Daewoo Doosan ADT MT36 MT36 SERIES II Operation & Maintenance Manual – PDF DOWNLOAD

MX159463-1 August 2014

ADT

Operation & Maintenance Manual MT36 / MT36 SERIES II MT36 / MT36 - Serial Number 410002 and Up

Operation & Maintenance Manual MT36 / MT36 SERIES II ADT MT36 / MT36 - Serial Number 410002 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

MX159463-1 August 2014 Copyright Doosan 2011

1. Foreword

MT36/MT36 SERIES II E

OPERATING & MAINTENANCE MANUAL

Serial no.

410002 and up

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

Manufacturer:

Dealer:

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

Operating & Maintenance Manual

Part no.:159463 Edition: March 1 2003

1. Foreword

2

Operating & Maintenance Manual

Table of contents

1. Foreword

1. Foreword ................................................................. 5 - 8 Foreword ....................................................................... 5 Safety information ......................................................... 6 Introduction ................................................................... 7 2. Safety instructions .............................................. 9 - 36 3. Operating controls ............................................. 37 - 76 Overview of the instruments and controls ................. 39 Instruments ................................................................. 40 Warning / indicator lights ............................................ 45 Switches ..................................................................... 52 Controls ...................................................................... 59 Cab ventilation ............................................................ 67 Other cabin equipment ............................................... 71

Engine and retarder brake chart .............................. 188 Torque limit tables .................................................... 189 Reference information (fill in tables) ....................... 189 Consumeable parts .................................................. 189 Product signs ............................................................ 190 Periodic service (fill in tables) .................................. 191 9. Alphabetical Index ......................................... 193 - 198

4. Running-in period ............................................... 77 - 82 Running-in operation ................................................. 79 Running-in services ................................................... 80 5. Operating instructions ....................................... 83-114 Some simple rules to be observed prior to operation 85 Starting the engine ..................................................... 86 Operating the dump truck ........................................... 88 Parking the dump truck .............................................. 99 Stopping the engine ................................................... 99 Checks after stopping the engine ............................ 100 Loading and tipping ................................................. 100 Tyre handling ............................................................ 102 Cold weather ............................................................ 104 Long term storage .................................................... 105 Battery power assistance ......................................... 106 Towing the dump truck ............................................. 107 External air filling ...................................................... 107 Manual release of parking brake ............................. 108 Tyre filling point ........................................................ 108 Troubleshooting ....................................................... 109 6. Lubricants ....................................................... 115 - 122 Lubrication schedule ................................................ 117 Oil specification sheet .............................................. 119 Filling capacities ....................................................... 120 Transmission oil list .................................................. 121 7. Maintenance ................................................... 123 - 178 Maintenance precautions ........................................ 125 Maintenance table .................................................... 126 8 Hours / Daily service ............................................. 127 40 Hours / Weekly service ........................................ 137 500 Hours Service .................................................... 141 1000 Hours Service ................................................. 155 2000 Hours Service ................................................. 167 4000 Hours Service ................................................. 175 Yearly recommended maintenance ........................ 177 8. Technical data ................................................ 179 - 192 Measurements .......................................................... 181 Engine ....................................................................... 182 Transmission ............................................................ 182 Hydraulic system ...................................................... 183 Air system ................................................................. 183 Tyre pressures .......................................................... 183 Electrical system ....................................................... 184 Metering conversion table ........................................ 186 Tool kit content .......................................................... 186 Performance chart .................................................... 187

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1. Foreword

4

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 priority.

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 89/392/EEC with amendments and 89/336/EEC 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 throughly 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 purchased 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 regualtions 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, chapter 2.

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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 also 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 articluated dump truck is designed to be used mainly for earthmoving at sites, both on and off road conditions.

General description Moxy MT36 is an 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.

Engine bonnet

Operators cab

Dump body

Hydraulic tank

Head and side light

Moxy has in 1999 received the Norwegian Award for “Good Design” for MT36.

This award is the highest design award in Norway given by “the Norwegian Design Council".

The Norwegian Design Council‘s reason for honouring Moxy with the Good Design award for MT36: "By the way of design, Moxy's new generation product is lifted to a higher competitive level.

The focus is put more on the comfort of the driver, and Moxy is way ahead where design, function and new technology are concerned. Moxy has clearly stepped up to first class. More emphasis was put on functional design with easier and safer solutions."

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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 lev-

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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Operating & Maintenance Manual

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 Immediately after operations 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.

• Be sure you know the phone numbers of persons you 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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Operating & Maintenance Manual

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.

• 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.

1

2

3

Battery main switch (OFF)

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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 unconsciousness. 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 com press. 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.

• The rear chassis stability decreases when tipping. Be alert when body is raised. Do not under any circumstances drive with raised 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

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

Operating & Maintenance Manual

27

2. Safety Instructions

- 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.

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 downposition).

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

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

5. Close the bonnet.

6. Lower the body.

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

b

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/stand underneath the body without applying the body support device!

Do not operate the dump truck with a raised and secured

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) before operation.

Warning - dangerous loads Warning - never coast in neutral • Never coast with the gear selector in the neutral position.

• The braking effect and the operator's safety will be reduced.

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) before operation.

33

2. Safety Instructions

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

Emergency exit • The emergency 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 operating manual (safety instructions, item 2.7)

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 on the left hand side in the cab, below the rear side window.

• Read the operating manual (safety instructions, item 2.7).

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 nearby.

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 burnt.

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.

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 (safety instructions, item 21) before operation.

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.

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.

MT25/MT26/MT31/MT36/MT41

ROPS/FOPS approval cab • Read the operating manual (safety instructions, item 2.9).

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.

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 refilling.

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

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

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 cab)

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 instructions, 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 refilling.

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

(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.

40

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.

Operating & Maintenance Manual

• 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 (safety instructions, item 6) before working with batteries.

3. Operating controls

Operating Controls

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

37

3. Operating Controls

Contents

3. Operating controls ................................................... 37-76 Overview of the instruments and controls ................ 39 Instruments ................................................................ 40 Warning / indicator lights ........................................... 45 Switches .................................................................... 52 Controls ..................................................................... 59 Cab ventilation ........................................................... 67 Other cab equipment ................................................. 71

* Numbers refer to positions on the electrical circuit diagram 38

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 62.

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

39

3. Operating Controls

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

1

2

3

Pos 1 2 3 4 5 6 7 8 9 10

4

5

6

7

Description Page Engine oil pressure gauge 41 Transmission oil temperature gauge 41 Engine coolant temperature gauge 41 Engine revolution counter and hour meter 42 Fuel gauge 42 Gear display 42 Speedometer 43 Air pressure gauge, front service brakes 44 Air pressure gauge, rear service brakes 44 Voltmeter 44

8

9

Remarks Optional

Optional

* Numbers refer to positions on the electrical circuit diagram 40

Operating & Maintenance Manual

10

3. Operating controls

Instruments 1. Engine oil pressure gauge 3* The gauge indicates the engine oil pressure. Normal operating pressure is 3 - 6 bar (above 800 rpm). Minimum pressure at low idle and warm oil is 0.7 bar. Normal pressure when starting with cold engine is above 6 bar.

If the engine oil pressure is too low during operation, the warning light (18) illuminates and the main warning light (19) will flash.

Check and note the error codes on the engine controller, see item 19 for procedure. Then stop the engine immediately and remedy the fault before restart.

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

Normal range is 80 - 110°C, max.permitted for a short period during retarder brake operation is 120°C. If the oil temperature in the transmission is too high during operation, the warning light 24 will light up.

Stop then 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.

3. Engine coolant temperature gauge 4* The gauge indicates the engine coolant temperature. Normal range is 70 - 93°C. Run engine at moderate speed and load until operating temperature is reached (warm-up period).

If the coolant temperature is too high during operation, the main warning light (19) will light up and the engine controller will reduce the engine load. Check and note the error codes on the engine controller, see item 19 for procedure.

If the temperature is further increased the warning light (17) will light up and main warning light (19) will start flashing (shut down condition). Check and note the error codes on the engine controller, see item 19 for procedure. Then stop the engine (possible fault) immediately.

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

41

3. Operating Controls

Instruments

4. Engine revolution counter and hour meter 1* The counter indicates the engine rpm.

Normal revolution: • Low idle: 650 rpm • Max. power and economic area:

1600 - 2000 rpm

• High idle:

2400 rpm

• Max. allowed rpm:

2600 rpm

The hour meter is electronic and indicates operated hours of the engine.

5. Fuel gauge 6* The gauge indicates fuel tank level from empty to full. Tank capacity: approx. 420 litres. Fill up with diesel when necessary, and at the end of the shift.

6. Gear display 10* 1. The lock-up lamp will light when the lock-up is engaged.

1 2

2. The display indicates the gear range from 1st gear to 6th gear.

3. The check lamp will light up if error has been detected.

If this lamp lights up: a. Stop the dump truck at a safe place.

3

b. Select neutral gear position and apply the parking brake. c. Open the fuse box panel behind the driver's seat. d. Check and note the error codes on the transmission controller. See next page for explanation of the transmission controller. e. Contact you Moxy Dealer.

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

• Item 1 and 3 will also light for approx. 3 sec. when the starter switch is turned on.

* Numbers refer to positions on the electrical circuit diagram 42

Operating & Maintenance Manual

3. Operating controls

Instruments

Transmission controller • The transmission controller has a two-digit crystal display to show present operation status and possible error code's.

• Switching the starter switch from OFF to ON start's a self diagnostic process of the transmission controller and at the end it will show the transmission oil temperature mode.

This temperature mode has three (3) levels which alters the clutch pressure modulation to ensure a safe and trouble-free gearshift.

