. SAFETY INSTRUCTIONS!

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7. Tyre handling General This is a general instruction for the standard tyres in the table under item 7.2. Contact tyre supplier or your local Moxy Dealer for exact specifications.

Off-road tyres produce more heat during operation than tyres for ordinary cars. Therefore, the tyres must be used correctly to obtain long lifetime and safe operation.

Please note that the following can cause overheating of tyres: • Too low tyre pressure • Overloading • Driving long distances non-stop • Travelling at high speed

CAUTION Extremely low temperature (below -40°C) requires special operation!

7.1. Difference in tyre diameter If it is necessary to change a wheel as a result of puncture or in emergencies, Moxy Engineering AS allows up to 3% difference in the tyre diameter on the same side of the tandem.

But the most ideal situation in all cases is to have the same tyre diameter on the same side of the tandem. This is strongly recommended.

7.2. Correct tyre pressures Tyre pressures mainly depend on operation speed and load. Road configuration, flotation/traction requirements, risk of cutting, hacking, shock damage and ambient temperatures, are also factors to consider.

Both too high and too low tyre pressure may result in damage and shortened lifetime of the tyres.Tyre pressure checks and corrections must be carried out on cold tyres.

Basic pressure for cold tyres (based on max. load and max. speed):

Model

MT25

MT26

MT31

110

Front (bar {psi})

Rear (bar {psi})

Type

30 k/m version

50 k/m version

30 k/m version

50 k/m version

Bridgestone VLT

4.0 {58}

5.0 {73}

4.0 {58}

5.0 {73}

Michelin XADN/XADT

3.5 {51}

4.5 {65}

3.5 {51}

4.5 {65}

Goodyear GP2B/GP4B

3.5 {51}

4.5 {65}

3.5 {51}

4.5 {65}

Continental STL 3

4.0 {58}

5.0 {73}

4.0 {58}

5.0 {73}

Bridgestone VLT

4.0 {58}

4.0 {58}

Michelin XADN/XADT

3.5 {51}

3.5 {51}

Goodyear GP2B/GP4B

3.5 {51}

3.5 {51}

Continental STL 3

4.0 {58}

4.0 {58}

Continental STL 2+

5.24 {75.9}

5.24 {75.9}

Triangle TL528

5.25 {76}

5.25 {76}

Bridgestone VLT

4.5 {65}

4.75 {69}

Michelin XADN/XADT

3.75 {54}

4.0 {58}

Goodyear GP2B/GP4B

3.75 {54}

4.0 {58}

Continental STL 3

4.27 {62}

4.75 {69}

Operating & Maintenance Manual

5. Operating Instructions

Model

MT36/41

MT41

Type

Front (bar {psi})

Rear (bar {psi})

Bridgestone VLT

3.35 {48.5}

4.2 {61}

Michelin XADN/

2.9 {42}

3.6 {52}

Goodyear RL2+

2.9 {42}

3.6 {52}

Continental STL 3

3.3 {48}

4.0 {58}

Triangle TB516

5.25 {76}

5.25 {76}

7.3. Specified loading Do not overload the dump truck. Maintain an even load distribution, avoid unbalanced loads.

Protect tyres from falling stones during loading.

7.4. Proper maintenance Perform tyre inspections according to Maintenance schedule.

Also roads and driving paths should be maintained to achieve max. tyre serviceability.

Damaged, excessively worn or aged tyres should be replaced. Remove foreign objects from the threads, these will sooner or later penetrate into the tyre.

Removal or repairing of tyres should be performed by a tyre specialist to avoid unsafe working conditions.

WARNING Always let the air out of the tyre before removing foreign objects and before demounting or repairing!

See also chapter 2, Safety Instructions (High pressure)

7.5. Transit, long distance drive-away on road This special type of driving requires special operation: • Check and adjust the tyre pressure on cold tyres before starting.

Do not reduce pressure during driving.

• Drive only without load.

• Drive 2 hours and stop for minimum 30 min. Drive another 2 hours and stop for minimum 1 hour. Repeat.

• Upper speed limit for this operation: 2000 rpm at 6th gear. Must not be exceeded!

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111

5. Operating Instructions

8. Cold weather Cold weather operation (below 0 °C) requires special care to avoid problems and to maintain high comfort and safety.

• The viscosity of oils in engine, transmission, differentials, and hydraulic system should be of a suitable viscosity for the lowest expected ambient temperature, see Oil Specification Sheet.

• The coolant must contain anti-freeze to avoid ice in the cooling system and to protect against corrosion, see chapter 7, maintenance, 2000 Hours Service.

• As the temperature drops, the battery capacity drops accordingly.

The batteries must be in good condition and fully charged when the dump truck is operated in low temperatures.

• Fuel must be of a low pour point, and the fuel tank must be filled up at the end of the shift. 0.5 - 2 % alcohol (isopropanol) can be added to avoid condensation.

• The washer fluid should contain a mix of alcohol (isopropanol) and water which at least is sufficient to avoid icing in the tubes.

• At very low temperatures (below -10 oC) use of engine heater can be necessary to avoid starting difficulties.

It is recommended to use an engine heater (optional equipment) at low temperatures. The engine heater has an electrical element which heats the engine coolant.

• Extend the warm-up period to secure that component lubrication is obtained.

The dump truck shall be operated with light load and reduced rpm during warming up.

• Pay special attention to the ground surface. In case of snow and ice, use snow chains on the wheels to secure the wheel grip.

• If the dump truck is equipped with exhaust-heated body, this should be connected to avoid material freezing to the body.

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Operating & Maintenance Manual

5. Operating Instructions

9. Long term storage If the dump truck shall be stored for a longer period of time, special preparation must be carried out to avoid deterioration and damage. Store it preferably indoors in a dry and ventilated room or outdoors under shelter.

9.1. Before storage: 1. Neutralise all operating controls, place the gear selector in neutral position, the retarder brake switch must be turned OFF and apply the parking brake.

2. Thoroughly wash and clean the dump truck.

3. Completely fill the fuel tank.

4. Replace oil and filters with new and lubricate all nipples. Check viscosities to match the expected ambient temperature.

5. If the ambient temperature is expected to drop below 0oC, always add antifreeze to the cooling water.

6. Fully charge the batteries and disconnect terminals.

Preferably stored separately in a cold place (010oC).

7. Cover all cylinder piston rods with rust protecting fluid.

8. Inflate the tyres to correct pressure. (See chapter 8).

9.2. During storage: Operate the truck once a month by driving it i.e. until engine temperature reaches normal operating temperatures.

This will lubricate all moving parts. At the same time check for leakages and recharge the batteries. Grease the nipples.

NOTE Check oil and fluid levels before starting the engine! Drive slowly and with care the first 5 minutes or 1 km.

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113

5. Operating Instructions

10. Battery power assistance In case of discharged batteries, the dump truck can be started by connecting charged batteries, 24 volts with capacity approx. equal to the discharged batteries.

• If the batteries have been discharged, check the reason why (are the batteries defective?, is there a short circuit somewhere on the dump truck? etc.)

• Discharged batteries should be charged as soon as possible.

• Check the electrolyte level and density after charging the batteries.

Connection:

A 3

4

2

1. Turn off the battery main switch on the left hand side fender.

2. Connect first cable (A) from positive (+) terminal on discharged batteries....

Good batteries

B

Low batteries

3. .... to the positive (+) terminal on the assisting battery.

5

Chassis of vehicle with low battery

4. Connect second cable (B) from negative (-) terminal on assisting battery....

5. .... to chassis on the dump truck with the discharged batteries, some distance from the batteries.

6. Turn on the battery main switch and start the engine in the normal way.

Disconnection: Disconnect cables in the opposite order, 5 - 4 - 3 - 2.

CAUTION • • • • •

114

Use cables with min. 25 mm2 cross section.

Connect in sequence described above.

Good clamp contact is essential.

Do not stand near a battery when connecting the cable to the chassis.

Do not disconnect the original battery cables.

Operating & Maintenance Manual

5. Operating Instructions

11. Towing the dump truck.

• The dump truck can be towed by fitting a wire/chain to the eye(s) in front/rear of the dump truck.

• Check that the wire/chain is capable of towing the load.

• The towing distance must not exceed 10 km, and the maximum allowed speed is 10 km/h!

• The engine must run at low idle to steer the dump truck in the normal way. If the engine is stopped, the steering movement will be heavier and slower than normal because there is no oil flow from the main hydraulic pump.

• The maximum towing force is: • Front: 100 kN (each) • Rear: 200 kN

CAUTION • • •

Cylinder mounting nuts

If fluid pressure is lost, the service brake will not function and the parking brake will be engaged.

An engaged parking brake can be loosened even if there is no fluid pressure in the system, see item 12.

It is not possible to start the engine by towing!

12. Manual release of parking brake Clevis pin Clevis Cylinder

If the parking brake must be disengaged when hydraulic pressure is not available, the following procedure should be followed: 1. Secure the dump truck with wheel chocks so that it will not move as the parking brake is disengaged.

2. Raise the body and secure it with the body support (see chapter 2 - safety instructions).

Jam nut Cylinder Pull rod

3. Loosen the jam nut that locks the clevis to the cylinder pull rod.

4. Turn the cylinder pull-rod to expose additional clevis threads. This will reduce spring pressure on the brake.

Continue turning the pull rod until there is clearance between the linings and disc.

At this point the parking brake will no longer function and the dump truck can be moved to a repair facility.

5. Repair the dump truck so that hydraulic pressure is available to the parking brake.

6. Remove the cylinder from the brake and screw the clevis into the cylinder pull rod until the centre of the clevis pin is 70-73 mm from the mounting face of the cylinder (no pressure).

7. Torque the jam nut to 13.6-20.3 Nm to lock the clevis to the cylinder pull-rod.

8. Reinstall the cylinder onto the brake.

Torque the cylinder mounting nuts to 40.5-54.5 Nm. 9. Reinstall the clevis pin and check for proper brake adjustment.

DANGER All braking systems are out of function when the parking brake is manual released. Extreme care must be taken to avoid spontaneous rolling.

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115

5. Operating Instructions

13. Manual release of the tip valve If the body is lifted and cannot be lowered by the tip control lever, i.e. hydraulic pressure has been lost, the tip valve may be manually released.

1. The bolt for manual release are to be found on the rear of the tip valve. The tip valve is located on the back of the cab on left hand side.

2. Before doing the following procedure, make sure to measure the length of the protruding bolt.

3. Screw in the bolt until the body is in the lowered position.

4. Then unscrew the bolt to its original length as measured on before hand.

CAUTION It is very important for the function of the tip valve that the length of the protruding bolt is exactly the same after the procedure as it was before the procedure was carried out.

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Operating & Maintenance Manual

5. Operating Instructions

14. Troubleshooting If the action below does not solve the problem or the fault cannot be found, contact Moxy dealer. *= Always contact your Moxy Dealer.

Area of dump truck Symptom/Problem

Dump truck will not start

Starts but engine cuts out suddenly, runs un-evenly or hunts.

Low output

Engine

Overheated (Warning light)

Low coolant temperature

Low oil pressure

Blue smoke, oil consumed

Black or white smoke

Oil in coolant or coolant in oil

Cause

Remedy/Solution

Main switch disconnected

Turn on

Out of fuel

Refill fuel, bleed system

Low battery current

Recharge

Blown fuse

Check circuit, replace fuse

Defective wiring

Check connections, wires

Hydrostatic lock

Repair *

Starter motor defective

Replace *

Electronic controller or sensors defective

Check/repair *

Fuel system disturbance

Check fuel lines, bleed system

Condensated water in diesel

Drain tank

Bad fuel quality

Change fuel

Low fuel level

Refill fuel

Fuel filters clogged

Replace filters

Air filter clogged

Replace or clean

Fuel tank breather clogged

Clean tank cover

Throttle system disturbance

Adjust/replace/repair

Wrong injection timing

Adjust *

Injector defective

Repair/replace *

Turbo charger defective

Repair/replace *

Worn engine or internal damage

Overhaul *

Electronic controller or sensors defective

Check/repair *

Low coolant level

Add coolant, check for leakages

Fan belt problem

Tighten/replace

Air in cooling system

Bleed system

Dirt inside cooling system

Clean and replace coolant

Radiator fins clogged/damaged

Clean

Thermostat faulty

Replace

Sensor/gauge defective

Replace

Coolant pump worn

Overhaul *

Sensor/gauge defective

Replace

Thermostat stuck open

Replace

Too low oil level

Add oil, check for leakage

Incorrect oil type

Change to correct oil type

Sensor/gauge defective

Replace

Oil pressure red - valve faulty

Overhaul *

Worn oil pump

Overhaul *

Too high oil level

Adjust to specified level

Incorrect oil type

Change to correct oil type

Worn engine or internal damage

Overhaul *

Clogged air filter

Replace or clean

Fuel pump/injection system worn or faulty

Adjust/repair *

Cylinder gasket defective

Replace *

Turbocharger defective

Repair/replace *

Internal leak in transmission cooler

Replace *

Worn engine or internal damage

Overhaul *

Internal leak on engine oil cooler

Replace *

Operating & Maintenance Manual

117

5. Operating Instructions

Area of dump truck Symptom/Problem

Knocking noise Engine

Main warning light illuminates

Too high temperature

Will not drive in any gear or only possible to drive in some gears

Transmission

Low oil pressure

Noise

Main warning light illuminates

Cause

Remedy/Solution

Bad fuel quality

Change fuel

Valves incorrectly adjusted

Adjust

Injection pump incorrectly adjusted

Adjust *

Injector defective

Replace *

Worn engine or internal damage

Overhaul *

Engine/engine controller failure

Stop the dump truck at a safe place, check the error codes and contact your moxy dealer.

Too low oil level

Add oil, Check for leakage

Incorrect oil type

Change to correct oil type

Cooling circut failure

Check/repair

Lock-up fault

Overhaul *

Worrn oil pump

Overhaul *

Too low oil level

Add oil, check for leakage

Blown fuse

Check circuit

Convertor prop. shaft

Replace

Electronic controller detection failure, neutral engaged

Check/repair *

Electronic controller or sensors defective

Check/repair *

Flywheel damper separated

Replace *

Drive line failure

Check/repair *

Internal transmission failure

Overhaul *

Automatic central lubrication failure

Check/repair *

Too low oil level

Add oil, check for leakage

Incorrect oil type

Change to correct oil type

Sensor/gauge defective

Replace

Pressure control valve failure

Check/repair *

Worn oil pump

Overhaul *

Internal transmission failure

Overhaul/replace *

Too high oil level

Adjust to specified

Incorrect oil type in differential(s)

Change to correct type

Worn transmission or internal damage

Overhaul/replace *

Transmission/transmission controller failure

Stop the dump truck at a safe place, select neutral gear position and check the error codes on the gear display. (Error codes shown below)

Error code on Transmission

Cause

Remedy/Solution

First digit 1, second digit 1-9

Digital input signals

Check/repair *

First digit 2, second digit 1-9

Analog input signals

Check/repair *

First digit 3, second digit 1-9 or A-E

Speed signals

Check/repair *

First digit 5, second digit 1-9

CAN signal error

Check/repair *

First digit 6, second digit 1-9 or A-F

CAN signal error

Check/repair *

First digit 7, second digit 1-9 or A-C

Analog current output signals

Check/repair *

First digit 8, second digit 1-9

Analog current output signals

Check/repair *

First digit 9, second digit 1-9 or A-F

Digital output signals

Check/repair *

First digit A, second digit 1-9

Digital output signals

Check/repair *

First digit B, second digit 1-9 or A-F

Clutch errors

Check/repair *

First digit D, second digit 1-9

Power supply

Check/repair *

First digit E, second digit 1-9

High speed signals

Check/repair *

First digit F, second digit 1-9

General errors

Check/repair *

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Operating & Maintenance Manual

5. Operating Instructions

Area of dump truck Symptom/Problem

Brakes

Cause

Poor braking effect or truck pull to one side when braking

Emergency steering light is on when driving

Truck will not go straight ahead, uneven steering movement or periodcally sticking Hydraulic system

Not possible to tip or activate slow tipping

No electrical power Electrical system Charge warning light on

Uncomfortable travel (jumping)

Chassis Vibrations

Remedy/Solution

Low brake fluid level

Add oil, check for leakage

Uneven worn brake pads

Replace pads

Insufficient fluid pressure

Check charging and system

A brake caliper is stuck

Repair *

No oil flow from main pump

Check and repair *

No oil flow from emergency pump

Check and repair *

Oil flow switch defective

Replace *

Low hydraulic pressure

Add oil, check for leakage

Air trapped in hydraulic system

Bleed system

Contaminated oil

Change oil and flush system

Incorrect oil type

Change to correct oil type

Steering cylinders internal leak

Overhaul *

Orbitrol or steering valve failure

Check and repair *

Low hydraulic oil level

Add oil, check for leakage

Clogged oil filter

replace

Insufficient hydraulic pressure

Check charging

Clogged tank strainer or breaher

Replace/clean

Low oil pressure

Check/repair *

Worn oil pump

Check/repair *

Tip valve failure

Overhaul *

Main switch disconnected

Turn on

Batteris discharged

Recharge

Battery terminals/wiring defective

Repair

Fan belt problem

Tighten/replace

Defective/worn alternator

Replace

Defective wiring

Check connections, wires

Defective shock absorber

Replace

Defective rubber suspension

Replace

Articulation turning ring worn

Overhaul *

Engnine or transmission mountings

Replace

Fan or flywheel loose/imbalance

Check/repair *

Defective elastic coupling

Check/repair *

Prop. shaft failure

Check/repair *

Drive line problem

Check/repair *

Operating & Maintenance Manual

119

5. Operating Instructions

120

Operating & Maintenance Manual

6. Lubricants

Lubricants

Operating & Maintenance Manual

121

6. Lubricants

Content

6. Lubricants ......................................................... 121 - 134 Lubrication schedule (MT25/26/31 Serial Number 710655 and up) .......................... 123 Oil specification sheet (MT25/26/31 Serial Number 710655 and up) .......................... 125 Filling capacities (MT25/26/31 Serial Number 710655 and up) .......................... 126 Oil specification sheet (MT36/41 Serial Number 810053 and up) .......................... 129 Filling capacities (MT36/41 Serial Number 810053 and up) .......................... 130 Transmission oil list............................................. 131 Automatic Transmission Fluid (ATF) .................. 132

122

Operating & Maintenance Manual

6. Lubricants

Lubrication schedule (MT25/26/31 Serial Number 710655 and up) Complete instructions in section 7. Maintenance.

Pos.

Component

1st service 100

500

Service interval 8

40

500

1000

2000

4000

Min. once a year

Lubricants filled from producer

Engine 1

Engine oil

V

2

Centrifugal cleaner

V

3

Engine oil filter

4

Fuel filter (2)

5

Coolant/cooling system

R

Shell Rimula Super 15W-40

C R R

V

C/V/R*

C/R

C/V/R*

40% Glycoshell

Engine Related 10

Air filter, outer element -Inner element: replace every 2 years

11

Batteries (2)

13

Fuel tank

C/R*

C/R*

V

V

R

R

R

R

V V

Transmission 20

Transmission oil

R

21

Filter (2)

R

21a

V

Water separator

D

Shell Rimula X 10W-30

R

22

Strainer

C

C

C

30

Front differential oil

R

V

R

R

31

Rear differential oil

R

V

R

R

32

Tandem housing oil (2)

R

V

33

Front reduction gear oil (2)

R

V

40

Hydraulic oil

42

Breather element on tank

43

Filter

R

43a

Filter

R

Drive Line Shell spirax A 90 LS

R R

R

Shell spirax AX SAE 80W-90

Hydraulic V

R

Shell Tellus T 46

R R R

Lubrication Points ª50

Articulation turning ring (4+2 points)

ª51

Tip hinges (1 point)

L-2

ª52

Tandem bearings (2+2 points)

L-6

ª53

Articulation bearings (2 points)

L-3

ª54

Steering cyl. bearings (4 points)

L-2

ª55

Tip cylinder bearings (4 points)

L-2

ª56

Tailgate arm hinge (optional) (2 points)

L-1

57

Door and fender hatches (8 points)

L

58

Cab rear hinges (4 points)

L

ª59

Suspension legs (2 points)

60

Cardan shaft (2 points)

L-2

61

Cardan shaft (2 points)

L-2

62

Cardan shaft (2 points)

L-2

63

Cardan shaft (2+2 points)

L-2

64

Park Brake

L

65

Tilt support

L

70

Cab ventilation filter

80

Hydr. pump, tiltable cab

L-6

Shell SRS 4000 NLGI - 2

L-1

Miscellaneous C/R*

V/R* Shell Tellus T15

R=Replace V=Check C=Clean L=Lubricate D=drain *=or when required L-X=The number after the L means the number of pump strokes per lubricator ª=Alternativel greased by automatic central lubrication system (optional) Operating & Maintenance Manual

123

6. Lubricants

Overview of oil and lubrication points (MT25/26/31 Serial Number 710655 and up) The numbers refer to table on previous page.

21a

Serial No. 710770 and up

43a

Serial No. 710655 710769

43a

57

124

Operating & Maintenance Manual

Serial No. 710790 and up

6. Lubricants

Oil specification sheet (MT25/26/31 Serial Number 710655 and up) This table presents guidelines for oil, coolant, fuel, lubricants and other fluids best suited for good performance and long life.

Component

Kind of fluid

-4 -20

14 -10

Ambient temperature 32 50 68 86 0 10 20 30 SAE 20W-30 SAE 30 SAE 40

Engine oil pan

°F °C

Remarks The engine oil should at least meet the requirements for one of the following oil classifications: - ACEA E3,. E4 or E5 - API CG-4 - Global DHD-1 - The Total Base Number (TBN) should be a minimum of 12-13 (ASTM 2896)

SAE 50

Engine oil

SAE 5W-30 SAE 10W-30

If fuel contains more than 0.3% (weight) sulphur: reduce the oil change interval.

Make sure the oil can sustain all temperature variations up until next oil change.

Ask your local Moxy Dealer or oil supplier

SAE 15W-40 Winter Fuel Tank

Diesel fuel

Summer-Diesel Cooling system

Water + antifreeze

30-50% Nitrate-free glycol antifreeze is recommended. See 2000 hours service.

ATF

ZF transmission

Acc. to: ASTM and ISO standards Cetane number: min.49.

Sulphur contents: max. 0.3%.

Max 2% isopropanol additive

Dexron - IID/-III Mercon -M

Engine Oil

When changing between AFT and engine oil, it is recommended to run the AEB-tester.

SAE 10W

Only oils in the transmission oil list can be used!

SAE 10W-30/10W-40

NOTE: Min. 20 monutes warming up period in neutral position is required when ambient temperature is within this area:

SAE 15W-40 SAE 20W-20 SAE 85W-90 Tandem housing, planetary reduction gear

Gear oil

According to: API GL-5 or MIL-L-2105D (gear oil with EP-additives)

SAE 80W-90 SAE 85W-140

Front diff.

Rear diff.

Gear oil with LSadditives

*=max. 2% (weight) VI-Improver and pour point depressant in the basic gear oil.

SAE 90 Other gear oils as above* HM ISO VG 32 HV ISO VG

Hydraulic oil

HM ISO VG 46 Hydraulic tank

HV ISO VG ATF

DEXRON IID Engine oil

SAE 10W

Lithiumsaponfield with EP-additive Consistency NLGI-1/1.5/2.

Lubricator Optional: Automatic Central lubr. system Hydraulic pump, tiltable cab

Only mineral based oils Viscosity approx. 20 cSt at normal operating temp.

Range: 10-250 cSt, max. 850 cSt at cold start.

Hydraulic oil: HM or HV oils (ISO 6743/4, CETOP RP 91H) or H-LP oils (DIN 51524).

• Contact oil supplier when operating in temperature below -25°C • Warm up in neutral after starting at temperature near lower limitation of the oil .

• If using Biological oil contact your Moxy Dealer before use. The oil must be approved by Moxy Engineering AS.

Universal grease

NLGI 2 NLGI 0/1 ISO VG 15

NOTE: If the cab should be tilted by use of the hydraulic pump at temperatures below -20°C, use oil fluid 4 Aero Shell or similar

Hydraulic oil

See remarks

CAUTION Remember, Automatic Transmission Fluid must not be mixed with engine or hydraulic oil.

Operating & Maintenance Manual

125

6. Lubricants

Filling capacities (MT25/26/31 Serial Number 710655 and up) All capacities are measured in litres (dm3), and are approximate values. To achieve correct level: check at dip stick, level eye, level plug etc.

Description: Specified capacity: Refil amount: etc.

Total tank/reservoir volume or total capacity from empty.

Refill volume after normal fluid draining. The differences are fluid left in components, piping

Component/Fluid

Specified capacity (litres)

Refill amount (litres)

MT25

MT25

Engine oil

MT26

MT31

33

Engine coolant 290

Transmission oil*

320

37 350

as required

57

29

Rear differential

32

29

Front differential

13.2

13.2

Tandem housing (each)

2 x 75

2 x 67.5

Front reduction gear (each)

2x3

2x3

128

Hydraulic system

*

126

138 4.5

Windscreen washer tank

=

MT31

33

45

Fuel Tank

MT26

150

101

111

123

4.5

Check level when engine runs at low idle.

Do not run engine without oil in the transmission.

Operating & Maintenance Manual

6. Lubricants

Lubrication schedule (MT36/41 Serial Number 810053 and up) Complete instructions in section 7. Maintenance.

Pos.

Component

1st service 100

500

Service interval 8

40

500

1000

2000

4000

Min. once a year

Lubricants filled from producer

Engine 1

Engine oil

V

2

Centrifugal cleaner

V

3

Engine oil filter

4

Fuel filter

5

Coolant/cooling system

V

Water separator

D

21a

R

Shell Rimula Super 15W-40

C R R C/V/R*

C/R

C/V/R*

40% Glycoshell

R

Engine Related 10

Air filter, outer element -Inner element: replace every 2 years

C/R*

C/R*

V

V

11

Batteries (2)

13

Fuel tank

V

20

Transmission oil

R

R

R

21

Filter (2)

R

R

R

22

Strainer

C

C

C

30

Front differential oil

R

V

R

R

31

Rear differential oil

R

V

R

R

32

Tandem housing oil (2)

R

V

33

Front reduction gear oil (2)

R

V

34

Separate brake cooling tank, front

R

35

Separate brake cooling filter front

R

40

Hydraulic oil

42

Breather element on tank

43

Filter (2)

ª50

Articulation turning ring (4+2 points)

L-6

ª51

Tip hinges (1 point)

L-2

ª52

Tandem bearings (2+2 points)

L-6

ª53

Articulation bearings (2 points)

L-3

ª54

Steering cyl. bearings (4 points)

L-2

ª55

Tip cylinder bearings (4 points)

L-2

ª56

Tailgate arm hinge (optional) (2 points)

L-1

57

Door and fender hatches (8 points)

L

58

Cab rear hinges (4 points)

L

ª59

Suspension legs (2 points)

60

Cardan shaft (2 points)

L-2

61

Cardan shaft (2 points)

L-2

62

Cardan shaft (2 points)

L-2

63

Cardan shaft (2+2 points)

L-2

64

Park Brake

65

Tilt support

V

Transmission V

Shell Rimula X 10W-30

Drive Line Shell spirax A 90 LS

R R

R

Shell Donax TD 5W-30

R R

Hydraulic V

R

Shell Tellus T 46

R R

R

Lubrication Points

Shell SRS 4000 NLGI - 2

L-1

L L

Miscellaneous 70

Cab ventilation filter

80

Hydr. pump, tiltable cab

C/R*

V/R* Shell Tellus T15

R=Replace V=Check C=Clean L=Lubricate D=drain *=or when required L-X=The number after the L means the number of pump strokes per lubricator ª=Alternativel greased by automatic central lubrication system (optional) Operating & Maintenance Manual

127

6. Lubricants

Overview of oil and lubrication points (MT36/41 Serial Number 810053 and up)

34

The numbers refer to table on previous page.

35 21a

43

128

Operating & Maintenance Manual

6. Lubricants

Oil specification sheet (MT36/41 Serial Number 810053 and up) This table presents guidelines for oil, coolant, fuel, lubricants and other fluids best suited for good performance and long life.

Component

Kind of fluid

-4 -20

14 -10

Ambient temperature 32 50 68 86 0 10 20 30 SAE 20W-30 SAE 30 SAE 40

Engine oil pan

°F °C

Remarks The engine oil should at least meet the requirements for one of the following oil classifications: - ACEA E3,. E4 or E5 - API CG-4 - Global DHD-1 - The Total Base Number (TBN) should be a minimum of 12-13 (ASTM 2896)

SAE 50

Engine oil

SAE 5W-30 SAE 10W-30

If fuel contains more than 0.3% (weight) sulphur: reduce the oil change interval.

Make sure the oil can sustain all temperature variations up until next oil change.

Ask your local Moxy Dealer or oil supplier

SAE 15W-40 Winter Fuel Tank

Diesel fuel

Summer-Diesel Cooling system

Water + antifreeze

30-50% Nitrate-free glycol antifreeze is recommended. See 2000 hours service.

ATF

ZF transmission

Acc. to: ASTM and ISO standards Cetane number: min.49.

Sulphur contents: max. 0.3%.

Max 2% isopropanol additive

Dexron - IID/-III Mercon -M

Engine Oil

When changing between AFT and engine oil, it is recommended to run the AEB-tester.

SAE 10W

Only oils in the transmission oil list can be used!

SAE 10W-30/10W-40

NOTE: Min. 20 minutes warming up period in neutral position is required when ambient temperature is within this area:

SAE 15W-40 SAE 20W-20 Tandem housing, planetary reduction gear Front diff.

Rear diff.

Dontax TD 5W-30

Gear oil

Gear oil with LSadditives

*=max. 2% (weight) VI-Improver and pour point depressant in the basic gear oil.

SAE 90 Other gear oils as above* HM ISO VG 32 HV ISO VG

Hydraulic oil

HM ISO VG 46 Hydraulic tank

HV ISO VG ATF

DEXRON IID Engine oil

SAE 10W

Hydraulic pump, tiltable cab

Only mineral based oils Viscosity approx. 20 cSt at normal operating temp.

Range: 10-250 cSt, max. 850 cSt at cold start.

Hydraulic oil: HM or HV oils (ISO 6743/4, CETOP RP 91H) or H-LP oils (DIN 51524).

• Contact oil supplier when operating in temperature below -25°C • Warm up in neutral after starting at temperature near lower limitation of the oil .

• If using Biological oil contact your Moxy Dealer before use. The oil must be approved by Moxy Engineering AS. Lithiumsaponfield with EP-additive Consistency NLGI-1/1.5/2.

Lubricator Optional: Automatic Central lubr. system

According to: API GL-4 or MIL-L-2104D (gear oil with EP-additives)

Universal grease

NLGI 2 NLGI 0/1 ISO VG 15

NOTE: If the cab should be tilted by use of the hydraulic pump at temperatures below -20°C, use oil fluid 4 Aero Shell or similar

Hydraulic oil

See remarks

CAUTION Remember, Automatic Transmission Fluid must not be mixed with engine or hydraulic oil.

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129

6. Lubricants

Filling capacities (MT36/41 Serial Number 810053 and up) All capacities are measured in litres (dm3), and are approximate values. To achieve correct level: check at dip stick, level eye, level plug etc.

Description: Specified capacity: Refil amount: etc.

Total tank/reservoir volume or total capacity from empty.

Refill volume after normal fluid draining. The differences are fluid left in components, piping

Component/Fluid

Specified capacity (litres)

Refill amount (litres)

MT36

MT36

MT41

MT41

Engine oil

34

34

Engine coolant

51

42

Fuel Tank

425

Transmission oil*

490

As required

55

38

Rear differential

46

43

Front differential

13.2

13.2

2 x 150

2 x 135

Tandem housing (each) Front reduction gear (each)

2 x 7.5 250

Hydraulic system

4.5

Windscreen washer tank

*

130

=

2 x 7.5 275

184

209 4.5

Check level when engine runs at low idle.

Do not run engine without oil in the transmission.

Operating & Maintenance Manual

6. Lubricants

Transmission oil list API-GL-4 Lubricant class 03A Mineral oil-based engine oil in accordance with Group standard ZFN 13030 (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4//SF/SG/SH/SJ/SL or ACEA, categories A, B, E) Viscosity class: SAE 20W-20 / 30 / 10W-30 / 10W-40 / 15W-30 / 15W-40 / 20W-40 Note: All mineral oil-based trade products which satisfy the above specifications may be used.