Code

Self diagnostic display

Temp. mode

8.8

0.C (up to +15 °C) -,C (from +15 °C up to +40 °C)

5.3

A.8

0.3

1.0

Time 3 sec. 3 sec. 3 sec. 3 sec. 3 sec. 0.0 (+40 °C and up)

Error code E.C

0.9

E.C

F.A

0.5 sec. 3 sec. 0.5 sec. 3 sec.

• Once an error is detected the display will show the error code until 5 minutes after it is repaired.

• If more than one error has been detected, each code will be shown for about 3 second.

• If an error code has been recorded but is no longer present, the error code is displayed after the self diagnostic procedure and before the temperature mode.

7. Speedometer 2* The gauge indicates the dump truck travel speed in kilometres per hour (km/h).

The display on the speedometer counts: • The total travel distance (can not be reset) in kilometres.

• The partial travel distance in kilometres.

Push the button to switch between the total and the partial travel distance.

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

43

3. Operating Controls

Instruments

8. Air pressure gauge, front service brakes 7* The gauge indicates the air pressure in brake circuit 1.

Normal operating pressure is between 7.0 and 7.8 bar. Do not attempt to drive the dump truck at air pressure below 5 bar. Warning light (11) will light when the pressure is below 4.5 - 5 bar.

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

9. Air pressure gauge, rear service brakes 8* Same values as in item 8 for the brake circuit 2 (warning light 12).

10. Volt meter 9* The gauge indicates the voltage in the electrical system.

Normal range is between 24 - 30 volts, normal value is 28 volts.

If the gauge shows less than 24 volts, battery charge warning light (20) will illuminate, check V-belts, regulator and alternator.

* Numbers refer to positions on the electrical circuit diagram 44

Operating & Maintenance Manual

3. Operating controls

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

Pos 11 12 13 14 15 16 17 18 19 20 21 22

11

12

13

17

18

19

23

24

25

29

30

31

14

15

16

20

21

22

26

27

28

32

33

34

Description Page Front service brakes warning light 46 Rear service brakes warning light 46 Parking brake warning light 46 Brake fluid warning light 46 Emergency steering warning light 46 Parking brake indicator 46 Engine coolant temperature warning light 47 Engine oil pressure warning light 47 Main warning light, engine failure 47 Battery charge warning light 49 Air filter warning light 49 Spare space 49

Pos 23 24 25 26 27 28 29 30 31 32 33 34

Description Page Spare space 49 Transmission temperature warning light 49 High gear indicator 49 Hydraulic filter warning light 50 Spare space 50 Low gear indicator 50 High beam indicator 51 Engine brake indicator 51 Inter axle differential lock indicator 51 Direction light indicator 51 Retarder brake indicator 51 Spare space 51

Note: Indicator light for "Automatic central lubrication", see item 49 under "Switches" in this chapter. * Numbers refer to positions on the electrical circuit diagram Operating & Maintenance Manual

45

3. Operating Controls

Warning / indicator lights 11. Front service brakes warning light, red 12-A1* 11

12

13 Lights if air pressure in brake circuit 1 is below approx. 5 bar.

12. Rear service brakes warning light, red 12-B1* Lights if air pressure in brake circuit 2 is below approx. 5 bar.

14

15

16

13. Parking brake warning light, red 12-C1* Lights if air pressure in brake circuit 3 is below approx. 5 bar.

14. Brake fluid warning light, red 12-A2* Lights if there is a failure in a brake fluid circuit when the brakes are operated (too long stroke in a master cylinder due to air in the system or leakage).

15. Emergency steering warning light, red 12-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).

16. Parking brake indicator, red 12-C2* Light when the parking brake (61) 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 46

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights 17. Engine coolant temperature warning light,red 13-A1* 17

18

19

Lights if the engine coolant rises above 102 °C.

18. Engine oil pressure warning light, red 13-B1* Lights if oil pressure is lower than 0.7 bar.

20

21

22

19. Main warning light, engine failure, red 13-C1* Lights or flashes if there is an engine /engine controller failure.

Normal operation The main warning light on the instrument panel shall not light during normal operation, but some of the lamps on the engine controller will / can light or flash. These lamps are as follows: • • • • • 1

The The The The The

Starting lamp.

Running lamp.

Torque limit lamp Boost limit lamp Control Status lamp - flashes during normal operation.

The engine controller is located behind the cover on the backwall (behind the instructor's seat back rest, if that is fitted).

Engine / engine controller failure 19.1. If this main warning light on the instrument panel lights: The engine controller will reduce the engine load.

Procedure for reading error codes: 1. If possible, adjust the engine rpm to a low idle, check that the engine oil pressure warning light does not illuminate and check the coolant temperature gauges on the instrument panel.

3 2

2. Stop the dump truck at a safe place as soon as possible.

Do not turn off the starter switch until you have read and noted the error codes on the engine controller, procedure below.

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

Error codes

4. Open the cover on the back wall (1) (remove the instructor's seat back rest, if that is fitted).

5. Press down the test/fault switch (2) and keep it depressed.

6. All lamps (3) on the engine controller and the main warning lamp on the instrument panel will light up for 2 seconds to indicate that they are intact and in working order.

Make a note if any of the lamps are defective.

7. Then an error code will flash for 5 seconds. Note which lamp it is.

8. The operating mode will then be shown for 2 seconds.

9. The first error code that flashes indicates the most serious engine error or operating error. If the test/fault switch is still kept down, the process will be repeated automatically as above.

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

continued overleaf 47

3. Operating Controls

Warning / indicator lights 10.After having read and noted the error code, the test/fault switch can be released, and the starter switch shall be turned off.

11.Contact your Moxy Dealer.

12.When the error has been rectified, the engine can be restarted.

13. If the main warning light still light up, other errors may be registered.

14. The procedure for reading error codes must then be repeated (item 4-11).

• A short explanation of the codes is listed under troubleshooting.

19.2. If this main warning light on the instrument panel flashes, YOU ARE IN A SHUT DOWN CONDITION! Depending of the nature of the error, the engine controller will take various steps to protect the engine: • It can reduce the engine load.

• It can allow the engine to run at a constant low speed (1200 - 1500 rpm).

• If a serious functional error is detected, it can switch of the engine automatically.

Procedure for reading error codes: 1. If possible, adjust the engine rpm to a low idle, check that the engine oil pressure warning light does not illuminate and check the coolant temperature gauges on the instrument panel.

2. Stop the dump truck at a safe place as soon as possible.

Do not turn off the starter switch until you have read and noted the error codes on the engine controller, procedure below.

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

4. Open the cover on the back wall (remove the instructor's seat back rest, if that is fitted).

5. Follow the same procedure for reading the error codes as mentioned in item 19.1 item 4-14.

6. If the engine is switched off automatically by the Shutdown function and no error code reading can be obtained, there may be an error in the engine speed sensor.

Contact your Moxy Dealer.

• A short explanation of the codes is listed under troubleshooting.

NOTE •

•

•

If the main warning light illuminates / flashes, check and note the error codes on the engine controller and contact your Moxy Dealer in all cases.

Do not turn off the starter switch until you have read and noted the error codes! The codes will be reset to zero, and it will not be possible to read them.

All error codes will be stored in the memory of the engine controller.

* Numbers refer to positions on the electrical circuit diagram 48

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

20. Battery charge warning light, red 13-A2* 17

18

19

Lights if the battery charging voltage is too low (alternator or V- belt fault).

21. Air filter warning light, red 13-B2* 20

21

22

Lights if the engine air filter is clogged and needs maintenance.

See 1000 hours service for procedure.

22. Spare space

23. Spare space 23

24

25

24. Transmission temperature warning light, red 14-B1* Lights if the oil in the transmission rises above 120 °C. 26

27

28

25. High gear indicator, green 14-C1* Lights when the high gear mode is activated (switch 41, 1st position).

When changing between high and low gear the indicators will flash until the new range is engaged.

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

49

3. Operating Controls

Warning / indicator lights

26. Hydraulic filter warning light, red 14-A2* 23

24

25

Lights at normal oil operating temperature if the hydraulic filter is clogged and needs to be replaced.

See 2000 hours service for procedure.

Please be aware that the warning light can also light when the dump truck is started and the oil is cold, and at high engine rpm. Check then that the light switches off when the oil has reached normal operating temperature.

26

27

28

CAUTION If the warning light illuminates when the oil has normal operating temperature, replace the filter as soon as possible.

27. Spare space

28. Low gear indicator, green 14-C2* Lights when the low gear mode is activated (switch 41, 2nd position).

When changing between high and low gear the indicators will flash until the new range is engaged.

* Numbers refer to positions on the electrical circuit diagram 50

Operating & Maintenance Manual

3. Operating controls

Warning / indicator lights

29. High beam indicator, blue 15-A1* 29

30

31

Lights when high beam (switch 54B) on the headlights are activated.

30. Engine brake indicator, orange 15-B1* 32

33

34

Lights when the engine brake is engaged (switch 53, 1st or 2nd position).

31. Inter-axle differential lock indicator, orange 15-C1* Lights when the inter-axle differential lock is engaged (switch 42)

32. Direction light indicator, green 15-A2* Flashes when direction indicator (switch 54 E/F) or hazard light (switch 44) is activated.

• Will flash fast if an external direction indicator bulb is burnt out. (acc. to market demand).

33. Retarder brake indicator, orange 15-B2* Lights when the retarder brake is engaged (switch 53, 2nd position).

34. Spare space

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

51

3. Operating Controls

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

53

35

36

38

37

39

40

41

44

42

45

43

46

Or 47 Pos 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

48

49

50

Description Main light switch Cab and engine compartment light Rotating beacon switch Working lights on the sun visor (forward) Working lights on cab roof (backwards) Spare space High and low gear switch Inter-axle differential lock Spare space Hazard light switch Tipping system switch Test switch for brake warning light Mirror heating switch Electrically heated driver's seat switch Automatic central lubrication indicator light Spare space Spare space Spare space Engine and retarder brake switch

51 Page 53 53 53 53 53 53 54 54 54 55 55 55 56 56 56 57 57 57 58

52 Remarks

Optional Optional Optional

Optional Optional Optional

* Numbers refer to positions on the electrical circuit diagram 52

Operating & Maintenance Manual

3. Operating controls

Switches

35

36

37

35. Main light switch 20* 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 54) will also illuminate.

Built-in light.