Lubricant class 03B API-GL-4 in accordance with Group standard ZFN 13030 (API CD/CE/CF-4/CF/CG-4/CH-4/CI-4/SF/SG/SH/SJ/SL or ACEA, categories A, B, E) Viscosity class: SAE 10W / 5W-30 / 5W-40

Manufacturer

Trade name

ARAL AG, BOCHUM/D ARAL BASICTURBORAL SAE 10W BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH BLASOL 10W20 CASTROL INTERNATIONAL, PANGBOURNE CASTROL ENDURON PLUS 5W-40 READING/GB COMP.BRASIL. D. PETRO. IPIRANGA, RIO DE ULTRAMO TURBO 10W JANEIRO/BR FL ITALIA S.P.A., VILLASTELLONE/I AKCELA SUPER 10 (SAE 10W) FL ITALIA S.P.A., VILLASTELLONE/I AMBRA SUPER 10 (SAE 10W) FL ITALIA S.P.A., VILLASTELLONE/I URANIA C SAE 10 W FUCHS LUBRICANTS (UK) PLC, HANLEY/GB TITAN TXE 10 FUCHS PETROLUB AG, MANNHEIM/D FUCHS TITAN UNIVERSAL HD SAE 10W GINOUVES GEORGES SA, LA FARLEDE/F YORK 730 SAE 10W KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 T 400 SAE 10W LIQUI MOLY GMBH, ULM/D TOURING HIGH TECH SAE 10W LUBRICATION ENGINEERS, INC., FORT WORTH, MONOLEC GFS ENGINE OIL SAE 10 TEXAS/USA MEGUIN GMBH & CO. KG MINERALOELWERKE, MEGOL MOTORENOEL HD-C3 SG SAE 10W SAARLOUIS/D MINERALÖL-RAFFIN. DOLLBERGEN, UETZEPENNASOL MOTOR OIL EXTRA C SAE 10W DOLLBERGEN/D MORRIS LUBRICANTS, SHREWSBURY/GB RING FREE XHD 10W ORLY INTERNATIONAL G.I.E., VIEUX-THANN/F ORLY DRACO 3001 SAE 10W PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO PKO HD 4 SAE 10W PANOLIN AG, MADETSWIL/CH PANOLIN EXTRA DIESEL 10W REPSOL LUBRICANTES, MADRID/E TELEX W SAE 10W SHELL ASEOL AG, BERN 5/CH ASEOL MONOGRADE CF 10W SHELL INTERNATIONAL PETROLEUM COMP LTD, SHELL RIMULA X 10W LONDON/GB SRS SCHMIERSTOFF VERTRIEB GMBH, WINTERSHALL REKORD 10W SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S DIESELWAY 10W TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL RUBIA S 10W VALVOLINE EUROPE, DORDRECHT/NL ALL FLEET PLUS 10W VEEDOL INTERNATIONAL, PANGBOURNE VEEDOL DIESEL HDC SAE 10W READING/GB

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131

6. Lubricants

Transmission oil list Automatic Transmission Fluid (ATF) Lubricant class 03D Automatic Transmission Fluids (ATF) in accordance with Group standard ZFN 13030 Manufacturer ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL LUBE OIL GMBH, LEUNA/D ARAL AG, BOCHUM/D ARAL AG, BOCHUM/D

Trade name ADDINOL ATF D II D ADDINOL ATF D III ARAL GETRIEBEÖL ATF 22 ARAL GETRIEBEÖL ATF 55 F-30589 AVIA MINERALÖL-AG, MÜNCHEN/D AVIA FLUID ATF 86 AVIA MINERALÖL-AG, MÜNCHEN/D AVIA FLUID ATF 98 BAYWA AG, MÜNCHEN/D BAYWA ATF 3000 BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH ATF GM BP INTERNATIONAL, PANGBOURNE, READING/GB BP AUTRAN DXIII BP INTERNATIONAL, PANGBOURNE, READING/GB BP AUTRAN MBX BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX ATF SUPER CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL TQ DEXRON III (F-30520) CASTROL INTERNATIONAL, PANGBOURNE READING/GB CASTROL TQ-D (22256) CEPSA LUBRICANTS S.A., MADRID/E CEPSA ATF 70 CHEVRONTEXACO, GHENT/B TEXAMATIC 4291 CHEVRONTEXACO, GHENT/B TEXTRAN PSM CYCLON HELLAS S.A., MAROUSSI ATHENS/GR ATF TYPE D DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR ATF 289 DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR ATF DMM EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA ESSO ATF D2 EXXON MOBIL CORPORATION, FAIRFAX, VIRGINIA/USA MOBIL ATF 220 FL ITALIA S.P.A., VILLASTELLONE/I AKCELA TRANS XHD FL ITALIA S.P.A., VILLASTELLONE/I AMBRA HYDRODEX 3 FL ITALIA S.P.A., VILLASTELLONE/I TUTELA CAR GI/E FL ITALIA S.P.A., VILLASTELLONE/I TUTELA GI/A FUCHS PETROLUB AG, MANNHEIM/D TITAN ATF 3000 FUCHS PETROLUB AG, MANNHEIM/D TITAN ATF 4000 GENOL GMBH & CO., WIEN/A GENOL ATF MULTIFLUID GINOUVES GEORGES SA, LA FARLEDE/F YORK 686 GINOUVES GEORGES SA, LA FARLEDE/F YORK 785 HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENDALL ATF DEXRON II D HUILES BERLIET S.A., SAINT PRIEST/F HRD STARMATIC 3 HYDROTEX, CARROLLTON, TEXAS/USA HY-TORQUE Z (ATF) IGOL FRANCE SA, AMIENS/F ATF 430 KRAFFT S.A., ANDOAIN/E ATF SYNTHETIC D3 KRAFFT S.A., ANDOAIN/E KRAFFT ATF 21247 KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 14 KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/NL Q8 AUTO 15 LIQUI MOLY GMBH, ULM/D LIQUI MOLY ATF DEXRON IID MAZIVA ZAGREB D.O.O, ZAGREB/HR NA ATF SUPER MEGUIN GMBH & CO. KG MINERALOELWERKE, SAARLOUIS/DMEGOL HYDRAULIKOEL ATF DEXRON II D MINERALÖL-RAFFIN. DOLLBERGEN, UETZE-DOLLBERGEN/D PENNASOL FLUID GETRIEBEOEL TYP P/CN MORRIS LUBRICANTS, SHREWSBURY/GB LIQUIMATIC D II MORRIS LUBRICANTS, SHREWSBURY/GB LIQUIMATIC SUPER ATF OEL-BRACK AG, HUNZENSCHWIL/CH QUAKER STATE ATF Q3 PLUS OMV AG, SCHWECHAT/A OMV ATF D II (D22427) OMV AG, SCHWECHAT/A OMV ATF III PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO MULTIPURPOSE TRANSMISSION FLUID II D PANOLIN AG, MADETSWIL/CH PANOLIN ATF DEXRON III PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN HEAVY DUTY SYNTHETIC BLEND ATF Continued overleaf 132

Operating & Maintenance Manual

6. Lubricants

Manufacturer PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETRO-CANADA LUBRICANTS, MISSISSAUGA/CDN PETROGAL S.A., LISBOA/P PETROL OFISI A.S, MASLAK-ISTANBUL-TURKEY/TR PRZEDSIEBIORSTWO MODEX-OIL, KWIDZYN/PL RAFINERIA NAFTY JEDLICZE SA, JEDLICZE/PL S.A.E.L., MADRID/E S.A.E.L., MADRID/E SHELL ASEOL AG, BERN 5/CH SHELL DEUTSCHLAND OIL GMBH, HAMBURG/D SHELL DEUTSCHLAND OIL GMBH, HAMBURG/D SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SHELL INTERNATIONAL PETROLEUM COMP LTD, LONDON/GB SLOVNAFT VURUP A.S., BRATISLAVA/SK SRS SCHMIERSTOFF VERTRIEB GMBH, SALZBERGEN/D STATOIL LUBRICANTS, STOCKHOLM/S STATOIL LUBRICANTS, STOCKHOLM/S SUN OIL COMPANY (BELGIUM) N.V., AARTSELAAR/B SYNECO SPA, SAN GIULIANO MILANESE/I TEDEX OIL SP.Z.O.O., PIASECZNO/PL TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL LUBRIFIANTS S.A., PARIS/F UNIL S.A., SAUMUR CEDEX/F VALVOLINE EUROPE, DORDRECHT/NL VEEDOL INTERNATIONAL, PANGBOURNE READING/GB VEEDOL INTERNATIONAL, PANGBOURNE READING/GB YACCO, ST PIERRE LES ELBEUF/F ZELLER + GMELIN GMBH & CO., EISLINGEN/D

Operating & Maintenance Manual

Trade name MERCON V ATF SYNTHETIC BLEND ATF GALP TRANSMATIC D II PO ATF-2 VECO MATIC IID HIPOL ATF III GULF ATF D II D GULF ATF HIGH TECH ASEOL ATF DB UNIVERSAL DEAFLUID 4011 DEAMATIC SHELL DONAX TA (D-21631) SHELL DONAX TA (D-21666) SHELL DONAX TA (D-21774) SHELL DONAX TX (G-32003) SHELL DONAX TX (G-34077) MADIT AUTOMATIC WINTERSHALL ATF III STATOIL TRANSWAY DX II STATOIL TRANSWAY DX III SUNAMATIC 153 ATF PLUS TEDEX ATF DEXRON II D ELFMATIC G3 FINAMATIC HP FINAMATIC II D TOTAL FLUIDE AT 42 TOTAL FLUIDE ATX MATIC D VALVOLINE ATF TYPE D VEEDOL ATF DEXRON III (F30521) VEEDOL ATF-M (22764) YACCO ATF III DIVINOL FLUID III F

133

6. Lubricants

134

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7. Maintenance

Maintenance

Operating & Maintenance Manual

135

7. Maintenance

Contents

7. Maintenance ...................................................... 135 - 202 Maintenance precautions ................................... 137 Maintenance table .............................................. 139 Initial 100 Hours Service .................................... 142 Initial 500 Hours Service .................................... 146 8 Hours / Daily Service ....................................... 149 40 Hours / Weekly Service ................................. 159 500 Hours Service .............................................. 162 1000 Hours Service ............................................ 178 2000 Hours Service ............................................ 191 4000 Hours Service ............................................ 197 Yearly recommended maintenance .................... 201

136

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7. Maintenance

Maintenance precautions • Always prepare the dump truck before starting any maintenance, adjustments or other work on the dump truck, see Service Position in the Safety Instructions chapter (Chapter 2).

• Fuel and oil are dangerous substances.

Never handle fuel, oil, grease or oily clothes in places where there is any fire or flame. As preparation in case of fire, always know the location and the use of fire ex tinguishers and other fire fighting equipment.

• Wear a well-fitting helmet, safety shoes and working clothes.

When drilling, grinding or hammering always wear protective goggles.

• Flames should never be used instead of lamps. Never use a naked flame to check leaks or level of oil, fuel, anti-freeze or electrolyte.

• Park the dump truck on firm, flat ground. Apply the Articulation Lock.

• When working with others; Choose a group leader, follow the leader's instructions. Do not perform any maintenance beyond the agreed work.

• Always stop the engine when performing maintenance near moving parts.

• During maintenance; Do not allow any unauthorised person to stand near the dump truck.

• Unless you have special instructions to the contrary, maintenance should always be carried out with engine stopped. If maintenance is carried out with the engine running, there must be two persons present: One operating the engine, and the other one performing the maintenance. In such a case, never touch any moving parts.

• Exhaust gas is dangerous. When working inside, be particularly careful to have good ventilation.

• Thoroughly wash the engine. In particular, be careful to clean the filler caps, grease fittings and the area around the dipsticks.

Be careful not to let any dirt or dust into the system.

• Wash the dump truck, be careful not to wet electrical components or inside cab.

• Always use Moxy genuine parts for replacement.

• Always use the grades of grease and oil recommended by the manufacturer. Choose the viscosity specified for the ambient temperature. See chapter 6.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

137

7. Maintenance

removed while adding oil.

• Always use pure oil or grease, and be sure to use clean con-

• W h e n a d d i n g oil or checking the

Un de rp rep ara tio n

• Before servicing/working on or opening the hydraulic system, remember always to release the pressure in the accumulators.

Empty the accumulators through t h e a c c u m u l a tor test connectors, or by operating the brake pedal repeatedly while the engine is • When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into the oil.

• Before draining the oil, warm it up to a temperature of 30o to 40o C. Be aware of possible internal pressure when opening any drain, level or filling plug. Hot oil can spurt out and inflict personal injury.

oil level, check that the oil is at the correct level.

• After greasing up, always wipe off

the old grease which was forced out.

• When changing the oil or filter, check the drained oil and filter for any signs of excessive metal particles or other foreign materials.

• W h e n r e m o v ing parts containing O-rings,gaskets or seals, clean may spurt out.

• Be particularly careful when removing the expansion tank cap. If this is done immediately after using the engine, there is a d a n ger that boiling water and steam

the mounting surface and replace with new sealing parts.

• When lubricating oil or cooling

• A f t e r r e p l a c ing oil, filter element

or strainer, bleed the air from the circuit.

• When the strainer is located in the oil filler, the strainer must not be

water has been drained, keep an eye on the instrument panel so that the dump truck is not operated without oil or cooling water.

* Numbers refer to positions on the lubrication schedule, chapter 6 138

Operating & Maintenance Manual

7. Maintenance

Maintenance table Initial 100 Hours Service 1. Transmission

2. Hydraulic System

1.1. Change oil 20* Replace filter element 21* Clean strainer 22*, at least once a year 2.1.Replace hydraulic return filter element 43*.

2.2.Replace hydraulic high pressure filter element 43a*.

162

1.1.Check/adjust PDE injector rocker arms 2.1.Run the AEB-Tester 3.1.Change oil 32*

166 166 168

164 165

Initial 500 Hours Service 1. Engine 2. Transmission 3. Tandem housings 8 Hours / Daily Service 1. General 2.

3.

4.

5.

6.

7.

8.

9.

1.1.Walk around check, before start 169 1.2.Check driver's seat, before start 169 Engine 2.1.General condition check - look for leakages remedy as necessary 170 2.2.Drain the water separating fuel filter 4* 170 2.3.Check oil level, before start 1* 171 2.4.Check coolant level, before start 5* 171 2.5.Check fuel level, before start 13* 172 2.6.Function check of the centrifugal cleaner, after operation 2* 172 Transmission 3.1.Check oil level, before operation 20* 173 Hydraulic system 4.1.Check oil level, before start 40* 174 Lubrication 5.1.Door and fender hatches, 8 lubricators 57* 175 5.2. Cab rear hinges, 2 lubricator 58 * 176 Brake system 6.1.Parking brake check braking (holding) capacity, before operation 176 6.2.Service brake (main brake) check braking (holding) capacity, before operation 176 6.3.Service brake (main brake) check function, before operation 177 6.4.Accumulators check the oil pressure, before operation 177 Steering 7.1.Check function, before operation 178 Engine brake 8.1.Check function, before operation 178 Engine/retarder brake 9.1.Check function, before operation 178

40 Hours / Weekly Service 1. Cab ventilation

1.1.Clean prefilter 70* 1.2.Air conditioner system 2.1.Check tyre pressures, before operation 3.1.Check the lubricant level in the reservoir.

2. Tyres 3. Automatic central lubrication (Lincoln lubrication system)3 3. Automatic central 3.1.Check the grease level in the reservoir. lubrication (Grovenveld lubrication system)

179 179 180 180

181

500 Hours Service 1. Engine

1.1.Change oil 1* 1.2.Clean centrifugal cleaner 2* 1.3.Replace oil filter 3* 1.4.External cleaning of the radiator, at least once a year 5*

182 183 186 187

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

139

7. Maintenance

Maintenance table 500 Hours Service

2. Drive line 3. Brake system 4. Wheels 5. Tip- and steering cylinders 6. Cab ventilation

1.5.Check batteries 11* 1.6.Check battery terminals for tightness and corrosion 2.1.Check oil levels 3.1.Check lining thickness 3.2.How to adjust the parking brake.

4.1.Check wheel nuts torque.

5.1.Check expander bolts.

188 188 189 191 192 193 193

6.1.Air conditioner system, test operation 6.2.Check cab ventilation filter element condition 70* 7.1.Check the system

194 195 196

7. Automatic central lubrication (Lincoln lubrication system) 7. Automatic central 7.1.Check the system lubrication (Grovenveld lubrication system)

197

1000 Hours Service 1. Driver's seat 2. Engine

3.

4.

5.

6.

7.

8.

9.

1.1.General safety check 2.1.Replace fuel filter 4* Replace water separating fuel filter 4* 2.2.Bleed the fuel system: 2.3.Check batteries, at least once a year 11* 2.4.Check multi-groove belt condition, at least once a year 2.4.1.Inspect the multi-groove belt.

2.5.Air filter 10* Transmission 3.1.Change oil 20* Replace filter element 21* Clean strainer 22*, at least once a year Hydraulic system 4.1.Replace breather element 42* 4.2.Replace hydraulic return filter element 43*.

Front differential 5.1.Change oil, at least once a year 30* Rear differential 6.1.Change oil, at least once a year 31* Pinion bearing 7.1.Inspect the pinion bearing, on both sides of the tandem housings Front reduction gears 8.1.Change oil, at least once a year 33* Electrical system 9.1.Check wiring

198 198 199 199 200 200 201 203

205 206 208 209 209 210 210

2000 Hours Service 1. Engine

2. Brake system 3. Tandem housings (MT36/41

1.1.Check/adjust valve clearance (5 cylinder) 1.1.Check/adjust valve clearance (6 cylinder) 1.2.Check the coolant, at least once a year 5* 1.2.1.Check the appearance of the coolant 1.2.2.Coolant with glycol only: Check glycol content 1.2.3.Coolant with only anti-corrosive: Check protection against corrosion 2.1.Inspect brake lines, at least once a year.