36. Cab and engine compartment light 21* Push the switch to light the cab and the engine compartment lights.

Turn off during operation. Built-in light.

37. Rotating beacon switch 22* Push switch to activate the rotating beacon on top of the cab roof.

Built-in light.

38

39

40

38. Working lights on the sun visor (forward) 23* Push the switch to activate the working lights on the sun visor.

Will only be activated if the main light switch (35) is switched on.

Built-in light.

39. Working lights on cab roof (backwards) 24* Push the switch to activate the working lights on the cab roof.

Will only be activated if the main light switch (35) is switched on.

Built-in light.

40. Spare space

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

53

3. Operating Controls

Switches

41

42

43

41. High and low gear switch 26* Push the switch to select high or low gear.

Position I: High gear Position II: Low gear To activate high or low gear, the dump truck must be stationary, the gear selector must be set to neutral (N) position and the engine must run at low idle.

An indicator light, 25 or 28 will light when high or low gear is activated. Buil-in light.

NOTE When changing between high and low gear the indicator lights will flash until the new range is engaged.

If the indicator lights does not stop flashing, return the switch to before-position and move the dump truck a little and try again.

42. Inter-axle differential lock 27* 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 (31) will light when the lock is engaged.

Built in light.

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

• when necessary!

43. Spare space

* Numbers refer to positions on the electrical circuit diagram 54

Operating & Maintenance Manual

3. Operating controls

Switches

44

45

46

44. Hazard light switch 29* Push switch to activate the hazard light, all direction indicators will flash at the same time. An indicator light (32) on the instrument panel will flash concurrently. Built-in light.

45. Tipping system switch 30* Push the switch to override the tipping system. For safety reasons, the tipping system is made in such way that it is not possible to tilt the body centre of gravity over the tipping hinges.

• If an empty body shall be raised, it may be necessary to push the switch and keep it depressed while the body is lifted with the tip control lever. Release the switch when the body is raised.

• If the body is resting on the body support, it is necessary to push the switch and keep it depressed while the body is lifted slightly. Release the switch when the body is off the body support and lower the body.

WARNING Do not use this switch when tipping with load!

46. Test switch for brake warning light 31* Push the switch and check that the warning light for brake fluid circuit failure (14) lights up.

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

55

3. Operating Controls

Switches

47. Mirror heating switch 32* 47

48

49

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

Engage only when necessary!

48. Electrically heated driver's seat switch 33* Green or

Push the switch to activate the heating of driver's seat.

Built-in light.

Yellow

49. Automatic central lubrication indicator light, green or yellow 34* Lights when the automatic central lubrication is activated.

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. The indicator light will then light up once. This pattern will be repeated 4 times.

Blink codes for the indicator light: (the buzzer will sound when the indicator light is flashing) • The light flashes 4 times once (0.5s on/0.5s off) as soon as the starter switch has been turned on: Cause: The automatic central lubrication is activated.

• The light does not flash when the starter switch is turned on: Cause: 1.The system is not powered. Check fuses and connection to earth and replace if necessary.

2. Lamp or wiring to lamp could be defective. Check lamp and wiring and replace if necessary.

• The light flashing for 2 minutes (0.5s on/0.5s off) at the beginning of each cycle: Cause: Minimum grease level in the reservoir has been reached. Refill the reservoir as soon as possible, see 500 hours service for procedure.

Located inside the cover

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

Test button

• The light continuously light after starter switch has been turned on: Cause: System out of order! Immediate action is required.

Possible causes: 1. Insufficient grease pressure during 10 consecutive cycles (or 10 consecutive times in the same main pipe channel). Check cause and reset by depressing the test button (on the reservoir) for at least one second while the starter switch is turned on.

2. 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.

continued overleaf * Numbers refer to positions on the electrical circuit diagram 56

Operating & Maintenance Manual

3. Operating controls

Switches

• The light flashing during one complete cycle (2.0s on/2.0s off): Cause: Single test run being executed (see "test") • The light flashing continuously (0.2s on/0.2s off): Cause: Continuous cycle test run being executed (see "test")

Test

Located inside the cover

• 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

50

51

52

• In order to provide additional 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 turned off.

50. Spare space

51. Spare space

52. Spare space

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

57

3. Operating Controls

Switches

53. Engine and retarder brake switch 47* The switch has two positions: 1. Push the switch to position I to engage only the engine brake.

The engine brake will only engage when a gear is selected, lockup connected and the throttle pedal released.

Built-in light.

An indicator light (30) will light when engaged.

2. Push the switch to position II to engage the retarder brake together with the engine brake.

The retarder brake and the engine brake will only engage when a gear is selected, lock-up connected and the throttle pedal released. Built-in light.

Indicator lights (30 and 33) will light when engaged.

* Numbers refer to positions on the electrical circuit diagram 58

Operating & Maintenance Manual

3. Operating controls

Controls

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

54

55

56

57

58

59

60

61

Pos 54 55 56 57 58 59 60 61 62 63 64 65

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

62

63

65

64

Page 60 62 63 63 64 65 65 65 66 66 67

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

59

3. Operating Controls

Controls 54. Column switch 16* The column switch is a multi-function switch for main lights, horn, direction indicators and windscreen wiper/washer.

Main lights (A, B, C):

B

A. Low beam (when switch 35 is in position 2)

C A

B. High beam (when switch 35 is in position 2), indicator 29 will light.

C. High beam flash. Automatic return.

D. Horn, centre button automatic return.

D

E

E. Right turn, all right direction indicators flash.

Indicator light 32 flashes correspondingly.

F. Left turn. All left direction indicators flash.

Indicator light 32 flashes correspondingly.

F

* Numbers refer to position on the electrical circuit diagram 60

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 motor. 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

61

3. Operating Controls

Controls 56. 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 62

Operating & Maintenance Manual

3. Operating controls

Controls 57. 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 fluid circuit failure lights up (warning light 14), stop the dump truck immediately!

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

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

63

3. Operating Controls

Controls

59. Gear selector 46* The dump truck is equipped with a fully automatic transmission with 6 forward and 2 reverse speeds. Gear shift pattern is speed and engine load dependent. The gear display (6) on the dashboard will always show the engaged gear position.

Pos N: Neutral gear position Depress the lock button on left hand side of the gear selector when shifting from neutral to reverse position.

Pos D: Forward drive position.

Used for normal travel. Automatic gear shift between 1st6th gear according to dump truck speed and engine load.

When shifting from D-position to 5-position it is necessary to depress the lock button.

Pos 5 - L: These positions are used in places where it is difficult to travel at high speed, when travelling on soft ground, downhill etc.

The speed ranges are as follows: Pos 5: Automatic gear shift between 1st and 5th gear, according to dump truck speed and engine load.

Pos 4: Automatic gear shift between 1st and 4th gear, according to dump truck speed and engine load.

Pos 3 Automatic gear shift between 1st and 3rd gear, according to dump truck speed and engine load.

Pos L: Automatic gear shift between 1st and 2nd gear, according to dump truck speed and engine load.

Pos R: Reverse drive position: Automatic gear shift between 1st-2nd gear according to dump truck speed and engine load.

The transmission will always select the 1st reverse when the gear selector is set to "R".

The lock-up will only engage in 2nd gear (R2).

See also chapter 5, Operating Instructions

NOTE The lock button on left hand side of the gear selector must be depressed: • when shifting from neutral position to reverse position • when shifting from D - position to 5 - position.

* Numbers refer to position on the electrical circuit diagram 64

Operating & Maintenance Manual

3. Operating controls

Controls 60. Tip control lever The lever controls the body lifting and lowering.

The lever has 3 positions:

Hold

1. Lower (body down/power down and floating position).

2. Hold (hold and floating position).

3. Lift (body up).

Lock device

Lower

Lift

The lever are mechanically locked in the hold and lower positions.

Lift the lock device to release the lever in these positions. 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. Spring return from lift to hold.

61. Parking brake lever

OFF ON

The parking brake is on (locked) when the lever is in the backward position. An indicator light (16) will light when the parking brake is on. Lift 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 is in motion unless in an emergency situation. Warning light (16) 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 air pressure is below normal pressure (warning light 13 and buzzer). The parking brake will not be fully released, and the service brakes may not have max. braking effect.

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

65

3. Operating Controls

Controls 63. 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.

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

• Left door and front sidewindow on right hand side.

• If the door is blocked by any means you can get out through the front sidewindow.

• Pull the handle under the window backwards. The rubber seal must be pulled completely off before pushing the front sidewindow out.

* Numbers refer to position on the electrical circuit diagram 66

Operating & Maintenance Manual

3. Operating controls

Cab ventilation

65. Cab ventilation

For machines up to serial no. 410251 1

4

3

2

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.

5

For machines from serial no. 410252 (SERIES II) 1

2

3

4

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.

5. Only installed on machines up to serial no. 410251: Recirculation switch 55* The switch has two positions: Pos I:Fresh air in cab. Air intake is fully open.

Pos. II:Recirculation of the internal air. The ventilation fan must be used to circulate the air.

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 dump truck 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

67

3. Operating Controls

Cab ventilation Setting heat and ventilation Without air conditioning - 410251

How to get...... ......maximum heat: • • • • •

410252 -

All nozzles fully open.

Heater regulator (65.3) on max., i.e right position Fan switch (65.1) on max, i.e. speed 3.