3.1.Change oil 32*

211 212 213 213 214 215 216 216

1.1.Internal cleaning, every 4 years 5* 1.2.Change coolant, every 4 years 5* 2.1.Change oil 40* 3.1.Change oil 32*

217 218 219 220

4000 Hours Service 1. Cooling system 2. Hydraulic system 3. Tandem housings (MT25/26/31)

* Numbers refer to positions on the lubrication schedule, chapter 6 140

Operating & Maintenance Manual

7. Maintenance

Maintenance table Yearly recommended maintenance 1.

2.

3.

4.

5.

6.

Transmission Drive line Tanks Hydraulic system Exhaust system Bearings

1.1.General condition check 2.1.General condition check 3.1.General condition check 4.1.Inspect the hydraulic hoses 5.1.Safety check 6.1.Check clearance

221 221 221 222 222 222

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

141

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

1. Transmission 1.1. Change oil 20* Replace filter element 21* Clean strainer 22*, at least once a year • Changing transmission oil, replacement of transmission filter and cleaning of the strainer shall also be carried out every 1000 hours.

Drain oil: 1. The dump truck must be standing on level ground.

2. The oil must be at operating temperature.

3. Unscrew the dip stick (located behind the cab).

4. Remove cover plate under the transmission, by removing the 4 M12 bolts.

5. Remove cap.

6. Place drain hose with connection on drain nipple.

7. Once transmission oil is emptied remove hose and replace cap.

Rear cover

CAUTION Use gloves when checking the oil level or filling oil. The exhaust pipes and nearby area may be hot and fingers and hands could be burnt.

Cap

Drain nipple

Replace filter elements (located on the left hand side): Access to the filters through the engine bottom guard 8. Remove the engine bottom guard (front cover) 9. Clean well around the filters.

10. Place a suitable container beneath the filters to catch spillage.

11. Unscrew the filter elements.

12. Check for wear particles in the oil.

13. Apply oil to the seals on the new elements.

14. Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand.

continued overleaf

* Numbers refer to positions on the lubrication schedule, chapter 6 142

Operating & Maintenance Manual

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

Clean strainer: Access to remove the strainer

15. The strainer is located on the left hand side of the drain plug.

16. Unscrew the three nuts (1) and washers (2).

17. Remove the cover (3).

18. Replace the O-ring on the cover, if necessary.

Rear cover

19. Remove the strainer (4) and clean it.

20. Reassemble and torque nuts to 23 Nm.

1

21. Remount the all bottom guards and covers.

2 3 4

Fill new oil: 22. Fill new oil, according to the transmission oil list and oil specification sheet (chapter 6), through the dip stick tube.

23. Insert the dip stick again and turn handle clockwise to tighten the sealing.

Check: 24. Start the engine and check oil level (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage!

25. Warm up the oil and check for leaks. Re-check level and adjust if necessary.

NOTE • •

Do not overfill! Both too high and too low level can cause serious internal damage!

For rough operation conditions the oil and the filter element must be changed more often (every 500 hours) and the strainer must be cleaned as well.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

143

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

2. Hydraulic System 2.1. Replace hydraulic return filter element 43*.

•

Replacement of hydraulic return filter element shall also be carried out every 1000 hours of operation.

1. Accumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the filter. Procedure is described in chapter 2, item 27.

2. The filter is located on the back of the hydraulic tank. Remove the cover to get into the filter.

3. Clean well around the filter housing.

4. Place a suitable container beneath the draining hose to catch spillage.

5. Use a filter key to unscrew the old filter (counterclockwise).

Remove also the old O-ring.

The old filter contains 4 litres oil. Discard the filter element, and oil according to environmental requirements.

6. Check for wear particles in the oil.

7. Clean the O-ring groove, apply oil to the new O-ring and install it.

8. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more.

9. Fill 4 litres hydraulic oil, as specified in chapter 6, lubricants, through the oil filler on the top of the filter unit (under the cover on the top of the hydraulic tank).

10. Screw the oil plug back into place and clean off any oil spill.

11. Start engine and check for leaks.

The accumulators will be recharged with oil when the engine is re-started.

Fill 4 litres hydraulic oil throguh the oil filler.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

* Numbers refer to positions on the lubrication schedule, chapter 6 144

Operating & Maintenance Manual

7. Maintenance

Initial 100 Hours Service Maintenance to be performed after the first 100 hours only.

2.2. Replace hydraulic high pressure filter element 43a*.

•

Replacement of hydraulic high pressure filter element shall also be carried out every 1000 hours of operation.

1. Accumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the filter. Procedure is described in chapter 2, item 27.

2. The filter is located on the inside of the main frame and the engine.

3. Clean well around the filter housing.

4. Place a suitable container beneath the draining hose to catch spillage.

5. Use a filter key to unscrew the old filter (counterclockwise).

Remove also the old O-ring.

6. Check for wear particles in the oil.

7. Clean the O-ring groove, apply oil to the new O-ring and install it.

8. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more.

9. Screw the oil plug back into place and clean off any oil spill.

10. Start engine and check for leaks.

The accumulators will be recharged with oil when the engine is re-started.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

145

7. Maintenance

Initial 500 Hours Service Maintenance to be performed after the first 500 hours only.

1. Engine 1.1. Check/adjust PDE injector rocker arms • Checking/adjusting PDE injector rocker arms shall also be carried out after the first 500 hours of operation.

• Contact Moxy Dealer for checking/adjusting of the PDE injector rocker arms • The checking/adjusting of the PDE injector rocker arms

2. Transmission 2.1. Run the AEB-Tester AEB = Automatic Filling Parameter Adjustment

To optimise the transmission, run the AEB-Tester.

1. Remove the cover on the backwall (remove the instructor's seat back rest, if that is fitted).

2. Follow the procedure described in the table on next page.

The gear display will show the AEB's actions. ("Display message" in the table on the next page).

TCU = Transmission Control Unit

* Numbers refer to positions on the lubrication schedule, chapter 6 146

Operating & Maintenance Manual

7. Maintenance

Initial 500 Hours Service Maintenance to be performed after the first 500 hours only.

Run the AEB-Tester continued..............

Moxy part no.

8453

AEB = Automatic Filling Parameter Adjustment TCU = Transmission Control Unit

How to run the AEB-Tester

Display message

Remarks

1

Warm up the transmission oil, the oil must have a temperature at 70 - 80°C

Normal operating messages

2

-Move the gear selector to neutral position.

-Engage the parking brake.

-

3

Turn OFF the starter switch

-

4

Plug the AEB-Tester into the diagnostic contact no. 607

-

5

Start the engine

"PL"

6

Set engine speed to low idle rpm

"PL" if starts condition is OK

7

Press button on the AEB-Tester

"ST" if it starts condition is OK

The button must not be released before TCU

8

Keep the button depressed until the AEB has started

"K1" .....

(Information about the AEB state)

TCU has started the AEB and goes to adjusting K1, K2, ..., KR. (Button may be released)

9

Wait until AEB is finished

"OK" (AEB has been successful)

10

Turn OFF the starter switch and unplug the AEB-Tester

-

11

Remount the cover on the backwall

-

TCU must recognise "PL" for at least 2 seconds before you can press the button.

NOTE • • •

If the oil temperature is too low or too high, following message will apear on the gear display: T or T . Adjust the oil temperature and try again.

If there is a malfunction, turn the starter switch off and start the engine again.

The AEB will not start if any error codes are shown on the gear display, except error code "F6"

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

147

7. Maintenance

Initial 500 Hours Service Maintenance to be performed after the first 500 hours only.

3. Tandem housings 3.1. Change oil 32* • Change of tandem housing oil shall also be carried out every: 4000 hours of operation for MT25/26/31 2000 hours of operation for MT36/41.

1. The dump truck and tandem housings must be horizontal.

2. Unscrew drain plugs (1) on the inside of the housings.

3. Drain the oil into a suitable container.

4. Clean plugs, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the filler plugs (2) to correct level.

2

6. Clean plugs, replace seals if necessary and reinstall.

• Tightening torque: 80 Nm.

1

7. After test driving, check that level is at lower edge of the level plug.

CAUTION Be aware of possible internal pressure when the oil is hot!

* Numbers refer to positions on the lubrication schedule, chapter 6 148

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

1. General 1.1. Walk around check, before start • Check for leaks at the engine (see also item 2.1), transmission, differentials, reduction/tandem housings, tanks, hydraulic hoses and lubrication system.

• General check for loose bolts on the driveline, specially on radiator, engine/transmission brackets and at the prop.shaft flanges.

• Check for damage, wear and other abnormalities on the visible parts of frames, body, tyres, cylinders, etc.

• Check lights. Replace burnt out bulbs.

If leakages, loose bolts, damages or other abnormalities are observed,remedy if necessary (before operation). If necessary contact your local Moxy Dealer.

1.2. Check driver's seat, before start • Check function.

• Check all seat adjustments for easy operation.

• Check function of the air valve.

• Check safety belt for proper lock functions.

See chapter 3, seat adjustment, for more detailed information.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

149

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2. Engine

5 Cylinders

2.1. General condition check - look for leakages Remedy as necessary 1. Start the engine.

2. Look for leakage of oil, coolant, fuel, air and exhaust.

3. Tighten or change leaking connections. Check the overflow holes (1) which show whether the O-rings between the cylinder liner and crankcase are leaking, see figure. a. If coolant is leaking out, the O-rings are leaking. b. If oil is leaking out, the liner shelf is leaking.

4. A small amount of leakage from the overflow holes during the engine's running-in period is normal. (Seals and O-rings are lubricated with soap or oil when fitted).

This leakage normally stops after a time.

6 Cylinders

If there is a large amount of leakage - contact your Moxy Dealer.

2.2 Drain the water separating fuel filter 4* The water separating fuel filter is located on the left hand side of the engine.

Drain the filter by unscrewing the tap in the bottom of the filter.

Draining tap

* Numbers refer to positions on the lubrication schedule, chapter 6 150

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2.3. Check oil level, before start 1* • If the engine has been running: Let the engine remain stationary for at least 1 minute before checking the oil level.

• The dipstick (1) is found on the left hand side of the engine.

2

• The correct level shall be between upper and lower mark on the dip stick (1) (dump truck on level ground).

• Fill up with oil (2) if level has dropped to the lower mark.

See oil specification sheet, chapter 6 for correct oil type.

1

2.4. Check coolant level, before start 5* • The level in the expansion tank shall be between minimum and maximum when the dump truck is on level ground. See marks.

Refill with coolant of correct mixture if level is lower than minimum.

• If large quantities are required to correct the level, check and remedy the cause in such a case.

CAUTION Be careful when removing the filler cap of a hot engine.

Hot coolant and steam can spurt out!

Never add large amounts of cold coolant when engine is hot. The temperature difference can cause cracks in the engine.

Always top up with pre-mixed coolant.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

151

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2.5. Check fuel level, before start 13*

1

1. Turn on the starter switch key (to pos. 1) and check on the fuel gauge that there is enough fuel (1).

2. Fill up with fuel if necessary (2).

NOTE Always make sure that there is enough fuel in the tank.

NEVER run out of fuel, fuel injectors will be damaged.

2

2.6. Function check of the centrifugal cleaner, after operation 2* The rotor rotates very fast, and will normally carry on rotating after the engine is stopped.

1. Stop the engine when it is hot.

2. Listen for spinning sound from rotor, or feel if cleaner housing vibrates.

3. The rotor normally rotates 30 - 60 seconds after the engine has stopped.

4. If not, dismantle and check the cleaner, see 500 hours service.

* Numbers refer to positions on the lubrication schedule, chapter 6 152

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

3. Transmission 3.1. Check oil level, before operation 20* 1. The dump truck must be standing on level ground.

2. The gear selector shall be in neutral and confirm that the parking brake is ON. 3. Run the engine at low idle.

4. Turn the dip stick handle (behind the cab, right hand side) a few turns to the left to release the seal pressure.

5. Pull out the dip stick and clean it with a clean cloth.

6. Insert dip stick fully and remove it again (at least 2x) 7. Check level:

Cold oil, 40 °C: Hot oil, 80 °C:

lower mark upper mark

8. If necessary correct the level by adding oil according to the transmission oil list (chapter 6) through the dip stick tube.

Never mix engine oil with ATF oil 9. I n s e r t the dip and turn handle clockwise to tighten the sealing.

stick

again

CAUTION Use gloves when checking the oil level or filling oil. The exhaust pipes and nearby area may be hot and fingers and hands could be burnt.

Do not overfill with oil! Both too high and too low level can cause serious internal damage!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

153

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

4. Hydraulic system 4.1. Check oil level, before start 40* 1. Read the oil level in the oil level gauges (located on the back of the hydraulic tank).

• The upper gauge shows max. level at warm oil • The lower gauge shows min. level at cold oil.

2. Fill up with oil (see oil specification sheet, chapter 6) if necessary.

Oil filler located on the top of the hydraulic filter.

NOTE The dump truck must be horizontal and dump body completely lowered!

* Numbers refer to positions on the lubrication schedule, chapter 6 154

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hour of operation or daily.

5. Lubrication Grease lubrication points until pure grease is forced out of the components. Wipe off.

5.1. Door and fender hatches, 8 lubricators 57* There are 2 lubricators on the door, 2 lubricators on right hand side fender, 2 lubricators on left hand side fender and 2 lubricators on the cover upon the hydraulic tank (one per hinge) These lubricators must be manually greased, even if the automatic central lubrication is fitted.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

155

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

5.2. Cab rear hinges, 4 lubricator 58 * There is 1 lubricator on each side of the cab and 1 lubricator on the right and left side of the front attachment These lubricators must be manually greased, even if the automatic central lubrication is fitted.

6. Brake system 6.1. Parking brake Check braking (holding) capacity, before operation 1. Apply the parking brake (indicator light).

2. Set the gear selector in 1st gear.

3. Increase the engine speed slowly.

4. The parking brake must be able to keep the dump truck stationary at engine speeds up to 1400 rpm. If not, check parking brake system and contact your Moxy Dealer.

6.2. Service brake (main brake) Check braking (holding) capacity, before operation 1. Apply the parking brake (indicator light).

2. Depress the brake pedal.

3. Release the parking brake.

4. Set the gear selector in 1st gear.

5. Increase the engine speed slowly.

6. The service brake must be able to keep the dump truck stationary at engine speed up to 1400 rpm. If not, check the brake system and contact your Moxy Dealer.

* Numbers refer to positions on the lubrication schedule, chapter 6 156

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

6.3. Service brake (main brake) Check function, before operation 1. Apply the parking brake (indicator light).

2. Stop the engine.

3. Check for hydraulic oil leakage at accumulators, pipes, hoses and calipers.

4. Start the engine and release the parking brake.

5. Check that the brake system warning light (chapter 3) does not illuminate.

6. Drive the dump truck slowly on firm, level ground and depress the brake pedal firmly.

7. Check that the braking effect is good and equal.

6.4. Accumulators Check the oil pressure, before operation 1. The dump truck must be parked on a horizontal ground.

2. Apply the parking brake.

3. Start the engine and let it run at low idle until the accumulators are fully charged (warning light off).

4. Stop the engine.

5. Release the parking brake, wait 5 sec. Apply the parking brake, wait 10 sec. Release the parking brake again, wait 5 sec. Apply the parking brake again, wait 10 sec. Continue until the brake warning light comes on.

• Count how many times the parking brake can be applied until the brake system warning light comes on 6. The parking brake should be applied at least 6 times before the warning light comes on. If not, check the brake system and contact your Moxy Dealer.

WARNING Accumulators contain oil under high pressure!

• Always empty the accumulators before working on or opening the hydraulic system.

• Procedure: • Stop the engine.

• Operate the brake pedal repeatedly until the accumulators are empty.

Accumulators can also be emptied through the accumulator test connectors.

Be aware of that the accumulators will be recharged with oil when the engine is restarted.

7. Recharge the accumulators by starting the engine and let it run at low idle until the accumulators are fully charged (warning light off).

8. Stop the engine 9. With the parking brake applied, check the service brake as follows: 10. Apply the service brake pedal, hold for 10 sec. Release the brake pedal and wait 5 sec. Apply the brake pedal again and hold for 10 sec. Then release the brake pedal again and wait 5 sec.

Continue until the brake warning light comes on.

• Count how many times the service brake pedal can be applied until the brake system warning light comes on

11. The service brake pedal should be applied at least 5 times before the warning light comes on. If not, check the brake system and contact your Moxy Dealer. * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

157

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

7. Steering 7.1. Check function, before operation 1. Drive slowly forwards (5-10 km/h) and check that the emergency steering light goes off.