Air flow regulator (65.2) to driver's feet i.e. left position.

Recirculation switch (65.5) on pos II, recirculation (- 410251).

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

- 410251 ...... pleasant working temperature:

410252 -

• All nozzles fully open.

• Heater regulator (65.3) on max., i.e. right position • When the correct temperature has been obtained, turn heater regulator (65.3) (left) until you maintain the desired temperature.

• Air flow regulator (65.2) turned to the position which feels most comfortable.

• Recirculation switch (65.5) on pos I, fresh air (- 410251).

• Fan switch (65.1) set to speed 1 or 2.

- 410251 ......fresh air in cab:

410252 -

• All nozzles fully open.

• Heater regulator (65.3) on min., i.e. left position • Air flow regulator (65.2) on max. air flow towards the driver's feet, i.e. left position.

• Recirculation switch (65.5) on pos I, fresh air (- 410251).

• Fan switch (65.1) on max, i.e. speed 3.

* Numbers refer to position on the electrical circuit diagram 68

Operating & Maintenance Manual

3. Operating controls

Cab ventilation Setting heat and ventilation Without air conditioning - 410251

410252 -

How to get...... ......rid of condensation and ice on all windows: • Nozzles towards the windows fully open.

• Heater regulator (65.3) on max., i.e. right position • Air flow regulator (65.2) on max. air flow towards the windows, i.e. right position.

• Recirculation switch (65.5) on pos I, fresh air (- 410251).

• Fan switch (65.1) 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 draughts 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

69

3. Operating Controls

Cab ventilation Air conditioner - 410251

410252-

How to get...... ......a pleasant temperature quickly: • Nozzles towards the driver's feet fully open.

• Heater regulator (65.3) on min., i.e. left position • Air flow regulator (65.2) on max. air flow towards the driver's feet, i.e. left position.

• Air flow switch (65.5) on pos II, recirculation (- 410251).

• Fan switch (65.1) on max, i.e. speed 3.

• Switch (65.4) pressed down, i.e. air conditioner engaged.

- 410251 When the temperature has been lowered to the level you want:

410252 -

• Turn the fan switch (65.1) to the position which maintains the desired temperature.

• Turn the air flow regulator (65.2) to the position which feels most comfortable.

• Adjust the nozzles towards the driver to a comfortable position.

- 410251 ...... rid of air humidity in the cab:

410252 -

• All nozzles fully open.

• Heater regulator (65.3) on max., i.e right position • Air flow regulator (65.2) on max. air flow towards the windows, i.e. right position.

• Recirculation switch (65.5) on pos II, recirculation (-410251).

• Fan switch (65.1) on max., i.e speed 3.

• Switch (65.4) 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 70

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Driver's seat The seat is air-sprung 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.

1

4

2

Seat adjustment.

3

1.

Lumbar support adjustment.

Stepless adjustment of the support.

5/6

2.

Backrest inclination adjustment.

3.

Seat cushion inclination.

Stepless adjustment of seat cushion Forward - clockwise. Backward - counterclockwise.

4.

Forward and backward adjustment.

Lift lever up and slide the seat to a suitable position - release lever.

5.

Height adjustment.

Stepless seat height adjustment.

Elevation - clockwise. Lowering - counter clockwise.

Automatic weight adjustment.

6.

Quick seat lowering.

For comfortable step in and out.

Lower the seat - valve outwards. When seated, press valve in and seat automatically returns to individual setting.

7.

Headrest.

8.

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

9.

Adjustment screw Stepless inclination adjustment.

10.

Backrest.

11.

Suspension height limiter.

I. Lever to the right: Comfort position, max. suspension height, 150 mm.

II. Lever in middle position: Suspension height limited to 90 mm.

III.Lever to the left: Fixed position, no height suspension.

Seat must be in correct position, 75 mm above bottom position when locking.

48.

Electrically heated seat.

7 8

9 8

10

11

47

48

49

The seat can be heated by pushing the switch.

Refer to item 48 in this chapter.

12345678 12345678 12345678 12345678 12345678 12345678 12345678 12345678

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

71

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 key.

* Numbers refer to position on the electrical circuit diagram 72

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Open

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.

Close

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

• Fire extinguisher, 2 kg, ABE class II powder.

(Distributor / Dealer fitted)

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

73

3. Operating Controls

Other cab equipment

• Warning triangle.

Ashtray

Retractable roller sunblind on front windscreen

Cab light The cab light switch has three positions: • On • Off • Door activated

* Numbers refer to position on the electrical circuit diagram 74

Operating & Maintenance Manual

3. Operating controls

Other cab equipment

Radio/Cassette player 201,212* The radio has following security features: Detachable panel, switchable warning light, 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 sliding the "REL" key downwards.

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

2.

Switchable warning light The red light flashes when the detachable panel is removed.

• Stop or start the light flashing by pressing the "POWER" key.

3.

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

4.

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.

5.

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

75

3. Operating Controls

* Numbers refer to position on the electrical circuit diagram 76

Operating & Maintenance Manual

4. Running-in period

Running-in period

Operating & Maintenance Manual

77

4. Running-in period

Content

4. Running-in period ..................................................... 77-82 1. Running-in operation .......................................... 79 2. Running-in service .............................................. 80

78

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 air pressure in the various circuits is normal.

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

79

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, 250 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: 30 mm (from serial no. 410001 and up to 410136) Spanner: 32 mm (from serial no. 410137 and up)

2. Lubricating.

Grease all lubricating points.

3. Battery:

Checking electrolyte level in the batteries, see 40 hours/weekly service, item 1.1.

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

4. V-belt:

Checking poly-V belts 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.

• Walk around check .............................................. item 1.1.

• Check driver's seat .............................................. item 1.2.

• General condition check - look for leakages, ...... item 2.1.

• Check oil level, engine ......................................... item 2.2.

• Check coolant level .............................................. item 2.3.

Coolant should be filled up when the engine is stopped after first stop, see 2000 hours service, item 1.3 check the coolant.

• Check fuel level ................................................... item 2.4.

• Function check of the centrifugal cleaner, ........... after first operation ............................................... item 2.5.

• Drain air tanks, after first operation ..................... item 2.6.

• Check oil level, transmission ............................... item 3.1.

• Check oil level, hydraulic system ........................ item 4.1.

• Check brake fluid levels ....................................... item 5.1.

• Check parking brake capacity, ............................ item 7.1.

• Check main brake capacity .................................. item 8.1.

• Check main brakes function, ............................... item 8.2.

• Check steering function ....................................... item 9.1.

• Check engine brake function ............................... item 10.1.

• Check engine and retarder brake function .......... item 11.1.

2.2

First 100 hours: 1. Change transmission oil.

20*

See 1000 hours service, item 4.1.

2. Replace transmission filter. 21*

See 500 hours service, item 2.1.

3. Clean strainer.

22*

See 1000 hours service, item 4.1.

4. Replace hydraulic filter.

43*

See 2000 hours service, item 2.3.

5. V-belt: Checking poly-V belts condition See 1000 hours service, item 2.4.

6. Retorque window wiper spindle nuts.

• Torque setting: 35 Nm (M10), 18 Nm (M8) 7. Lubricating. Grease all lubricating points.

* Numbers refers to position on lubrication schedule, chapter 6 80

Operating & Maintenance Manual

4. Running-in period

2.3

First 250 hours: 1. Check brake lining thickness.

See 500 hours service, item 4.1.

How often the brake linings have to be checked/replaced depends on how much the brakes are used and/or application.

After checking the brake linings for the first 250 hours, consider whether or not the brake linings should be checked more often, based on lining wear.

2.4

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

• Rear differential.

• Tandem housings.

• Reduct. gears, front.

30* 31* 32* 33*

See 1000 hours service, item 5.1.

See 1000 hours service, item 6.1.

See 2000 hours service, item 5.1.

See 1000 hours service, item 7.1.

2. Check/adjust: • Valve clearance. Procedure described in 2000 hours service, item 1.2.

• Hydraulic oil pressure. Contact your local Moxy dealer.

3. Lubricating. Grease all lubricating points.

4. 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.

• Replace filter element, transmission ................... item 2.1.

• Clean breather, transmission ............................... item 2.2.

• Check brake lining thickness ............................... item 4.1.

• Check wheel nuts torque ..................................... item 5.1.

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

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

• Refill the reservoir for autom. central lubrication . item 7.1 • Check the automatic central lubrication system .. item 7.2

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

81

4. Running-in period

82

Operating & Maintenance Manual

5. Operating Instructions

Operating Instructions

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5. Operating Instructions

Content

5. Operating instructions ............................................. 83 - 114 Some simple rules to be observed prior to operation85 1. Starting the engine .............................................. 86 2. Operating the dump truck .................................... 88 3. Parking the dump truck ........................................ 99 4. Stopping the engine ............................................ 99 5. Checks after stopping the engine ....................... 100 6. Loading and tipping ............................................ 100 7. Tyre handling ....................................................... 102 8. Cold weather ........................................................ 104 9. Long term storage ............................................... 105 10. Battery power assistance .................................... 106 11. Towing the dump truck ........................................ 107 12. External air filling ................................................. 107 13. Manual release of parking brake ........................ 108 14. Tyre filling point ................................................... 108 15. Troubleshooting ................................................... 109

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5. Operating Instructions

Some simple rules to be observed prior to operation.

• 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, medicines or other drugs.

• 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 operation, 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 instructor or passanger 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 or passenger 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 the air pressure in the brake system before you start driving.

• The cab is the driver's protection and conforms to 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 over.

• The cab has two exits, one door and the front sidewindow on the right hand side as emergency exit. The front sidewindow is opened by pulling the handle under the window backwards. The rubber seal must be pulled completely off before pushing the front sidewindow out.

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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 in the battery box (if disconnected) otherwise there will be no power supply.

1.1. Confirm that parking brake is ON

ON

1.2. Confirm that gear selector is in neutral position

N

1.3. Turn the starter switch ON, pos 1 Check warning lights before starting: • engine oil pressure • charging light • parking brake • brake circuits • emergency steering warning light, switches off above 5 km/h.

• 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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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. 20 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 min.

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

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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5. Operating Instructions

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

1. Clean/defrost the windows before driving.

6. Sound the horn as alert.

2. Fasten the seatbelt before driving.

7. Depress the brake pedal.

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

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

OFF

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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 effic iency in all forward gears and second reverse gear.

Connection/disconnection is automatic but engine speed related.

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

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

Gear position 5 The transmission shifts automatically between 1st and 5th gear, according to dump truck speed and engine load.

Gear position 4 The transmission shifts automatically between 1st and 4th gear, according to dump truck speed and engine load.

Gear position 3 The transmission shifts automatically between 1st and 3rd gear, according to dump truck speed and engine load.

Gear position L The transmission shifts automatically between 1st and 2nd gear, according to dump truck speed and engine load.

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5. Operating Instructions

The gear positions 5 - L are used: • in places where it is difficult to travel at high speed.

• when travelling on soft ground.

• when starting off the dump truck on a slope when it is loaded.

• when going downhill if it is needed to use the braking force of the engine and upshift is not wanted.

Gear shift program: The gear shift program is automatic controlled by the throttle pedal position and the acceleration of the dump truck.

If the dump truck is unloaded it will accelerate fast. As a result, the gear shift will happen at low rpm.

With loaded dump truck the acceleration will not be so fast, and the gear shift will happen at high rpm.

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

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

Dropbox High - low gear Low gear Low gear Always use low gear when operating cross-country with a load.

High gear Use high gear when operating with an empty dump truck and when operating with a loaded dump truck under good conditions.

Changing gear

High gear

If it is necessary to change between high and low gear during a work cycle, this is the best achived when the dump truck is stopped at the loading or tipping point.

Proceed as follows: 1.

2.

3.

4.

5.

Stop the dump truck Set the gear selector to neutral position (N) Run the engine at low idle.

Select high or low gear by pushing the switch.

Confirm that the indicator light changes from high to low (or opposite).

6. If the indicator light flashes between high and low, return the switch to the before-position and move the dump truck a little.

7. Try again.

Engine and retarder brake mode The engine and retarder brake are operated by a switch.

In order to engage the engine brake or the engine and retarder brake, the throttle pedal must be fully released, a gear selected and the lock-up connected. Max. allowed engine rpm is 2400 rpm. If this rpm is exceeded, the transmission will shift up.

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Operating hints Different types of terrain require different operating techniques.

D

5-4-3-L

5-4-3-L

• Use position D, automatic gear shift, for normal travel.

• When controlling Hi/Lo switch, stop the dump truck completely and run the engine at low idle.

• In terrain, before uphill/downhill driving, select position 5 - 4 - 3 or L for the estimated speed in the area, avoid repeated up and down shift in hilly terrain.

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

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

• Use position 5 - 4 - 3 or L when going downhill to keep high engine rpm and high braking power.

OFF

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

1

2

• Stop the truck and release the throttle pedal completely. After moving the gear selector, do not depress the throttle pedal until you detect that the trans mission clutch has engaged.

• Always drive allowing the lockup clutch to connect.

• When moving the gear selector from the neutral position (N) to the reverse position (R) or from the D-position to the 5position, press the lock button on the gear selector before moving it.

N

• Neutral position must not be selected during driving.

• 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

R

1. Before reversing, make sure that no persons or objects are behind the dump truck or in the articulation area.

4. After moving the gear selector, do not press the throttle pedal until you detect that the transmission clutch has engaged.

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

5. Increase the engine speed.

3. Place the gear selector in reverse position (R), if you are going from neutral position (N) to reverse position (R) it is necessary to press the lock button before moving it.

The reverse drive position has automatically gear shift between 1st and 2nd gear. The lock-up clutch will not be engaged in the 1st gear of reverse.

WARNING • •

Be careful when reversing, the rear visibility is limited!

If the dump truck is driving forward at a speed of 4 km/h or more and the gear selector is moved to reverse position, the transmission will not shift to reverse, due to preventing excessive load on the power train

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.

Always drive allowing the automatical 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.

• Engine coolant temp.: 70-93°C. • Engine oil pressure: 3-6 bar at normal engine temp. (optional instrument)

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• Transm. oil temp.:

80-110°C, max 120°C a short period when using the retarder brake.

• Air pressures:

7.0 - 7.8 bar.

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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) Air over hydraulic operated dry single disc brake on each wheel. Front and rear axle have 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 Air operated, speed dependent brake which restricts exhaust flow. Efficient only when lock-up clutch is connected.

Retarder brake Hydrodynamic, wear resistant and speed dependent oil retarder fitted together with the 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, air released single disc brake on the rear prop. shaft. Self-adjusting system.

2.7. Engine and retarder brake operation The engine and retarder brake is switch operated.

The switch has three steps: 1. OFF 2. Only engine brake 3. Engine brake and retarder brake • The engine brake or engine and retarder brake will only be engaged if a gear is selected, lock-up connected and throttle pedal released.

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

• When operating the engine brake or the engine and retarder brake use engine speed above 1800 rpm.

• Max. allowed engine speed when using the engine brake or engine and retarder brake is 2400 rpm . If this rpm is exceeded, the transmission will shift up.

• To avoid overspeed of the engine, the engine brake will automatically engage if the engine speed exceeds 2600 rpm.

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5. Operating Instructions

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.

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

N

5. Apply the parking brake.

ON

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

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5. Operating Instructions

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.

L

2. Apply the engine and retarder brake.

ON

4. Press the lock button and move gear selector to Lposition as quickly as possible.

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

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

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.

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 diff. 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

CAUTION

3

Use the interaxle 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 crossgradient 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 curves and road width.

• Operate the dump truck sensibly and avoid crossgradient travel. Select a low speed and negotiate the terrain without exagerated 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 (L - 3 - 4 or 5).

Rule:Select the same gear for operating downhill as you would for operating up the same hill.

• Do not under any circumstances drive the dump truck with raised body.

• Always use the engine brake or the engine and retarder brake for constant retardation.

Long time engagement and unnecessary use of the service brakes can cause excessive wear and a possibility of loss of braking effect due to over-heated brake discs.

• Keep engine speed at the upper area, 1600 - 2000 rpm in heavy conditions and at hill travel. Select the L - 3 - 4 or 5 position at steep hill travel.

• 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.

5-4-3-L

• Do not park or leave the dump truck on grades or slopes, the risk for spontaneous rolling is high!

G KIN R PA

• Pay attention to the transmission oil temperature when the retarder brake is applied.

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• ALWAYS keep the engine speed below max. allowed rpm when travelling downhill!

The engine brake will automatically be engaged if the engine speed exceeds 2600 rpm.

This is to avoid overspeed of the engine.

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2.13. Important operating instructions

• The dump truck must not coast with gear selector in neutral position.

N

• Engine speed within 1600 2000 rpm with engaged lockup is recommended during driving.

• Engine speed must be reduced, and the dump truck must be stopped completely before changing between reverse and forward gears.

• The engine brake will automatically be engaged if the engine speed exceeds 2600 rpm, to avoid overspeed of the engine. max.

ON

N

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ON

• 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 Dealer to amend the fault.

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5. Operating Instructions

3. Parking the dump truck

ON

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. Neutralize all operating controls.

8. Secure the dump truck from spontaneous rolling by adding wheel chocks under the wheels before leaving the dump truck.

G KIN R PA

4. Stopping the engine

1. Stop the dump truck.

3. Before stopping the engine, check that the main warning light for engine failure is not on or flashing. See chapter 3, Operating Controls for procedure if the warning light is on or flashing.

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 may be shortened.

Never stop the engine immediately after driving except in case of emergency.

4. Turn the key in starter switch to OFF position.

OFF

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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. Release the air pressure from the air tanks, to drain condensation.

4. Check for leakage of oil or water.

5. 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 6. Remove any waste paper or other flammable material which may cause fire in the engine compartment.

7. 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.

• When loading large rocks, cover the body bottom with 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, on the 3rd stage.

The lowering speed on the 3rd stage is proportional with the engine speed.

7. The tip control lever shall stay in hold (float) position when not operated.

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 crossgradients!

Utilisation of top tailgate has safety restrictions!

See Chapter 2. SAFETY INSTRUCTIONS!

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5. Operating Instructions

7. Tyre handling General This is a general instruction for the standard tyres in the table under item 6.2. 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 5% 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 alsofactors 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 carry out on cold tyres.

Basic pressure for cold tyres (based on max. load and max. speed): Type Bridgestone VLT ** Michelin XADN/XADT Good Year GP2B/GP4B/RL-2+

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Front bar (psi) 4.25 (62) 3.50 (51) 3.50 (51)

Rear bar (psi) 4.50 (65) 4.0 (58) 3.90 (57)

5. Operating Instructions

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 maintenanced 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: 32 km/h.

Must not be exceeded!

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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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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/engine brake switch must be turned OFF and apply the parking brake.

2. Release the air pressure in all circuits. (see chapter 7, daily service) 3. Thoroughly wash and clean the dump truck.

4. Completely fill the fuel tank.

5. Replace oil and filters with new and lubricate all nipples.

Check viscosities to match the expected ambient temperature.

6. If the ambient temperature is expected to drop below 0oC, always add antifreeze to the cooling water.

7. Fully charge the batteries and disconnect terminals.

Preferably stored separately in a cold place (0-10oC).