2. Turn the steering wheel at an even speed until end stop, both sides.

3. Check that the movement is uniform.

8. Engine brake 8.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

2. Apply the engine brake by releasing the throttle pedal.

3. Check that the exhaust sound changes.

4. Check the indicator light for function and note the braking power.

5. Depress the throttle pedal again and note that the engine brake goes off (i.e no braking power, exhaust sound

9. Engine and retarder brake 9.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

2. Apply the retarder brake by depressing the retarder brake switch and release the throttle pedal. The engine brake will also then apply.

3. Check that the exhaust sound changes.

4. Check the indicator lights for function, both engine and retarder brake and note the braking power.

5. Depress the throttle pedal again and notify that both the engine and retarder brake goes off (i.e no braking power and the indicator lights switches off).

* Numbers refer to positions on the lubrication schedule, chapter 6 158

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

1. Cab ventilation 1.1. Clean prefilter 70* 1. Open 2 clamps and remove the cover (1).

2. Remove the pre-filter (2), and clean it with compressed air.

• Replace if necessary 3. Reassamble the opposite way.

4. Adjust the check interval if another requirement is experienced.

2 1

NOTE Never start driving without prefilter. The heater could be damaged.

1.2. Air conditioner system • The equipment must be used for at least five minutes every week, to distribute oil in the system, this prevent leaks and ensure that the seals are lubricated • See operating controls, chapter 3, cab ventilation, about how to use the air conditioner.

• This must also be done during cold weather operation.

NOTE At ambient temperatures below + 4° C the air conditioner will not engage. Warm up the cab before

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

159

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

2. Tyres 2.1. Check tyre pressures, before operation When the pressure shall be measured, the dump truck must be unloaded.

Measure the pressure for cold tyres with a tyre pressure gauge and adjust if necessary. For tyre pressure recommendation, see chapter 8 - Technical data, and chapter 5 - Operating instructions.

WARNING Stand behind the tread when checking the inflation pressure.

Pressures inside tyres are substantial and an explosion

Located under the cover

3. Automatic central lubrication (Lincoln lubrication system) 3.1. Check the lubricant level in the reservoir.

Refill the reservoir if the level has dropped to a minimum.

1. Carefully clean the filler nipple and the coupling on the filler hose.

2. Fit the filler hose on the filler nipple.

3. Fill the reservoir up to the maximum level indicated on the reservoir. Use only grease as specified in chapter 6, lubricants (Use pump supplied with dump truck).

4. Remove the filler hose.

NOTE Filler nipple

• •

•

Do NOT use grease which contains graphite, teflon or molybdenum Even if the automatic central lubrication is installed, do not forget that there are still some greasing points that must be greased by hand, these are the door, fender hatches and the cab rear hinges.

If system has been empty you may have to activate pump manually to clear air and codes from system.

WARNING • The grease must be free from impurities and must not change consistancy over time.

• Always switch off power when filling the reservoir tank.

• Risk of bursting reservoir tank if you overfill!

• If reservoir tank has been completely emptied it could take up to 10 minutes for the lubrication sytem to acheive full output again. * Numbers refer to positions on the lubrication schedule, chapter 6 160

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

Located under the cover

3. Automatic central lubrication (Grovenveld lubrication system) 3.1. Check the grease level in the reservoir.

Refill the reservoir if the level has dropped to a minimum The reservoir must also be refilled if the indicator light flashes for 2 minutes (0.5s on/0.5s off) at the beginning of each cycle.

1. Remove the dust cap from the filler coupling.

2. Carefully clean the filler coupling and the coupling on the filler hose.

3. Fit the filler hose on the filler coupling.

4. Fill the reservoir up to the maximum level indicated on the reservoir. Use only grease as specified in chapter 6, lubricants.

Filler coupling

5. Remove the filler hose and fit the dust cap.

NOTE • •

Do NOT use grease which contains graphite, teflon or molybdenum Even if the automatic central lubrication is installed, do not forget that there are still some greasing points that must be greased by hand, these are the door, fender hatches and the cab rear hinges

4. Continue with all items in 8 Hours / Daily Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

161

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1. Engine 1.1. Change oil 1* If the dump truck is used for particulary demanding operation, especially in a dusty environment or if the deposits in the centrifugal cleaner are thicker than 20 mm: Change oil more often.

1. Remove the cap on the drain plug, install the draining hose (tool kit) and drain the oil when the engine is hot.

Access through the drain hole in engine bottom guard (1).

1

2. When all oil is drained, remove the draining hose and re-install the cap.

4. Reinstall the cover for drain hole in engine bottom guard.

5. Fill oil through filler (2). Do not overfill!

6. Check oil level on dip stick (3).

CAUTION The oil may be hot! Wear protective gloves and eye protection.

3

2

* Numbers refer to positions on the lubrication schedule, chapter 6 162

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.2. Clean centrifugal cleaner 2* (at the same time as oil change, item 1.1)

1. Clean the cover. Unscrew the nut and remove cover.

CAUTION Open the cover with care. The oil and inner parts may be hot!

2. Lift out the rotor assembly and loosen the nut for the rotor cover three turns.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

163

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3. If the nut sticks: Secure the nut, absolutely not the rotor, in a vice and turn the rotor three turns by hand or using a screwdriver.

4. Gently tap the nut with the hand or with a plastic hammer to separate the rotor from bottom plate.

5. Undo the nut and remove the rotor cover.

6. Carefully prise the strainer loose from the bottom plate.

7. Scrape off the deposits from the inside of rotor cover.

• If there are no deposits, this shows that the cleaner is not working.

• Clean more frequently if deposits are thicker than 20 mm.

8. Clean all parts in diesel fuel.

* Numbers refer to positions on the lubrication schedule, chapter 6 164

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

9. Place the O-ring in position in the rotor cover.

• The O-ring must not be damaged.

Change if necessary.

10. Assemble the rotor.

11. Tighten rotor nut firmly by hand.

12. Reinstall the rotor.

• Check that it rotates easily.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

165

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

13. Check that the O-ring in the cover is not damaged.

Hard or damaged O-ring must be replaced.

14. Tighten cover firmly by hand.

15. If the nut is tightened too hard (for instance by using tools), the cover, nut or rotor shaft may be damaged!

16. Replace damaged parts!

17. Function check The rotor rotates very fast, and will normally carry on rotating after the engine is stopped. a. Stop the engine when it is warm. b. Listen for spinning sound from rotor, or feel if cleaner housing vibrates. c. The rotor normally rotates 30 - 60 seconds after the engine has stopped. d. If not, dismantle and check the cleaner.

1.3. Replace oil filter 3* (at the same time as oil change, item 1.1) 1. The filter is located on the right hand side of the engine.

2. Remove the old filter and discard it according to environmental requirements.

3. Oil the rubber gasket on the new genuine filter.

4. Fit the new genuine filter.

5. Tighten the filter by hand as tight as possible.

6. Start the engine and check for leaks.

If the deposits in the centrifugal cleaner exceed 20 mm, the oil filter must be changed more often, at the same time as cleaning the centrifugal filter and changing the oil.

NOTE • •

Never use tools to tighten the filter.

It can be damaged and thecirculation obstructed!

Use only genuine filter!

* Numbers refer to positions on the lubrication schedule, chapter 6 166

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.4. External cleaning of the radiator, at least once a year 5* If necessary, the cooling system should be cleaned more often.

1. Clean externally the radiator fins and hoses by using a brush.

The radiator can also be washed with water from the backside.

2. Check that the radiator is not blocked on the air side and that the fins are not damaged.

3. Carefully scrape the deposit away from the radiator fins.

If necessary, a paraffin-based engine cleaner may be used.

4. Check the fins, rubber hoses, clamps and pipes for corrosion, damage and leakages.

5. Bent fins can be carefully straightened, e.g. using a steel wire brush.

CAUTION The cooling system must not be cleaned using caustic soda. It can damage aluminium parts.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

167

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.5. Check batteries 11* 10 - 15 mm

• Checking of batteries shall also be carried out after the first 8 hours of operation.

1. Open left hand side fender cover (open the bonnet first and then the fender cover) 2. Undo the plugs and check electrolyte level in all cells.

3. The fluid level in each cell shall be between 10-15 mm above the plates.

4. Refill with distilled water if level is lower.

NOTE Only distilled or chemically cleaned water must be used.

1.6. Check battery terminals for tightness and corrosion Clean if necessary, apply acid-free vaseline on the terminals and retighten the clamps.

* Numbers refer to positions on the lubrication schedule, chapter 6 168

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

2. Drive line 2.1. Check oil levels • Measurements must be carried out when dump truck is parked on a horizontal ground.

• Check that oil level is near the bottom edge of the plugs.

• Refill with oil if level is too low.

• If the dump truck tandem housing is angled, the reading will be incorrect.

CAUTION Be aware of possible internal pressure when the oil is hot!

1. Front differential 30* Use a hexagonal key to unscrew the upper filling/ level plug.

• Plug torque: 80 Nm

2. Rear differential 31* Use a hexagonal key to unscrew the filling/level plug at the rear of housing.

• Plug torque: 80 Nm.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

169

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3. Tandem housings 32* Use a hexagonal key to unscrew the level plugs on the inside of the housing.

• Plug torque: 80 Nm.

4. Front reduction gears 33* Turn the hubs until level indicator is horizontal. Use a hexagonal key to unscrew the plugs.

• Plug torque: 80 Nm.

* Numbers refer to positions on the lubrication schedule, chapter 6 170

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Service brake

3. Brake system 3.1. Check lining thickness • Checking of brake lining thickness shall also be carried out after the first 500 hours of operation.

1. Service brakes: Check brake linings. Brake linings should be changed before the thickness of the linings on the most worn areas reaches 3,5 mm.

• How often the brake linings have to be checked/ replaced depends on how much the brakes are used and/or applications.

After checking the brake linings for the first 500 hours, consider whether or not the brake linings should be checked more often, based on lining wear.

2. Parking brake: Lift body and apply the body support.

Remove the protection on the top of the parking brake and check thickness of linings. Change when approaching limit.

• In connection with replacement perform adjustment, see next page.

Standard lining thickness: Service brakes: 22.0 mm Parking brake: 20.0 mm Min. thickness:

Parking brake

Service brakes: 3.5 mm.

Parking brake: 5.1 mm.

CAUTION This applies to normal driving. For rough operating conditions with much braking and/or driving in water, the brake linings should be checked more often!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

171

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

3.2. How to adjust the parking brake.

To be performed in connection with replacement of parking brake linings.

• Before removing the parking brake linings, do as follows:

1

1. Apply the parking brake.

2. Lift the body.

3. Apply the body support (1) (see also safety instructions, chapter 2).

4. Stop the engine.

5. Secure the dump truck with wheel chocks (see also safety instructions, chapter 2) 6. Release the parking brake by the parking brake switch.

Washer-adjuster plug

7. Remove the adjuster plug and washer from the cylinder bracket.

Adjuster

8. Use a 6 mm allen wrench to adjust the brake (turning the allen wrench in clockwise direction). Stop turning the allen wrench when you feel resistance, which indicates that the adjuster pistons are fully retracted.

• When you de-adjust the brake (increase disc clearance) you will hear a "clicking" sound and feel a "pulsing" sensation during the adjustment.

• To ensure that the automatic adjustment will occur: Adjust the brake an additional 1/4 turn after you reach the resistance point.

• Do not use an air gun to adjust or de-adjust the parking brake!

Components could be damaged.

Allen wrench

9. The parking brake linings can now be replaced.

• After installation of new parking brake linings, do as follows: 1. Adjust the caliper by reducing the caliper-to-disc clearance to ZERO (turning the allen wrench in counter clockwise direction).

2. Check that the load plate fully contacts the lining backing plate.

3. To increase the disc clearance, turn the allen wrench SEVEN CLICKS in clockwise direction, which sets the initial clearance.

4. Install the adjuster plug and washer.

• Tightening torque: 11-17 Nm 5. Apply and release the parking brake 15-20 times to allow the adjuster to set the final caliper clearance.

* Numbers refer to positions on the lubrication schedule, chapter 6 172

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

4. Wheels 4.1 Check wheel nuts torque.

Torque setting 450 Nm.

5. Tip- and steering cylinders 5.1 Check expander bolts.

• Checking of the expander bolts torque setting shall also be carried out after the first 100 hours of operation.

Torque setting: • Tip cylinder bolt: • Steering cylinder bolt:

250 Nm 380 Nm

• The torque must be checked on on both sides of the bolts.

• Be aware of the lubrication nipples on the bolts when checking the torque.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

173

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

6. Cab ventilation 6.1. Air conditioner system, test operation 1. Start the engine.

2

2. Press down the air conditioner switch, set the fan switch to position 3 (see also chapter 3) and open all nozzles.

1

3. Check that the temperature in the cab decreases.

• If the temperature does not decrease: • Check whether the fuse is burnt out, if yes, replace the fuse.

• If the fuse is not burnt out, there can be a failure or too little refrigerant in the system: CONTACT YOUR LOCAL MOXY DEALER

WARNING •

If the air conditioning system does not work properly, contact your Moxy Dealer.

•

Always use safety glasses or goggles, gloves, boiler suit and protective footwear when inspecting, servicing and repairing the air conditioning system.

•

Refrigerant R134a has a property that can cause frostbite if it comes into contact with bare skin or eyes.

•

Always work on the air conditioning system in well ventilated places.

•

The system contains refrigerant R134a under pressure. Repair and refilling of the refrigerant circuit must only be done by accredited personnel.

•

Dispose of waste oil/fluids in an enviromentally friendly manner!

•

High concentration of the refrigerant in gaseous form can cause drowsiness, headache, dizziness and at worst unconsciousness. Very high concentration of the gas can even cause cardiac insufficiency.

Do not smoke when servicing the air conditioning system!

•

Be careful with all hoses connected to the air conditioning system. There is always a certain over pressure in the system. Therefore, never undo hoses or the filler opening on the compressor except during repairs to the system.

•

If there is any suspicion of leakage, the system must not be filled up - leave the leakage site and contact your Moxy Dealer for repairs.

•

Get your Moxy Dealer to check the air conditioning system yearly and refill refrigerant, if necessary.

•

See also chapter 2, Safety Instructions

* Numbers refer to positions on the lubrication schedule, chapter 6 174

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

6.2. Check cab ventilation filter element condition 70* 1. Remove the rear panel on the right hand side inside the cab (behind the driver's seat).

2. Open the cover (1) with a screw driver.

3. There is two filter elements (2).

4. Check if the filter elements are clogged or damaged.

• Replace if necessary.

5. Reassemble the opposite way.

1

6. Adjust the check interval if another requirement is experienced.

2

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

175

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Located under the cover

7. Automatic central lubrication (Lincoln lubrication system) 7.1. Check the system • Check the pump for damage and leakage.

• Check the grease lines for damage and leakage.

• Check, if possible, the condition of the grease points the system serves. Sufficient fresh grease should be present.

• Check the operation of the system. Perform a cycle test (see chapter 3 for how to perform a cycle test).

Note that every time you perform a cycle test, grease is supplied to the grease points.

• Clean the pump-unit and its surroundings.

NOTE •

•

If you use a high-pressure air or water gun to clean the dump truck, do not spray directly onto the pump unit. Water or dirt might enter the pump-unit through the de-aerating openings.

For cleaning the sytem use benzine or petroleum.

Do not use tri-perchloroethylene or similar solvents. Also do not use polar organic solvents such as alcohol, methylacohol, acetone or similar.

* Numbers refer to positions on the lubrication schedule, chapter 6 176

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Located under the cover

7. Automatic central lubrication (Grovenveld lubrication system) 7.1. Check the system • Check the pump for damage and leakage.

• Check the grease lines for damage and leakage.

• Check, if possible, the condition of the grease points the system serves. Sufficient fresh grease should be present.

• Check the operation of the system. Perform a cycle test (see chapter 3 for how to perform a cycle test).

Note that every time you perform a cycle test, grease is supplied to the grease points.

• Clean the pump-unit and its surroundings.

NOTE •

If you use a high-pressure air or water gun to clean the dump truck, do not spray directly onto the pump unit. Water or dirt might enter the pump-unit through the de-aerating openings.

8. Continue with all items in 40 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

177

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

1. Driver's seat 1.1. General safety check • Check for play in seat gliders. Max. allowed in length or sideways 1 mm. Grease the gliders.

• Check shock absorbers for oil leakages.

• Check seat mounting to the dump truck.

• Check safety belt and lock mechanism for wear and damage.

• Check that no pins are loose / worn in the seat base.

• Replace worn/damaged parts.

2. Engine 2.1 Replace fuel filter 4* Replace water separating fuel filter 4* The filters consist of one filter unit each.

The filters are located on the left hand side of the engine.

The fuel filter in the front of the engine and the water separating fuel filter on the rear of the engine, see illustration.

1. Wash the filters externally and unscrew it.

Discard the filters according to environmental requirements.