8. Cover all cylinder piston rods with rust protecting fluid.

9. Inflate the tyres to correct pressure. (see chapter 8) 10.Lock the sliding windows, door, fender hatches and bonnet.

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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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 defect?, 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

1. Turn off the battery main switch in the battery box.

3

4

2

2. Connect first cable (A) from positive (+) terminal on discharged batteries....

3. .... to the positive (+) terminal on the assisting battery.

Good batteries

B

Low batteries

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 • • • • •

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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.

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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,180 kN (each) • Rear, 250 kN

CAUTION •

• •

If air pressure is lost, the service brake will not function and the parking brake will be engaged. The air system can be filled from an external air supply, see item 12.

An engaged parking brake can be loosened even if there is no air in the system, see item 13.

It is not possible to start the engine by towing!

12. External air filling Filling of the air system can be done from an external air supply through the air connector fitted on the left hand side, under the engine bonnet. In the tool kit there is a hose for this purpose. The parking brake must be applied, and wheel chocks placed under the wheels.

1. Remove the protection cap.

2. Connect the hose nipple to the connector.

3. Start filling and check the pressure at the cab gauges.

The dump truck can now be moved if the parking brake can be released.

WARNING • •

The pressure will gradually drop when braking. Pay attention to the braking effect!

Make sure that the parking brake is applied (on) before filling from an external air supply. If the parking brake is not engaged, the dump truck may roll spontaneously!

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5. Operating Instructions

13. Manual release of parking brake If the parking brake can not be disengaged by the parking brake lever i.e. air pressure has been lost, it may be manually released: 1. Place wheel chocks under the wheels.

2. Raise the body and secure it with the body support (see chapter 2 - safety instructions) 3. Screw the parking brake caliper adjusting screw in an anti-clockwise until the brake is released.

DANGER All braking systems are now out of function. Extreme care must be taken to avoid spontaneous rolling.

14. Tyre filling point The air filling connector (see item 12) can also be used for filling air into the tyres.

1. Connect the hose to the connector and fill air.

2. Check the air pressure with a separate gauge.

3. For basic tyre pressures, see chapter 8. Technical Data.

WARNING Be sure to use a self-locking nipple and do not stay in front of the tyre during filling!

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5. Operating Instructions

15. Troubleshooting If the action below does not solve the problem or the fault cannot be found, contact Moxy dealer.

*= Always contact your Moxy Dealer.

Phenomen

Cause

Action

Will not start

Main switch disconnected Out of fuel Low battery current Blown fuse Defective wiring Hydrostatic lock Starter motor defective Electronic controller or sensors defective

Turn on Refill fuel, bleed system Recharge Check circuit, replace fuse Check connections, wires Repair* Replace* Check/repair*

Starts but stops again, runs un-evenly or hunts.

Low output

Fuel system disturbance Condensated water in diesel Bad fuel quality Low fuel level Fuel filters clogged Air filter clogged Fuel tank breather clogged Throttle system disturbance Wrong injection timing Injector defective Turbo charger defective Worn engine or internal damage Electronic controller or sensors defective

Check fuel lines, bleed system Drain tank Change fuel Refill fuel Replace filters Replace or clean Clean tank cover Adjust/replace/repair Adjust* Repair/replace* Repair/replace* Overhaul* Check/repair*

Overheated (warning light)

Low coolant level Fan belt problem Air in cooling system Dirt inside cooling system Radiator fins clogged/damaged Thermostat faulty Sensor/gauge defective Coolant pump worn

Add coolant, check for leakages Tighten/replace Bleed system Clean and replace coolant Clean Replace Replace Overhaul*

Low coolant temperature

Sensor/gauge defective Thermostat stuck open

Replace Replace

Low oil pressure

Too low oil level Incorrect oil type Sensor/gauge defective Oil pressure red. valve faulty Worn oil pump

Add oil, check for leakage Change to correct oil type Replace Overhaul* Overhaul*

Blue smoke, oil consumed

Too high oil level Incorrect oil type Worn engine or internal damage

Adjust to specified level Change to correct oil type Overhaul*

Black or white smoke

Clogged air filter Fuel pump/injection system worn or faulty Cylinder gasket defective Turbocharger defective

Replace or clean Adjust/repair* Replace* Repair/replace*

15.1. Engine:

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5. Operating Instructions

Phenomen

Cause

Action

Oil in coolant or coolant in oil

Internal leak in transmission cooler Worn engine or internal damage Internal leak on engine oil cooler

Replace* Overhaul* Replace*

Knocking noise

Bad fuel quality Valves incorrectly adjusted Injection pump incorrectly adjusted Injector defective Worn engine or internal damage

Change fuel Adjust Adjust* Replace* Overhaul*

Main warning light illuminates

Engine / engine controller failure

Stop the dump truck at a safe place and check the error codes on the engine controller.

Following error codes can be read on the engine controller: Control status lamp lights Shut down lamp lights Torque limit lamp lights Boost limit lamp lights Power - lamp lights

Main warning light flashes SHUT DOWN CONDITION

Engine controller has detected an internal fault.

Engine temperature has reached a warning threshold or the sensor has failed.

Air inlet temperature has reached a warning threshold or the sensor has failed.

Engine controller has detected a loss of boost pressure.

Speed potentiometer or idle safety switch has failed.

Engine / engine controller failure

Check/repair* Check/repair* Check/repair* Check/repair* Check/repair*

Stop the dump truck at a safe place, check the error codes on the engine controller and stop the engine as soon as possible.

Following error codes can be read on the engine controller: Control status lamp lights Shut down lamp lights Starting lamp lights Running lamp lights Power + lamp lights

Engine controller has detected an internal fault.

Engine temperature has reached a shut down threshold or the sensor has failed.

Engine has exceeded its overspeed threshold.

Actuator feedback sensor failure.

Oil pressure has dropped below a threshold level or the sensor has failed.

Check/repair* Check/repair* Check/repair* Check/repair* Check/repair*

15.2. Transmission: Too high temperature

Too low oil level Incorrect oil type Cooling circuit failure Lock-up fault Worn oil pump

Add oil, check for leakage Change to correct oil type Check/repair Overhaul* Overhaul*

No drive in any gear or only possible to drive in some gears

Too low oil level Blown fuse Converter prop. shaft Electronic controller detect failure, neutral engaged Electronic controller or sensors defective Flywheel damper separated Drive line failure Internal transmission failure

Add oil, check for leakage Check circuit Replace

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Operating & Maintenance Manual

Check/repair* Check/repair* Replace* Check/repair* Overhaul*

5. Operating Instructions

Phenomen

Cause

Action

Low oil pressure

Too low oil level Incorrect oil type Sensor/gauge defective Pressure control valve failure Worn oil pump Internal transmission failure

Add oil, check for leakage Change to correct oil type Replace Check/repair* Overhaul* Overhaul/replace*

Noise

Too high oil level Incorrect oil type in differential(s) Worn transm. or internal damage

Adjust to specified level Change to correct type Overhaul/replace*

Transmission / controller failure

Stop the dump truck at a safe place, select neutral gear position and apply the parking brake.

Check and note the eroor codes on the transmission controller.

Check lamp on the gear display illuminates/flashes

Following error codes can be read on the transmission controller: Error code

2.

3.

4.

5.

7.

9.

Cause

Re-enaction Action of controller

0.1 0.2

Defective controller power source system

0.3

Neutral safety

0.4 0.5

Defective controller system

0.6

Defective transmission cut relay system

0.9

Defective exhaust brake solenoid system

1.0

Defective engine speed sensor system

1.1

Defective transmission input shaft speed sensor system

1.2

Defective transmission intermediate shaft speed sensor system

1.3

Defective transmission output shaft speed sensor system

1-6,8

Clutch slipping or defective speed sensor system

A.1 0.7 1.5 1.6

Defective model selection signal system

1.9 1-6,8 1-6,8

Defective transmission valve oil temperature sensor system

1-6,8 1-6,8 1-6,8 8.1 8.3 8.2 8.4

Defective flow control valve system

F.A

H / L solenoid system error

F.B

Retarder solenoid system error

F.D

Diff.-lock solenoid system error

F.E

Diff.-lock ON / OFF selection system error

F.F

H / L selection system error

Defective shift lever system

Defective pressure control valve system

Defective pressure control solenoid system Defective torque contverter inlet port pressure sensor system Defective torque converter outlet port pressure sensor system

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111

5. Operating Instructions

Symbol explanation for trouble shooting on the transmission controller.

Key: [ ]

1 - 8: Digits from 1 to 8 appears in the display pattern.

1 : Lock-up clutch related parts 2 : H clutch related parts 3 : L clutch related parts 4 : 1st clutch related parts 5 : 2nd clutch related parts 6 : 3rd clutch related parts 8 : Reverse clutch related parts : Blank (no display)

Method of re-enacting the error display It is possible to re-enact and investigate the error display as follows.

system: Turn the starter switch OFF

ON.

system: Turn the starter switch OFF ON, and operate the lever slowly in turn to N, R, N, D, 5, 4, 3, L ( Stop for at least 3 seconds at eash position before going to the next position). system: Start the engine with the gear selector in neutral (N) position. system: Using the clutch displayed in the error display (at the speed range used), carry out the travel test.

Display Either 7 or 9

Correcponding clutch

Speed range

.1

Lock-up clutch

.2

H clutch

F2, F4, F6

.3

L clutch

F1, F3, F5, R

2, 3, 4, 5

.4

1st clutch

F1, F2

Either 7 or 9

.5

2nd clutch

F3, F4

.6

3rd clutch

F5, F6

.7

Reverse clutch

L/U

R

system: Actuate the exhaust brake during the travel test. (When travelling in lock-up, operate the brake with the accelerator at idling).

Operation of controller when error is detected When the transmission controller detects an error, it shows the error and takes following action.

system: Transmission neutral, the transmission returns to neutral because of a error in the power source system or controller. system: Transmission neutral, there is danger of damage to the chassis electrical system and controller, so the controller automatically turns the output OFF. system: Transmission neutral, there is possibility of error in the hydraulic or mechanical system, so to avoid fatal damage to the transmission itself, the controller automatically switches the transmission to neutral. system: Speed range held, but neutral (N) held when lever is at neutral (N).

Because of the condition of abnormality, the controller judges it to be impossible to change gear, so the speed range is held. system: Travel is possible, but some functions stop.

The controller automatically stops the functions of the system which is abnormal.

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5. Operating Instructions

Phenomen

Cause

Action

15.3. Brakes: Poor braking effect or truck Low brake fluid level pull to one side when braking Uneven worn brake pads Air in brake fluid circuit Insufficient air pressure A brake caliper is stuck

Add fluid, check for leakage Replace pads Bleed brakes Check charging and system Repair*

15.4. Air system: Low air pressure (all circuits) System leakage Governor problem Compressor failure

Check circuits Adjust setting/repair Overhaul*

High air pressure

Governor problem

Adjust setting/repair

Emergency steering light on when driving

No oil flow from main pump, or no oil flow from emerg. pump Oil flow switch defective

Check and repair* Check and repair* Replace*

Truck will not go straight ahead, uneven steering movement or periodically sticking

Low hydraulic oil level Air trapped in hydraulic system Contaminated oil Incorrect oil type Steering cylinders internal leak Orbitrol or steering valve failure

Add oil, check for leakage.

Bleed system Change oil and flush system Change to correct oil type Overhaul* Check and repair*

Not possible to tip or slow tipping

Low hydraulic oil level Clogged oil filter Insufficient air pressure Clogged tank strainer or breather Low oil pressure Worn oil pump Tip valve failure

Add oil, check for leakage Replace Check charging Replace/clean Check/repair* Check/reapir* Overhaul*

No electrical power

Main switch disconnected Batteries discharged Battery terminals/wiring defective

Turn on Recharge Repair

Charge warning light on

Fan belt problem Defective/worn alternator Defective wiring

Tighten/replace Replace Check connections, wires

Defective shock absorber Defective rubber suspension Articulation turning ring worn

Replace Replace Overhaul*

15.5. Hydraulic system:

15.6. Electrical:

15.7. Chassis: Uncomfortable travel (jumping)

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5. Operating Instructions

Phenomen

Cause

Action

Vibrations

Engine or transm. mountings Fan or flywheel loose/imbalance Defective elastic coupling Prop. shaft failure Drive line problem

Replace Check/repair* Check/repair* Check/repair* Check/repair*

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6. Lubricants

Lubricants

Operating & Maintenance Manual

115

6. Lubricants

Content

6. Lubricants ................................................................. 115 - 122 Lubrication schedule ................................................. 117 Oil specification sheet ............................................... 119 Filling capacities ........................................................ 120 Transmission oil list ................................................... 121

116

Operating & Maintenance Manual

6. Lubricants

Lubrication schedule 1st time HOURS-->

POS COMPONENT ENGINE 1 2 3 4 5 10

100 500

Engine oil Centrifugal cleaner Engine oil filter Fuel filter Coolant/cooling system

SERVICE INTERVAL 8

40

V V

500 1000 2000 4000

Min. once a year

Shell Rimula Super 15W - 40

R C R R

V

V/R*

ENGINE RELATED Air filter, outer element, prefilter - 410251: -Inner element: replace every 3rd year 410252 -: -Inner element: replace every 2nd year

C/R*

11 Batteries (2) 12 Air system/air dryer 13 Fuel tank

V

C/R

V/R*

Transmission oil Filter Strainer Breather

R R C

40% Glycoshell

C/R*

V

D V

D

R

R D

V

R

R

C

C

R R

R R

TRANSMISSION 20 21 22 23

Lubricants filled from producer

Shell Donax TC SAE 30

R C

DRIVE LINE 30 Front differential oil 31 Rear differential oil

R R

V V

32 Tandem housing oil (2)

R

V

33 Front reduction gear oil (2)

R

V

Shell Spirax AX SAE 80W/90

R R

R

HYDRAULIC

- 410219: Shell Donax TM

40 Hydraulic oil 42 Breather element on tank 43 Filter

V

R R* R*

R

410220 - :Tellus T 46

LUBRICATION POINTS 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Articulation turning ring Tip hinges Tandem bearings Articulation bearings Steering cyl. bearings Tip cylinder bearings Tailgate arm hinge (optional) Door and fender hatches Cab rear hinges Suspension legs Cardan shaft Cardan shaft Cardan shaft Cardan shaft

Shell Spirax A 90 LS

Shell SRS 4000 *5/1 lubric.

2 lubric.

2 lubric.

2 lubric.

4 lubric.

4 lubric.

2 lubric.

4 lubric L 2 lubric.

L 4 lubric.

L 1 lubric 1 lubric 1 lubric 1 lubric

L L L

4 cont.

V

NLGI - 2

L L L L L L L L L L L

BRAKES 65 Brake fluid

R

R

Shell Donax YB

MISCELLANEOUS 70 Cab ventilation filter 80 Hydr. pump, tiltable cab R= Replace

V= Check

C= Clean

C/R* V/R* Shell Tellus T15 L= Lubricate

D= Drain

*= or when required

= Alternatively greased by automatic central lubrication system (optional)

*5/1 lubric.: Up to serial number 410251 there are 5 lubrication points on the articulation turning ring From serial number 410252 (SERIES II) there is 1 lubrication point on the articulation turning ring

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117

6. Lubricants

The numbers refer to table on previous page.

65

4

5

1

12

3

2 12

11

1

43 21

10

33

30

63 20 40

33 63 13

23 42

22

57

57

58 53

50

61 54

54 55 55

60 12 31 65

65

52

118

32

51

32

52

Operating & Maintenance Manual

NOTE! The air filter (10) is moved on the top of the engine from serial no. 410252 (SERIES II), see chapter 7, 1000 hours service.

6. Lubricants

Oil specification sheet 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

AMBIENT TEMPERATURE 14 32 50 68 86 °F -10 0 10 20 30 °C SAE 20W-30 SAE 30 SAE 40

Engine oil pan

Engine oil

SAE 50 SAE 5W-30 SAE 10W-30 SAE 15W-40

Fuel tank Cooling system

Diesel fuel

WIN T ER S UM M ER - D IE SE L

SAE 10W Engine oil

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 minimum 12-13 (ASTM 2896).

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 Acc. to: ASTM and ISO standards Cetane number: min. 49.

Sulphure contents: max. 0.3 %.

Max. 2 % isopropanol additive.

30-50 % Nitrite-free glycol anti freeze is recommended.

See 2000 Hours Service .

Water + antifreeze SAE 30

Transmission

REMARKS

API class: CD, CE, CF-4 Only oils in Transmission Oil List , can be used!

NOTE! Min. 20 minutes warming up period in neutral position is required when ambient temperature is within this area:

SAE 10W-30 SAE 15W-40

Tandem housing, Planetary red. gear Front diff.

Rear diff.

SAE 85W-90 Gear oil

SAE 80W-90

According to: API GL-5 or MIL-L-2105D (gear oil with EP-additives)

SAE 85W-140 Gear oil with LSadditives

*= max. 2% (weight) VI-Improver and Pour Point Depressant in the basic gear oil.

SAE 90 O t he r ge a r o ils a s a bo v e*

HM ISO VG 32

Hydraulic tank

HV ISO VG 32

Hydraulic oil

HM ISO VG 46 HV ISO VG 46

ATF

DEXRON IID

Universal grease

Lithiumsaponfied with EP-additive.

Consistency NLGI-1 / 1,5 / 2.

Optional: Universal Automatic grease Centr. lubr. system Brake Brake fluid system Hydr.

Hydraulic pump, oil tiltable cab

• Contact oil supplier when operating in temp. below -25°C. • Warm up in neutral after starting at temperatures 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.

SAE 10W

Engine oil Lubricator

Only mineral based oils.

Viscosity approx. 20 cSt at normal operating temperature.

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).

NLGI 2 NLGI 0/1

Grease should not contain graphite or PTFE. Consistency NLGI-2 or synthetic 2, NLGI 0/1 or synthetic 0/1 According to: SAE J1703 (DOT4 or DOT3) or FMVSS 116 DOT 5

ISO VG 15 See remarks

NOTE! If the cab should be tilted by use of the hydr. pump at temperatures below -20OC, use oil Fluid 4 Aero Shell or similar.

CAUTION Remember, Automatic Transmission Fluid must not be mixed with engine or hydraulic oil.

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119

6. Lubricants

Filling capacities 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: Total tank/reservoir volume or total capacity from empty.

Refil amount:

Refill volume after normal fluid draining. The differences are fluid left in components, piping etc.

Specified capacity

Component / Fluid

Refill amount

Engine oil

34

34

Engine coolant

50

40

Fuel tank

420

420

Transmission oil*

79

55

Rear differential

40

35

Front differential

16

16

2 x 112

2 x 106

Front reduction gear, each

2x6

2x6

Hydraulic system

220

135

Brake fluid

4,5

as req'd

Windscreen washer tank

2,7

2,5

Tandem housing, each

*=

Check level when engine runs at low idle.

Do not run engine without oil in the transmission.

** = New pads

120

Operating & Maintenance Manual

6. Lubricants

Transmission oil list Transmission to be filled with engine oil according to API class CD, CE or CF-4 in the SAE class 10W, 30, 10W-30, 15W-40.