2. Fit the new genuine filters and tighten it by hand.

• Never use tools to tighten the filters!

The filters may be damaged and the fuel flow hampered.

Fuel filter Water separating fuel filter

3. Bleed the fuel system, procedure on next page, item 2.2.

4. Start engine and check for leaks.

CAUTION Observe extreme cleanliness when working with the fuel system. Otherwise may operational interruption easily occur and the injection equipment may be damaged.

* Numbers refer to positions on the lubrication schedule, chapter 6 178

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2 Bleed the fuel system:

1

B

1. Attach a clear plastic hose to the bleeder nipple (1) to channel fuel into a container.

The bleeder nipple is located at the end of the fuel manifold at the front of the engine.

3

2. Open the bleeder nipple (1).

3. Pump with the hand pump (2) until bubble-free fuel flows out of the opened bleeder nipple.

2

• If the system is completely empty, it will take approx. 250 strokes.

• After changing the fuel filters, it will take approx. 170 strokes.

• Approx. 150 strokes are required to bleed the fuel manifold.

4. Close the bleeder nipple and remove the hose.

5. Undo the banjo screw for overflow valve (3) slightly.

Pump the hand pump (2) additional 20 strokes until the overflow valve opens.

If the engine fails to start after bleeding: • Open the bleeder nipple again and pump the hand pump until bubble-free fuel flows out.

• Tighten the bleeder nipple. Start the engine and check for leaks.

WARNING The engine may be hot! Use gloves when pumping with the hand pump to avoid burning your hands.

2.3. Check batteries, at least once a year 11* • Checking battery charge shall also be carried out after the first 8 hours of operation.

Use a hydrometer to check the density of the electrolyte.

The density of a fully charged battery should be: 1.240 at higher than +20 oC 1.280 at +20 oC, 1.294 at 0 oC, 1.308 at -20 oC. Recharge the battery if the density is lower than 1.20.

A discharged battery freezes at -5 oC.

WARNING The electrolyte level must be correct when charging! During recharge a explosive gas is emitted. Open cell plugs and ventilate properly to avoid explosion!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

179

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.4. Check multi-groove belt condition, at least once a year • Checking of multi-groove belt condition shall also be carried out after the first 8 and 100 hours of operation.

• Stop the engine to inspect the multi-groove belt (1), see item 2.4.1 for procedure.

• Change the belt (1) if damaged or worn, see figures 1-3 below.

• Check that the automatic belt tensioner (2) is in proper working order and keeps the multi-groove belt sufficiently tightened.

2.4.1

Inspect the multi-groove belt.

• Loosen the multi-groove belt from the belt pulleys but leave it around the fan shaft so that the direction of rotation for the multi-groove belt is not changed.

• Check the multi-groove belt carefully. If the multi-groove belt has one or more cracks, as shown in fig. 1, it should be replaced.

• Also check the wear on the multi-groove belt as shown in fig. 2 and 3.

NOTE Do not change the direction of rotation of the multi-groove belt if it is refitted.

Small superficial cracks in the belt can be accepted

Fig. 2 The multi-groove belt shows signs of wear.

Can be refitted.

Fig. 1 At large and deep cracks or if small pieces are missing, the belt should be replaced.

Fig. 3 The wear is down to the chord. The multi-groove belt must be replaced.

* Numbers refer to positions on the lubrication schedule, chapter 6 180

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.5. Air filter 10* The air filter is located on the top of the engine, under the bonnet.

• Always stop the engine before servicing the air filter.

• Open the bonnet and apply the bonnet catcher.

• Cleaning and replacement of outer and inner element, see this page and next page.

Outer element: Clean element every 1000 hours of operation or if the air filter warning light illuminates at full load on the engine.

• Replace the outer element after 5 times of cleaning, or at the latest after 2 years.

1. Loosen all clamps and remove the cover (fig. 1).

Dust cap

Fig. 1

2. Remove outer element with a light turning movement (fig. 2). Do not remove inner element when cleaning outer element!

3. To blow out the filter element, use tube with a bent end which is attached to a compressed air gun; the end of the tube must be bent by approx. 90°. It must be of sufficient length to reach down to the bottom of the filter element. Blow out the filter element using dry compressed air (max. 5 bar) by moving the tube up and down inside the filter element until there is no more dust coming out (fig. 3).

Fig. 2

• Never wash out or brush out the outer element.

When blowing out make sure that no dust is allowed to enter the inside area of the outer element.

4. Punch a mark in the edge of the inner element each time the outer element is cleaned.

5. Check the cleaned element for damage of the paper element and of the rubber seals.

• Cracks and holes in the paper element can be discovered by shining through light from an electric bulb (fig. 4).

6. Never carry on using a damaged outer element.

In case of doubt, always fit a new outer element.

Fig. 3

7. Reinstall the outer element, the cover, and fasten all the clamps. Turn the cover so that the dust cap is pointed downwards (max angle: 15°).

See also precautions on next page

Fig. 4

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

181

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Servicing the dust cap The dust cap require very little maintenance.

Possible dust packs to be removed by squeezing the cap (fig. 5).

Fig. 5

Inner element: • Replace element every 5th cleaning of the outer element, or after 2 years.

• Do not clean the inner element and do not reuse it after it has been taken out.

Only open the seal in order to replace the inner element.

Fig. 6

1. Loosen all clamps and remove the cover.

2. Remove outer element.

3. Remove the inner element; Use a suitable tool (e.g. screwdriver) to push through the seal of the inner element from the inside to the outside and pull both the straps upwards (fig. 6). and 7).

4. Use both straps to take hold of the inner element then pull out with a light turning movement (fig.

5. Install a new inner element into the housing.

6. Install a new or cleaned outer element.

7. Reinstall the cover, and fasten all the clamps.

Turn the cover so that the dust cap is pointed down wards (max angle: 15°).

Fig. 7

CAUTION • • •

• • • •

Do not attempt to reinstall a cleaned inner element.

Do not clean or replace the elements when the engine is running.

Replace the outer element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning.

Do not use an element in which folds, gasket or seal are damaged.

When cleaning the element, do not hit or hammer it.

Do not dismantle the inner element unnecessarily.

Punch a mark in the edge of the inner element each time the outer element is cleaned.

* Numbers refer to positions on the lubrication schedule, chapter 6 182

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

3. Transmission 3.1. Change oil 20* Replace filter element 21* Clean strainer 22*, at least once a year • Changing transmission oil, replacement of transmission filter and cleaning of the strainer shall also be carried out after the first 100 hours of operation.

Drain oil: 1. The dump truck must be standing on level ground.

2. The oil must be at operating temperature.

3. Unscrew the dip stick (located behind the cab).

4. Remove cover plate under the transmission, by removing the 4 M12 bolts.

5. Remove cap.

6. Place drain hose with connection on drain nipple.

7. Once transmission oil is emptied remove hose and replace cap.

Rear cover

CAUTION Use gloves when checking the oil level or filling oil. The exhaust pipes and nearby area may be hot and fingers and hands could be burnt.

Cap

Drain nipple

Replace filter elements (located on the left hand side): Access to the filters through the engine bottom guard 8. Remove the engine bottom guard (front cover) 9. Clean well around the filters.

10. Place a suitable container beneath the filters to catch spillage.

11. Unscrew the filter elements.

12. Check for wear particles in the oil.

13. Apply oil to the seals on the new elements.

14. Screw the filter elements in until contact with the sealing surface is obtained. Tighten the elements firmly by hand.

continued overleaf

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

183

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Clean strainer: Access to remove the strainer

15. The strainer is located on the left hand side of the drain plug.

16. Unscrew the three nuts (1) and washers (2).

17. Remove the cover (3).

18. Replace the O-ring on the cover, if necessary.

Rear cover

19. Remove the strainer (4) and clean it.

20. Reassemble and torque nuts to 23 Nm.

1

21. Remount the all bottom guards and covers.

2 3 4

Fill new oil: 22. Fill new oil, according to the transmission oil list and oil specification sheet (chapter 6), through the dip stick tube.

23. Insert the dip stick again and turn handle clockwise to tighten the sealing.

Check: 24. Start the engine and check oil level (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage!

25. Warm up the oil and check for leaks. Re-check level and adjust if necessary.

NOTE • •

Do not overfill! Both too high and too low level can cause serious internal damage!

For rough operation conditions the oil and the filter element must be changed more often (every 500 hours) and the strainer must be cleaned as well.

* Numbers refer to positions on the lubrication schedule, chapter 6 184

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

4. Hydraulic system 4.1. Replace breather element 42* • Accumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the element.

Procedure is described in chapter 2, item 27.

• Unscrew the old element on the hydraulic tank (under the cover).

• Check the o-ring for deterioration, apply oil and screw on a new element.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

185

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

4.2. Replace hydraulic return filter element 43*.

•

Replacement of hydraulic return filter element shall also be carried out after the first 100 hours of operation.

1. Accumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the filter. Procedure is described in chapter 2, item 27.

2. The filter is located on the back of the hydraulic tank. Remove the cover to get into the filter.

3. Clean well around the filter housing.

4. Place a suitable container beneath the draining hose to catch spillage.

5. Use a filter key to unscrew the old filter (counterclockwise).

Remove also the old O-ring.

The old filter contains 4 litres oil. Discard the filter element, and oil according to environmental requirements.

6. Check for wear particles in the oil.

7. Clean the O-ring groove, apply oil to the new O-ring and install it.

8. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more.

9. Fill 4 litres hydraulic oil, as specified in chapter 6, lubricants, through the oil filler on the top of the filter unit (under the cover on the top of the hydraulic tank).

10. Screw the oil plug back into place and clean off any oil spill.

11. Start engine and check for leaks.

The accumulators will be recharged with oil when the engine is re-started.

CAUTION Fill 4 litres hydraulic oil through the oil filler.

Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

* Numbers refer to positions on the lubrication schedule, chapter 6 186

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2. Replace hydraulic high pressure filter element 43a*.

•

Replacement of hydraulic high pressure filter element shall also be carried out the first 100 hours of operation.

1. Accumulators contain oil under high pressure!

Empty the accumulators, before unscrewing the filter. Procedure is described in chapter 2, item 27.

2. The filter is located on the inside of the main frame and the engine.

3. Clean well around the filter housing.

4. Place a suitable container beneath the draining hose to catch spillage.

5. Use a filter key to unscrew the old filter (counterclockwise).

Remove also the old O-ring.

6. Check for wear particles in the oil.

7. Clean the O-ring groove, apply oil to the new O-ring and install it.

8. Apply oil or grease to the threads and install a new filter element by turning it clockwise until seals make contact. Then tighten by hand 1/4 to 1/3 turn more.

9. Screw the oil plug back into place and clean off any oil spill.

10. Start engine and check for leaks.

The accumulators will be recharged with oil when the engine is re-started.

CAUTION Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

187

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

5. Front differential 5.1 Change oil, at least once a year 30* • Change front diff. oil shall also be carried out after the first 500 hours of operation.

1. Access to the drain plug through transmission bottom guard.

2. Open level / filling plug (1), special spanner in tool kit.

3. Unscrew drain plug (2).

1

4. Drain the oil into a suitable container.

5. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 6. Fill new oil, according to the oil specification sheet (chapter 6), through the level / filling plug, level shall be at lower edge of hole when dump truck is horizontal.

7. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

2 CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

* Numbers refer to positions on the lubrication schedule, chapter 6 188

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

6. Rear differential 6.1. Change oil, at least once a year 31* • Change rear diff.oil shall also be carried out after the first 500 hours of operation.

1. Open level/filling plug (1).

2. Unscrew drain plug (2) underneath the housing.

3. Drain the oil into a suitable container.

4. Clean the drain plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

1

6. Clean the plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

2 CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

Inspection cover

7. Pinion bearing 7.1. Inspect the pinion bearing, on both sides of the tandem housings 1. Remove the inspection cover.

2. Check the general condition of the pinion bearing.

Check for wear, cracks, deterioration, damages .

• Replace the bearing if necessary.

3. Reinstall the inspection cover.

NOTE For rough operating conditions, the pinion bearing should be checked more often.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

189

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

8. Front reduction gears 8.1. Change oil, at least once a year 33* • Change front reduct. gear oil shall also be carried out after the first 500 hours of operation.

1. The dump truck must be horizontal.

2. Turn the hub, so that the plug is pointed downwards.

1

3. Unscrew the plug (1).

4. Drain the oil into a suitable container.

5. Turn the hub 90o, so that the level indicator is horizontal (2).

6. Fill new oil, according to the oil specification sheet (chapter 6), through level/filling plug, level shall be at lower edge of hole when dump truck is horizontal.

7. Clean plug, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm.

2

8. Re-check oil level after test driving.

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

9. Electrical system 9.1. Check wiring The wiring harness must not be damaged. Check that the cables on the articulation hinge and on the rear frame/ body are not squeezed, have sharp bends or loose/bad connections.

10. Continue with all items in 500 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 190

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1. Engine

1 2 3 4 5

1.1. Check/adjust valve clearance (5 cylinder) • Checking/adjusting valve clearance shall also be carried out after the first 500 hours of operation.

• Contact Moxy Dealer for checking/adjusting of the valve clearance • The checking/adjusting of the valve clearance must only be carried out by qualified personnel.

• The air filter and air filter bracket has to be removed before adjustment takes place.

FLYWHEEL Cylinder numbering TDC position No. 6 cylinder

TDC position No. 1 cylinder

Adjust if necessary: • Inlet: 0,45 mm • Exhaust: 0,70 mm see instruction sign on one of the rocker covers.

Valves should be adjusted when the engine is cold, at least 30 minutes after operation.

Rocker cover gaskets must be changed if necessary.

• Tightening torque: 26 Nm 1. Set no. 1 cylinder to TDC (Top Dead Centre) by turning the engine in its direction of rotation until all four valves are closed.

2. Adjust the following valves: Cylinder

FLYWHEEL Intake valve Exhaust valve

1 Inlet and exhaust 2 Inlet 3 Exhaust 4 Inlet 5 Exhaust

3. Set no. 6 cylinder to TDC (Top Dead Centre) by turning the engine one revolution in its direction of rotation.

4. Adjust the following valves: Cylinder

The readings can only be taken from underneath

2 Exhaust 3 Inlet 4 Exhaust 5 Inlet 6 Inlet and exhaust

WARNING Block the starter device when working on the engine!

If the engine starts out of control, there is a SERIOUS RISK OF INJURY! Covers for reading on flywheel casing

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

191

7. Maintenance

1.1. Check/adjust valve clearance (6 cylinder) • Checking/adjusting valve clearance shall also be carried out after the first 500 hours of operation.

• Contact Moxy Dealer for checking/adjusting of the valve clearance • The checking/adjusting of the valve clearance must only be carried out by qualified personnel.

• The air filter and air filter bracket has to be removed before adjustment takes place.

FLYWHEEL Cylinder numbering TDC position No. 6 cylinder

TDC position No. 1 cylinder

Adjust if necessary: • Inlet: 0,45 mm • Exhaust: 0,70 mm see instruction sign on one of the rocker covers.

Valves should be adjusted when the engine is cold, at least 30 minutes after operation.

Rocker cover gaskets must be changed if necessary.

• Tightening torque: 26 Nm 1. Set no. 1 cylinder to TDC (Top Dead Centre) by turning the engine in its direction of rotation until all four valves are closed.

2. Adjust the following valves: Cylinder

FLYWHEEL

1 Inlet and exhaust 2 Inlet 3 Exhaust 4 Inlet 5 Exhaust

3. Set no. 6 cylinder to TDC (Top Dead Centre) by turning the engine one revolution in its direction of rotation.

Intake valve Exhaust valve

4. Adjust the following valves: Cylinder

The readings can only be taken from underneath

2 Exhaust 3 Inlet 4 Exhaust 5 Inlet 6 Inlet and exhaust

WARNING Block the starter device when working on the engine!

If the engine starts out of control, there is a SERIOUS RISK OF INJURY! Covers for reading on flywheel casing

* Numbers refer to positions on the lubrication schedule, chapter 6 192

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of opera-

1.2. Check the coolant, at least once a year 5*

Coolant: Water+Anti-freeze or Water + Anti-corrosive (see text)

NOTE Coolant composition: If there is a danger of freezing: • At least 30% glycol by volume (15 litres by total volume) • Max. 60% glycol by volume (30 litres by total volume) If there is no danger for freezing: • 10% anti-corrosive by volume (5 litres by total volume)

1.2.1 . Check the appearance of the coolant, at least once a year • Take a little coolant in a vessel and check that it is clean and clear.

• If the coolant is contaminated or cloudy: Consider changing the coolant.

• The water for the coolant should be free of dirt.

• Use drinking water with a pH of 6 - 9.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

193

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1.2.2. Coolant with glycol only: Check glycol content, at least once a year If there is risk of ambient temperature below 0 °C, use only glycol as protection against corrosion in the coolant.

• Cooling system with glycol must contain at least 30% glycol by volume (15 litres by total volume) to offer sufficient protection against corrosion.

• 30% glycol by volume (15 litres by total volume) provides antifreeze protection down to -16 °C. If more protection is required, see the table for calculating the necessary amount of glycol. The amount of glycol (antifreeze) is determined acc. to lowest expected temperature. Always be sure that it is enough glycol (anti-freeze) mixed with the water in the cooling system to avoid freezing, see table.

Total volume: 50 litres

We recommend only nitrite-free anti-freeze glycols with the following supplier designation: • BASF Glysantin G48 • Always fill up the anti-freeze if the glycol content drops below 30% by volume (15 litres by total volume).

A glycol content above 60% by volume (30 litres by total volume) will not improve the protection against corrosion.

WARNING • •

Ethylene glycol is highly dangerous if consumed and can prove fatal.

Avoid contact with the skin.

NOTE •

•

•

The coolant should be mixed before it is filled into the cooling system. Never top up with only water or only glycol.

The recommended glycols must not be mixed with glycol which has nitrite-based anti-corrosive nor with other anti-corrosive.

This could cause sludging and reduced cooling capacity.

The coolant should be changed when the cooling system is cleaned. Every 4000 hours or every 4 years.

* Numbers refer to positions on the lubrication schedule, chapter 6 194

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1.2.3. Coolant with only anti-corrosive: Check protection against corrosion, at least once a year There must always be sufficient anti-corrosive (inhibitor) in the coolant to protect the cooling system against corrosion.

• If there is no danger of freezing use only Anti-corrosive.

• The inhibitor in the Anti-corrosive must be nitrite-free with the following supplier designation: • BASF Glysacorr G93.

• The correct level of Anti-corrosive is 10% by volume (5 litres by total volume).

• Fill with Anti-corrosive as indicated on the packaging.

• Filling up with 1% by volume (0.5 litres by total volume) of Anti-corrosive should be done after every 2000 operating hours.

• Never fill up with water only or Anti-corrosive only.

Lost fluid should always be replaced by pre-mixed coolant: water + 10% Anti-corrosive by volume.

• Anti-corrosive content must not be lower than 5% by NOTEvolume or exceed 30% by volume.

• • • •

Anti-corrosive must not be mixed with glycol.

Mixing or over concentration can cause sludging and reduce cooling capacity.

Any coolant filter must not contain inhibitor.

The coolant should be changed when the cooling system is cleaned.

Every 4000 hours or every 4 years.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

195

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

2. Brake system 2.1. Inspect brake lines, at least once a year.

Replace pipes, hoses and fittings which are corroded (deep seated rust), deteriorated (aged), leaking or otherwise damaged.

CAUTION Check more often when operating in salty conditions or similar environment that may affect the brake system!

3. Tandem housings (MT36/41) 4.1. Change oil 32* 1. The dump truck and tandem housings must be horizontal.

2. Unscrew drain plugs (1) on the inside of the housings.

3. Drain the oil into a suitable container.

4. Clean plugs, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the filler plugs (2) to correct level.

6. Clean plugs, replace seals if necessary and reinstall.

• Tightening torque: 80 Nm. 7. After test driving, check that level is at lower edge of the level plug.

2

CAUTION

1 Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

5. Continue with all items in 1000 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 196

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

1. Cooling system 1.1 Internal cleaning, every 4 years 5* Removing deposits, oil and grease For internal cleaning use liquid dishwasher detergent designed for household use. Alter native BASF Glycacorr G93 or Texaco Havoline XLI can be used.

Important: The cleaning agent must not foam.

1. If possible, run the engine until it is warm and then drain the cooling system, see changing coolant, item 1.2 2. Remove the thermostat housing (1) and replace it with a hose. Plug the by-pass.

1

3. Fill the system with clean, hot water mixed with liquid dishwasher designed for household use.

Concentration 1% (0.1 L by 10 L water).

Alternative BASF Glycacorr G93 or Texaco Havoline XLI can be used.

4. Run the engine for about 20-30 minutes.

NOTE! Do not forget the cab heater system.

5. Drain the cooling system.

6 Fill the system again with hot water and run the engine for about 20 -30 minutes.

7. Drain the water from the cooling system.

8. Refit the thermostat housing and the connections.

9. Fill the system with coolant as described in the specifications in item 1.3 at 2000 hours service.

WARNING Handling cleaning agents for the cooling system: Read the warning label on the container

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

197

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

1.2 Change coolant, every 4 years 5* 1. Remove the filler cap from the expansion tank.

2. Drain the coolant in two places: • the "lowest point" on the engine block, see ill.

• the "lowest point" of the cooling system (1), under the oil cooler on left hand side. Access through the engine bottom guard.

3. Close the cocks.

4. Fill with correct mixture, pre-mixed coolant through the expansion tank filler hole (2). See item 1.3 at 2000 hours service.

2

1

* Numbers refer to positions on the lubrication schedule, chapter 6 198

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

2. Hydraulic system 2.1. Change oil 40* 1. Accumulators contain oil under high pressure!

Empty the accumulators, before draining the hydraulic oil. Procedure is described in chapter 2, item 27.

2. The drain plugs both for the main reservoir and the emergency steering reservoir are to be found on the right hand side of the hydraulic tank (on the bottom).

Remove the cover to get into the drain plugs.

3. Place a suitable container to catch spillage.

4. Remove the cap from both drain plugs.

5. Install the draining hose with nipple to the first drain plug and drain the oil into the container.

6. Install the draining hose to the second drain plug and drain the oil into the container.

7. Remove the draining hose and reinstall both caps.

8. The oil filler is located on the top of the hydraulic filter unit under the cover on the top of the hydraulic tank.

Drain plug

9. Fill new oil through the oil filler, according to the oil specification sheet, chapter 6.

• The accumulators will be recharged with oil when the engine is re-started.

Oil filler

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

199

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

3. Tandem housings (MT25/26/31) 3.1. Change oil 32* 1. The dump truck and tandem housings must be horizontal.

2. Unscrew drain plugs (1) on the inside of the housings.

3. Drain the oil into a suitable container.

4. Clean plugs, replace seal if necessary and reinstall.

• Tightening torque: 80 Nm. 5. Fill new oil, according to the oil specification sheet (chapter 6), through the filler plugs (2) to correct level.

6. Clean plugs, replace seals if necessary and reinstall.

• Tightening torque: 80 Nm. 7. After test driving, check that level is at lower edge of the level plug.

2 1

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

3. Continue with all items in 2000 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 200

Operating & Maintenance Manual

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be performed yearly.

1. Transmission 1.1. General condition check 1. Check tightness of lubrication system when engine is running.

• Tighten or change defective connections.

2. Check transmission rubber mountings and replace if necessary.

Inspect the mounting bolts.

2. Drive line 2.1. General condition check Check the general condition and mountings, joints, bearings, etc. for general deterioration, wear, damages and leakages.

• Replace or recondition if necessary.

1. Rear axle and tandem housing.

2. Articulation hinge and turning ring.

3. Suspension:

• shock absorbers • rubber dampers • arms and rods

4. All prop. shafts, universal joints included.

3. Tanks 3.1. General condition check Check the hydraulic and the diesel tank bolts/ mountings.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

201

7. Maintenance

Yearly recommended maintenance Maintenance recommended to be performed yearly.

4. Hydraulic system 4.1. Inspect the hydraulic hoses Replace hoses which are deteriorated, leaking or otherwise damaged.

5. Exhaust system 5.1. Safety check • Check fastening brackets, muffler, pipes and joints for leaks, damages and insecurity.

• If body is exhaust heated, check also that the channels in the body not are clogged by any means.

CAUTION Be aware of hot parts when engine has been running!

6. Bearings 6.1. Check clearance Contact your local Moxy Dealer for checking of the bearing clearance: • Tandem bearing • Tip bearings • Turning ring and articulation bearings • Wheel bearings

* Numbers refer to positions on the lubrication schedule, chapter 6 202

Operating & Maintenance Manual

8. Technical Data

Technical Data

Operating & Maintenance Manual

203

8. Technical Data

Contents

8. Technical Data .................................................. 203 - 220 Contents ............................................................. 204 Measurements .................................................... 205 Engine ................................................................ 206 Transmission....................................................... 206 Hydraulic system ................................................ 207 Tyre pressures .................................................... 207 Electrical system ................................................ 208 Metering conversion table .................................. 209 Tool kit content (standard) .................................. 209 Tool kit content (optional) ................................... 209 Performance chart .............................................. 210 Engine and retarder brake capacity chart ......... 213 Torque limits for bolts.......................................... 216 Reference information ........................................ 216 Consumeable parts ............................................ 216 Product signs ...................................................... 217 Periodic service .................................................. 219

204

Operating & Maintenance Manual

8. Technical Data

Measurements Machine dimension (mm)

MT25

MT26

2545

2750

-

2995

Total length

MT31

MT36

2990

3275

3475

3235

3350

3550

3735

3800

9488

Total width (with standard tyres) Total width (with optional tyres) Total height

3420

Total height, loaded

3365

MT41 10450

3530 3475

Overhang, front

3738

2650

2835

Overhang, rear

1028

1029

1270

Wheelbase

1770

1768

1960

Body upper height (rear edge)

2745

Body floor height (rear edge)

1975

Total height, raised body

5680

Ground clearance, raised body

490

Min. Ground clearance

490

2864

2946

3040

2100 5855

2390

5885

6450

6545

571

587

652

8370

8420

75°

70°

610

615

565

Min. ground clearance, loaded

435

510

516

Turning radius (ISO 7457)

7500

7560

7680

Body tipping angle

588

70°

Steering angle, both sides Standard tyre dimension Tyre load/speed index

3255

2325

45° 20.5 R25

23.5 R25

26.5 R25

29.5 R25

177B (2 stars)

185B (2 stars)

193B (2 stars)

194B (2 stars)

Machine weights (kg) Empty weight

20950*

22000

22650

27700

28800

Gross weight

43550*

45500

50650

61500

64900

Maximum payload

22600*

23500

28000

32700

37200

Front axle empty

10500*

10950

11150

13220

13400

Rear axle empty

10450*

11050

11500

14480

15400

Struck

10.7 (11.1*)

11.4 (11.9*)

13.6 (14.2*)

15.6 (16.1*)

17.9 (18.6*)

Heaped, SAE 2:1

13.0 (13.7*)

14.1 (14.8*)

16.8 (17.8*)

20.1 (21.0*)

22.7 (24.1*)

Weight distribution (kg)

Body capacity (m³)

Machine speed (km/h) 1st gear

Forward speeds 6

6

2nd gear

8

9

3rd gear

13

14

15

4th gear

20

22

23

5th gear

30

6th gear

46

51

2nd gear

13

14

3rd gear

30

33

1st gear Reverse speeds 3

32

34 53

6

33

15 31

34

Towing load on hooks (k/N) Front

100 (each)

Rear

200

Sound power level, dB (A) According to ISO 6395 (external)

111

Sound pressure level, dB (A) According to ISO 6395 (in cab)

74

Ambient operating temperature (°C) Min. (-)

20

Max. (+)

40

The measurements are valid for a standard, unloaded machine if nothing else is given. * - With top tailgate fitted.

Operating & Maintenance Manual

205

8. Technical Data

Engine

1 kW = hp 1,36

Water cooled, unit injected diesel engine with turbo charger and air to air intercooler Engine

MT25

Type Cylinder volume Bore x stroke No. of cylinders

MT26

MT31

MT36

MT41

Scania DC 9

Scania DC 12

9.0 litres

11.7 litres

127 x 140 mm

127 x 154 mm

5 (in line)

Power rating (ISO3046)

228 kW (310hp)

Power rating (ISO9249)

224 kW (305hp)

Max. torque (Nm)

6 (in line) 243 kW (331hp)

294 kW (400hp)

234 kW (324hp)

285 kW (388hp)

1157

317 kW (430hp) 1854

Engine speed, low idle

650 rpm ±50

Engine speed, high idle

2430 rpm ±50

Max. allowed engine speed

331 kW (449hp)

2600 rpm

Oil capacity

23 - 29 litres

Oil pressure, warm engine at 2200 rpm

27 - 34 litres 3.0 - 6.0 bar

Oil pressure, warm engine at 1000rpm

Min. 0.7 bar

Specific oil consumption

Min. 1.0 bar <0.3 g/kWh

Coolant volume Normal temperature

45 litres (approx.)

50 litres (approx.)

70-90°C

70-93°C

Thermostat

83°C

Max. system pressure

83°C 0.5 bar

Compression ratio Firing order

18:1

17:1

1-2-4-5-3

1-5-3-6-2-4

Engine rotation, seen from rear

Counterclockwise 0.45 mm, inlet valves 0.70 mm, ech. valves

Valve clearance (cold engine)

Transmission Automatic transmission. Integrated in the gearbox: torque converter, automatic lock-up clutch, retarder brake and lockable inter axle differential.

Transmission Type

MT25

MT26

MT31

MT36

ZF 6WG260

No. of forward gears

6

No.of reverse gears

3

Oil capacity Normal temperature Max. permitted temp. when using retarder brake Lock -up clutch Lock-up in/out Inter axle diff. distribution

206

MT41 ZF 6WG310

55 litres 50-105°C 150°C (short period only) In all gears Acc. to engaged mode 1/3 to front axle, 2/3 to rear axle, lockable

Operating & Maintenance Manual

8. Technical Data

Hydraulic system Applied for brakes, steering, cooling fan and work equipment. The system have two variable displacement piston pumps. One pump for the steering and the work equipment, where the steering circuit has priority above the work circuit. One pump for the brakes and cooling fan, where the brake circuit has priority above the cooling circuit. The main- and emergency steering pumps are fitted on the transmission.

Hydraulic system Tank capacity

MT25

MT26

MT31

MT36

MT41

101 litres

138 litres

150 litres

209 litres

323 litres

Normal oil temperature

40-90°C

Filter

One return flow filter and high-pressure filter Gear pump, engine speed dependant

Pumps

2 variable displacement piston pumps

Capacity per pump Steering/tipping

230 l/min at 2200rpm

Brakes/cooling fan etc.

320 l/min at 2200rpm 60 l/min at 2200rpm

Emergency steering pump

Piston pump, ground driven, speed dependent

Pump delivery

Max. 50l/min

Max. 40l/min

Pressure settings - main safety valves Tipping circuit- up (pump setting)

280 bar

Tipping circuit- down (pump setting) Shock valves in the tip circuit

300 bar (up), 80 bar (down)

Steering circuit

330 bar (up), 80 bar (down) 210 bar

Tipping cylinders

Single stage, double acting

Tipping time

11 seconds

Steering cylinders

12 seconds 2 x double acting with 1 piston

Steering wheel turns

Approx. 5

Accumulators

5 units, pre-charged with Nitrogen to pressure 112.5 bar

Tyre pressures Basic pressure for cold tyres (based on max. load and max. speed): Model

MT25

MT26

MT31

MT36/41

MT41

Type

Front (bar {psi})

Rear (bar {psi})

30 k/m version

30 k/m version

50 k/m version

50 k/m version

Bridgestone VLT

4.0 {58}

5.0 {73}

4.0 {58}

5.0 {73}

Michelin XADN/XADT

3.5 {51}

4.5 {65}

3.5 {51}

4.5 {65}

Goodyear GP2B/GP4B

3.5 {51}

4.5 {65}

3.5 {51}

4.5 {65}

Continental STL 3

4.0 {58}

5.0 {73}

4.0 {58}

5.0 {73}

Bridgestone VLT

4.0 {58}

4.0 {58}

Michelin XADN/XADT

3.5 {51}

3.5 {51}

Goodyear GP2B/GP4B

3.5 {51}

3.5 {51}

Continental STL 3

4.0 {58}

4.0 {58}

Continental STL 2+

5.24 {75.9}

5.24 {75.9}

Triangle TL528

5.25 {76}

5.25 {76}

Bridgestone VLT

4.5 {65}

4.75 {69}

Michelin XADN/XADT

3.75 {54}

4.0 {58}

Goodyear GP2B/GP4B

3.75 {54}

4.0 {58}

Continental STL 3

4.27 {62}

4.75 {69}

Bridgestone VLT

3.35 {48.5}

4.2 {61}

Michelin XADN/

2.9 {42}

3.6 {52}

Goodyear RL2+

2.9 {42}

3.6 {52}

Continental STL 3

3.3 {48}

4.0 {58}

Triangle TB516

5.25 {76}

5.25 {76}

Regarding tyre pressure: Contact your Moxy Dealer or tyre supplier to get further information.

Operating & Maintenance Manual

207

8. Technical Data

Electrical system MT25

MT26

MT31

System voltage

MT36

MT41

24 V

Battery

2x 12 V, 140 Ah

Grounding

2x 12 V, 225 Ah

Negative earth cable

Alternator

28 V, 100 A

Starter motor

4.0 kW (5.4hp)

6.7 kW (9.1hp)

Fuses and relays: The fuses and relays are located behind the cover on the backwall. Be sure to use fuses of correct size. Never install larger fuses than specified! If a certain fuse blows several times, the circuit must be checked and failure corrected.

Relays: 98 • Direction light • Hazard light

98B • Direction light (USA) • Hazard light (USA)

228 • Parking brake alarm

252 • Transmission controller

253 • Wiper, washer, horn

254 • Working light rear

85 • Wiper/ washer

87 • Engine controller

99 • Charging activated

100 • Starter lock

105 • High beam

106 • Reverse light

107 • Heated seat

108 • Heater unit

109 • Parking brake alarm

118 • Heated mirrors

119 • Engine cooler

120 • Control retarder

121 • Park brake alarm

129 • Brake light

102 • Working light • High beam

104 • Low beam

130 • Engine running

Fuses: Fusebox A (Natural) 1/15A • Ignition

2/15A • Low beam

3/15A • High beam

1/10A • Radio memory

2/10A • Air dryer

3/10A • Brake light • Cab light

4/15A • Wiper supply

Fusebox B (Yellow) 5/15A • Flamstart (MT25) • Spare (MT26/ 31/36/41)

6/15A • Air conditioner • Heater

1/10A • Engine controller

2/10A • Transm. controller

3/10A • Reverse light • Reverse alarm

5/10A • Extra high beam • Working light, roof

6/10A • Working light, rear

1/10A • Direction light • Instrument light

2/10A • Radio • Switch light • Control light

3/10A • Spare

5/10A • Parking light, L.H.S

6/10A • Spare

Fusebox C (Green) 4/10A • Lighter

4/10A • Heated mirrors • Heated seat

5/10A • Parking Light

6/10A • Hazard Light

5/10A • Transm.

• Parking brake alarm

6/10A • Park brake alarm • Retarder • Engine brake

Fusebox D (Black) 4/10A • Engine cooler

Fusebox E (Red) 1/10A • Central lubrication system • Flamestart

2/10A • Headlights

3/10A • Starter

4/10A • Parking light, R.H.S.

Bulbs: MT25

MT26

MT31

MT36

MT41

Light

Watts

Socket

Watts

Socket

Watts

Socket

Watts

Socket

Watts

Socket

Head lights (H3/H7)

75/70

P 43t/38

75/70

P 43t/38

75/70

P 43t/38

75/70

P 43t/38

75/70

P 43t/38

Side lights in head light

4

BA 9s

4

BA 9s

4

BA 9s

4

BA 9s

4

BA 9s

5

S 8.5

5

S 8.5

Direction indicators

Diode light

Stop lights Licence plate lights

5

Work light Reverse light

70

Rotating beacon (H1)

S 8.5 Pk 22s

5

70

P14.5s

S 8.5 Pk 22s

5

70

P14.5s

10

Instrument lights

2

208

70

Pk 22s

70

P14.5s

Pk 22s P14.5s

Diode light

Cab lights

Switch lights

Pk 22s P14.5s

Rear lights

Warning/indicator lights

S 8.5

1.2

BA 15s

10

BA 15s

2 W2x4.6d

1.2

10

BA 15s

2 W2x4.6d

1.2

10

BA 15s

2 W2x4.6d

Operating & Maintenance Manual

1.2

10

BA 15s

2 W2x4.6d

1.2

W2x4.6d

8. Technical Data

Metering conversion table Length:

1m 1 km

Volume:

1.094 yd 1000 m

= =

3.281 ft 0.621 mile

1 dm3 = 1 dm3 = 1 m3 =

1 litre 0.0353 ft3 35.32 ft3

= =

0.264 gal (US) = 61.02 in3

Weight:

1 kg = 1000 kg

2.20 lb = 35.27 oz = 1 ton (metric) = 0.984 ton (UK) = 0.902 ton (US)

Power:

1 kW

1.34 hp (British) 1.36 hk (Metric)

Torque:

10 Nm =

Pressure: Temperature:

= =

1.02 kpm 2

1 bar

=

1.02 kp/cm

o

= =

5/9 x (oF- 32) (9/5 x oC)+32

C F

o

Speed:

= =

1 km/h =

=

39.37 in 0.220 gal (UK)

=

7.38 lbf ft (pound-force foot)

=

14.5 p.s.i.

=

100 kPa

0.62 mph

Tool kit content (standard)

Operation manual Driver instruction Parts catalogue

Arm, hydraulic pump (tiltable cab) - only High Line Safety support (tiltable cab) Draining hose

Tool kit content (optional) Hex. socket 12 mm Hex. bit front hub Diagonal wrench

Wheel-spanner Grease gun Arm, wheel-spanner

Operating & Maintenance Manual

209

8. Technical Data

Performance chart Below diagram gives guidelines for calculation of the dump truck gradeability performance related to rolling + grade resistance. The traction capabilities depend on the ground conditions and surroundings, i.e. available wheel grip (friction), tyre pattern, weight on the wheels, etc.

How to find gradeability performance: 1. Read from actual dump truck weight (A) up to the percentage gradient (B).

(Rolling resistance is not included in the percentage grade).

2. From this point, read horizontally to the curve with highest speed range (C).

3. Then down to maximum speed (D).

MT25

UNDER PREPARATION

210

Operating & Maintenance Manual

8. Technical Data

MT26

UNDER PREPARATION

Rimpull Performance MT31 (Tier3 DC9 61A)

28

Empty

Loaded

24

Rimpull (kg*1000)

20

40%

35% 16

30%

25% 12

20%

15%

8

10% 7%

4

5% 4% 3% 0

0

5

10

15

20

25

30

35

40

45

50

55

Travel Speed (km/h) Operating & Maintenance Manual

60

20

25

30

35

40

45

50

55

Vehicle total weight (kg*1000)

211

60

8. Technical Data

MT36/41

UNDER PREPARATION

212

Operating & Maintenance Manual

8. Technical Data

Engine and retarder brake capacity chart Below diagram gives guidelines for calculation of the dump truck engine and retarder brake performance related to rolling + grade. The traction capabilities depend on the ground conditions and surroundings, i.e. available wheel grip (friction), tyre pattern, weight on the wheels, etc. If the driving conditions (f.ex curves) requires hard decellerating by using the main brake, driving in a lower gear is advised.

How to find downhill gradeability capacity: 1. Read from actual dump truck weight (A) up to the percentage gradient (B) (Rolling resistance is not included in the percentage grade).

2. From this point, read horizontally to the curve with highest speed range (C).

3. Then down to maximum speed (D).

MT25

UNDER PREPARATION

Operating & Maintenance Manual

213

8. Technical Data

MT26 UNDER PREPARATION

MT31

214

Operating & Maintenance Manual

8. Technical Data

MT36/41

Operating & Maintenance Manual

215

8. Technical Data

Torque limits for bolts This tables indicates standard torque limits in Nm for the various screw and bolt qualities and dimensions.

The torques are valid for screws on the outside of the components.

Metric Threads

Fine Metric Threads

Reference information Machine model:

Serial no.:

Prod. year:

In operation:

Engine s/no.:

Transm. s/no.:

Dealer:

Consumeable parts

Part No.

216

Quantity

Description

Operating & Maintenance Manual

UNF - Threads

8. Technical Data

Product signs

Punched serial number

MT25/26/31

260

12 (EPA)

Operating & Maintenance Manual

217

8. Technical Data

MT36/41

12

(EPA)

218

Operating & Maintenance Manual

8. Technical Data

Periodic service DELIVERY Hrs: ________ Date:______________ Stamp / Sign.:

Fill in the boxes according to the maintenance performed on the dump truck serial no.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

Operating & Maintenance Manual

219

8. Technical Data

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

SERVICE Hrs: ________ Date:______________ Stamp / Sign.:

220

Operating & Maintenance Manual

9. Index

Index

Operating & Maintenance Manual

221

9. Index

Index Symbols 1000 Hours Service 178 2000 Hours Service 191 4000 Hours Service 198 40 Hours Service 159 500 Hours Service 162 8 Hours Service 149

A Accumulators 32, 157 AEB-Tester 146 Air conditioner system 159, 160, 161, 174, 176, 177 Air conditioning system hazard prevention 20 Air filter 181 Air filter warning light 51 Articulation lock 31 Ashtray 78 Automatic central lubrication 160, 161, 176, 177 Automatic central lubrication indicator 53, 55 Automatic Transmission Fluid (ATF) 132

B Batteries 168, 179 Battery charge warning light 51 Battery hazard prevention 19 Battery power assistance 114 Bearings 202 Before operation 95 Bleed fuel system 179 Body support 29 Brake lines 196 Brake pedal 67 Brakes 22, 100 Brake system 156, 171, 196 Brake system warning light 50 Braking/stopping the dump truck 102 Breather element 185 Bulbs 208

C Cab and engine compartment light 58 Cab certification 33 Cab light 78 Cab ventilation 71, 159, 174 Central lubrication 160, 161, 176, 177 Centrifugal cleaner 163 Change coolant 198 Change oil, engine 162 Change oil, front differential 188 Change oil, front reduction gears 190 Change oil, hydraulic system 199 Change oil, rear differential 189 Change oil, tandem housings 148, 196, 200 Change oil, transmission 142, 183 Check/adjust valve clearance 191, 192 Check batteries 168, 179 Check battery terminals 168 222

Check braking (holding) capacity 156 Check cab ventilation filter element 175 Check clearance of bearings 202 Check coolant level 151 Check driver's seat 149 Check fuel injectors 146 Check fuel level 152 Check function, engine and retarder brake 158 Check function, engine brake 158 Check function, main brake 157 Check function, steering 158 Check glycol content in the coolant 194 Check lining thickness 171 Check multi-groove belt 180 Check of the centrifugal cleaner 152 Check oil level, drive line 146, 169 Check oil level, engine 151 Check oil level, front differential 169 Check oil level, front reduction gears 170 Check oil level, hydraulic system 154 Check oil level, rear differential 169 Check oil level, tandem housings 170 Check oil level, transmission 153 Check protection against corrosion in the coolant 195 Checks after stopping the engine 108 Check the appearance of the coolant 193 Check the coolant 193 Check tyre pressures 160 Check wheel nuts torque 173 Check wiring 190 Cigarette lighter 69 Clean centrifugal cleaner 163 Clean prefilter, cab ventilation 159 Clean strainer 142, 183 Clothing and personal protection items 12 Cold weather 112 Column switch 64 Consumeable parts 216 Controls 63 Coolant 193, 198 Cooling system 197 Correct tyre pressures 110

D Daily Service 149 Dangerous loads 24 Difference in tyre diameter 110 Differentials 104 Direction light indicator 53 Do not go close to high-voltage cables 18 Drive line 169, 201 Driver's seat 75, 178 Dump truck knowledge 11 Dump truck transportation 32

E Electrically heated driver's seat switch 60 Electrical system 190, 208 Emergency braking 102 Emergency exit 15, 70 Emergency retarder 23 Emergency steering 22 Operating & Maintenance Manual

9. Index

Emergency steering warning light 50 Engine 146, 150, 162, 178, 191, 206 Engine, general condition check 150 Engine and retarder brake 158 Engine and retarder brake capacity chart 213 Engine and retarder brake mode 97 Engine and retarder brake operation 101 Engine bonnet 27 Engine brake 100, 158 Engine brake indicator 53 Engine controller switch for code reading 60 Engine coolant level warning light 52 Engine coolant temperature warning light 51 Engine oil pressure warning light 51 Engine overspeed 23 Engine revolution counter and hour meter 45 Exhaust heating 24 Exhaust system 202 Expansion tank coolant level 21 External cleaning of the radiator 167 External door opener/lock 76

F Filling capacities 126, 130 Filling fuel or oil 21 Fire extinguisher 14 Fire prevention 16 Fire prevention for fuel and oil 13 First 100 hours 84 First 500 hours 85 First 8 hours 84 First aid kit 14 FOPS 15 Foreword 5 Forward drive position 96 Front differential 188 Front reduction gears 190 Fuel filter 150, 178 Fuel gauge 45 Fuel injectors 146 Fuses 208

G Gear display 46 Gear position N 96 Gear position V 96 Gear selector 68 Gear shifting 96 Gear shift program 96 General condition check, drive line 201 General condition check, engine 150 General condition check, tanks 201 General condition check, transmission 201 General description 7 General precautions 11 General safety check, driver's seat 178 Getting on and off the dump truck 12

H Hazard light switch 59 High-voltage cables 18 High beam indicator 53

High pressure 32 High temperatures 13 Hoisting 31 How to adjust the parking brake 172 Hydraulic filter warning light 52 Hydraulic return filter element 144, 145, 186, 187 Hydraulic system 154, 185, 199, 202, 207

I Important operating instructions 106 Indicator lights 49 Inspect brake lines 196 Inspect the hydraulic hoses 202 Instructor seat 76 Instruments 44 Intended use 7 Inter-axle differential lock 61 Inter-axle differential lock indicator 53 Inter axle differential 104 Internal cleaning, cooling system 197 Internal door opener 76 Introduction 7

L Labels 33 Lifting 31 Loading 108 Lock-up indicator 52 Long term storage 113 Lubricants 121 Lubrication 155 Lubrication, cab rear hinges 156 Lubrication, door and fender hatches 155

M Machine turning 21 Main light switch 58 Maintenance 135 Maintenance precautions 137 Maintenance table 139, 140, 141 Main warning light, engine failure 51 Main warning light, transmission failure 52 Manual gear shifting 97 Manual release of parking brake 115, 116 Manual release of the tip valve 116 Measurements 205 Metering conversion table 209 Mirror heating switch 60

N Neutral gear position 96 Normal operation 99

O Oil specification sheet 125, 129 Operating Controls 41 Operating hints 98 Operating Instructions 87 Operating the dump truck 95 Operation of brakes 22 Operator's cab 17 Operating & Maintenance Manual

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9. Index

Optional accessories 14 Other cab equipment 75

P Parking brake 100, 156, 172 Parking brake indicator 50 Parking brake switch 61 Parking the dump truck 107 Performance chart 210 Periodic service 219 Pinion bearing 189 Precautions before starting the engine 16 Precautions for mirrors, windows and lights 18 Precautions for optional accessories 14 Precautions on worksites 88, 89 Precautions when handling at high temperatures 13 Preselection of gears 97 Product signs 217 Proper maintenance 111 Protection against falling objects 15

R Radiator 167 Radio/Cassette player 79 Rear differential 189 Reference information 216 Refrigerant 20 Relays 208 Replace breather element 185 Replace fuel filter 150, 178 Replace hydraulic return filter element 144, 145, 186, 187 Replace transmission filter element 142, 183 Replace turbo filter 166 Retarder brake 100, 158 Retarder brake capacity chart 213 Retarder brake indicator 53 Retarder brake mode 97 Retarder brake switch 59 Retractable roller sunblind on front window 78 Reversing (back-up) operations 99 Roll-over protection 15 ROPS 15 Rotating beacon switch 58 Rules to follow when filling fuel or oil 21 Running-in operation 83 Running-in period 81 Running-in services 84 Run the AEB-Tester 146

S Safety at the worksite 16 Safety check, exhaust system 202 Safety equipment 77 Safety information 6 Safety Instructions 9 Safety labels 33 Safety rules 11 Seat belt on driver's seat warning light 52 Service brake 100, 156 Service position 30 Side window 77 224

Specified loading 111 Speedometer 48 Starter switch 69 Starting in cold weather 94 Starting the engine 93 Steering 103, 158 Steering column 66 Stopping the engine 107 Switches 57

T Tandem housings 148, 196, 200 Tanks 201 Technical Data 203 Test switch for brake warning light 59 Throttle pedal 67 Tiltable cab 27 Tip- and steering cylinders 173 Tip control lever 69 Tipping 109 Tool kit content 209 Top tailgate 26 Torque limits for bolts 216 Towing the dump truck 115 Transit, long distance drive-away on road 111 Transmission 142, 144, 153, 183, 201, 206 Transmission oil list 132 Transmission oil temperature gauge 48 Transportation 32 Travelling on slopes 22 Troubleshooting 117 Troubleshooting for Lincoln lubrication system 54 Turbo filter 166 Tyre handling 110 Tyre pressures 110, 207 Tyres 160

U Unauthorised modification 12 Up, down and crossgradient travel 105

V Valve clearance 191, 192 Ventilation for enclosed areas 17

W Wading 23 Walk around check 149 Warming up period 96 Warning / indicator lights 49 Warning light, engine failure, co-ordinator 51 Warning triangle 14 Weekly Service 159 Welding 25 Wheel chocks 30 Wheels 173 When starting the engine 18 Worker protection rules, refrigerant 20 Working and back-up lights 58 Working lights and extra high beam 58

Operating & Maintenance Manual

9. Index

Y Yearly recommended maintenance 201

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9. Index

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Operating & Maintenance Manual