Engine oils Manufacturer

Trade name

Manufacturer

Trade name

AGIP AGIP AGIP

Diesel sigma S Super diesel-multigrade Sigma turbo

GULF GULF

Super duty motor oil Super duty Plus

AMOCO

Amoco 300

KAIC KAIC

Heavy Duty Trans-Fluid 10W Heavy Duty Trans-Fluid 30

ARCO

Arcofreet S3 plus

LUBRIZOL

Lubrizol 9692A

BP BP

Autran TO-430 Vanellus C3

CALTEX CALTEX CALTEX CALTEX CALTEX

Torque Fluid 414 Torque Fluid 434 RPM delo 500 RPM delo 600 RPM delo SHP

MOBIL MOBIL MOBIL MOBIL MOBIL

Mobiltrans HD 10W Mobiltrans HD 30 Delvac 1300 Delvac super 10W30 Delvac super 15W40

CASTROL CASTROL

Turbo max, CRD Rx super

PENNZOIL PENNZOIL PENNZOIL

Power-tranz TO-4 10W Power-tranz TO-4 30 Supreme duty fleet Engine Oil

PENTROFINA

FINA kappa TD

CHEVRON CHEVRON CHEVRON CHEVRON

Drivetrain Fluid HD 10W Drivetrain Fluid HD 30 Delo 400 Delo 450

SHELL SHELL SHELL

Donax TC10W Donax TC 30 Rimula X

CITGO

Powershift 30

CONOCO

Fleet motor oil

TEXACO TEXACO TEXACO TEXACO

Transmission and Drivetrain Oil 10W Transmission and Drivetrain Oil 30 Ursa super plus Ursa premium

DRYDENE DRYDENE

Code #1201 Code #1202

ELF ELF ELF

Tranself KTR4 30 Elf performance 3D 15W-40 Elf performance XC 15W-40

TOTAL TOTAL TOTAL TOTAL

Transmission AC 10W Transmission AC 30 Rubia S Rubia X

UNION

Guardol

ESSO ESSO ESSO ESSO ESSO ESSO

Essotrans 10W Essotrans 30 Essolube D3, XD-3 XD-3 extra Esso heavy duty Exxon heavy duty

VEEDOL VEEDOL

Turbostar HDC diesel star

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121

6. Lubricants

122

Operating & Maintenance Manual

7. Maintenance

Maintenance

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

123

7. Maintenance

Contents

7. Maintenance ............................................................. 123 - 178 Maintenance precaustions ........................................ 125 Maintenance table ..................................................... 126 8 Hours / Daily Service .............................................. 127 40 Hours / Weekly Service ........................................ 137 500 Hours Service ..................................................... 141 1000 Hours Service .................................................. 155 2000 Hours Service .................................................. 167 4000 Hours Service .................................................. 175 Yearly recommended maintenance ......................... 177

* Numbers refer to positions on the lubrication schedule, chapter 6 124

Operating & Maintenance Manual

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).

• Wear a well-fitting helmet, safety shoes and working clothes. When drilling, grinding or hammering, always wear protective goggles.

• Park the dump truck on firm, flat ground. Apply the Articulation Lock.

• 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 part.

• When working with others; Choose a group leader follow the leader's instructions. Do not perform any maintenance beyond the agreed work.

• 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 extinguishers and other firefighting equipment.

• 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.

• Always stop the engine when performing maintenance near moving parts.

• During maintenance; Do not allow any unauthorised person to stand near the dump truck.

• 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.

• 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.

• Always use pure oil or grease, and be sure to use clean containers.

• Before servicing the air system, remember always to drain the air pressure through drain valves.

• 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.

• Be particularly careful when removing the expansion tank cap. If this is done immediately after using the engine, there is a danger that boiling water and steam may spurt out.

• After replacing 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 removed while adding oil.

• When adding oil or checking the 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.

• When removing parts containing o-rings, gaskets or seals, clean the mounting surface and replace with new sealing parts.

• When washing the dump truck, be careful not to wet electrical components or inside cabin.

• When lubricating oil or cooling water has been drained, keep an eye on the instrument panel so that the dump truck is not operated without oil or cooling water. * In case of difficult maintenance, refer to your Moxy Dealer.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

125

7. Maintenance

Maintenance table 8 Hours / Daily Service 1. General

Walk around check ............

Check driver's seat ............

General condition check ...

Check oil level ...................

Check coolant level ...........

Check fuel level .................

Check centrifugal cleaner .

Drain air tanks ...................

Check oil level ...................

Check oil level ...................

Check fluid levels ..............

127 127 128 128 129 129 130 130 131 131 132

5/1 lubricators ....................

2 — “ — .............................

2 — “ — .............................

Check braking capacity .....

Check braking capacity .....

Check function ..................

9. Steering Check function ..................

10. Engine brake Check function ..................

11. Engine and retarder br. Check function ..................

132 133 133 134 134 135 135 136 136

2. Engine

3.

4.

5.

6.

Transmission Hydraulic system Brake system Lubrication: • Artic. turning ring • Tip hinges • Tandem bearings 7. Parking brake 8. Service brake

1000 Hours Service 1. Driver's seat 2. Engine

(SERIES II) 3. Fuel tank 4. Transmission 5.

6.

7.

8.

Front differential Rear differential Front reduction gears Electrical system

2000 Hours Service 1. Engine

2. Hydraulic system

40 Hours / Weekly Service 1. Engine 2. Cab ventilation 3. Tyres 4. Lubrication: • Artic. bearings • Steering cyl. bearings • Tip cyl. bearings • Tailgate arm hinges

Check batteries .................

Check battery terminals ....

Clean prefilter ....................

Air conditioner ...................

Check tyre pressure ..........

137 137 137 138 138

2 lubricators .......................

4 — “ — .............................

4 — “ — .............................

2 — “ — ..............................

139 139 139 140

Safety check ...................... 155 Replace fuel filter .............. 155 Bleed the fuel system ........ 156 Check batteries ................. 156 Check poly-V belt .............. 157 Clean/replace air filter ....... 157 Clean/replace air filter ....... 159 Drain condensation ........... 161 Change oil ......................... 161 Clean strainer .................... 162 Change oil ......................... 165 Change oil ......................... 165 Change oil ......................... 166 Check wiring ..................... 166

3. Brake system 4. Parking brake 5. Tandem housings

Check fuel injectors ........... 167 Check/adj. valve clearance 167 Check coolant ................... 168 Replace air dryer ............... 170 Change oil ......................... 171 Replace breather element 171 Replace hydraulic oil filter 172 Inspect brake lines ............ 172 Change brake fluid ............ 173 Check breather .................. 174 Change oil ......................... 174

4000 Hours Service 1. Cooling system

External cleaning .............. 175 Internal cleaning ............... 175 Clean charge air cooler .... 176 Changing coolant .............. 176

500 Hours Service 1. Engine

2.

3.

4.

5.

6.

7.

8.

Change oil ......................... 141 Clean centrifugal cleaner .. 141 Replace oil filter ................ 145 Transmission Replace filter element ....... 146 Clean breather .................. 147 Drive line Check oil levels ................. 147 Brake system Check linings ..................... 149 Wheels Check wheel nuts torque .. 150 Cab ventilation Test of air conditioner ........ 151 Check cab ventilation filter 152 Automatic central lubr. Refill reservoir ................... 153 Check the system .............. 153 Lubrication: • Doors and fenders 4 lubricators ...................... 154 • Cab rear hinges 2 — “ — ............................. 154 • Suspension legs 4 — “ — ............................. 154

Yearly recommended maintenance 1.

2.

3.

4.

5.

6.

Transmission Drive line Tanks Hydraulic system Exhaust system Bearings

General condition check ... 177 General condition check ... 177 General condition check ... 177 Inspect the hydr. hoses ..... 178 Safety check ...................... 178 Check clearance ............... 178

* Numbers refer to positions on the lubrication schedule, chapter 6 126

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

127

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2. Engine 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) (below the side covers) which show whether the O-rings between the cylinder liners and crankcase are leaking, see drawing. a. If coolant is leaking out, the O-ring is leaking. b. If oil is leaking out, the liner shelf is leaking.

4. Check that the coolant pump drain hole (2) is not clogged, see drawing. If there is leakage, change the pump seal.

5. 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.

If there is a large amount of leakage - contact your Moxy Dealer.

2.2. Check oil level, before start 1* 1

2

• The correct level shall be between upper and lower mark on the dip stick (1) (dump truck on level ground).

• The dipstick (1) is found on the left hand side of the engine.

• If the engine has been running: Let the engine remain stationary for at least 1 minute before checking the oil level.

• Fill up with oil (2) (see oil specification sheet, chapter 6) if level has dropped to the lower mark.

Check level correctness.

* Numbers refer to positions on the lubrication schedule, chapter 6 128

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2.3. Check coolant level, before start 5* • The expansion tank shall be approx. half filled when the dump truck is on level ground.

Refill with coolant of correct mixture if level is lower.

• 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 can spurt out!

Never add large amounts of cold coolant when engine is hot. The temperature difference can cause cracks in the engine.

2.4. 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.

2

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

129

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

2.5. 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.

Front chassis

2.6. Drain air tanks, after operation 12* • Front chassis: Pull the handle on the left hand side of the truck outwards to release air pressures from all front chassis air tanks.

• Rear chassis: Pull the drain chain on the underside of the tank sideways to release the air pressure.

• If condensation is present in the escaping air, release system pressure completely and replace the air dryer, see 2000 hours service

Rear chassis

* Numbers refer to positions on the lubrication schedule, chapter 6 130

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 door, left 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.

9. Insert the dip stick again and turn handle clockwise to tighten the sealing.

CAUTION Do not overfill with oil! Both too high and too low level can cause serious internal damage!

4. Hydraulic system 4.1. Check oil level, before start 40* 1. Read the oil level in the oil level gauge.

Level shall be approx. at the middle of the gauge.

2. Fill up with oil (see oil specification sheet, chapter 6) if necessary.

NOTE The dump truck must be horizontal and dump body completely lowered!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

131

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

5. Brake system 5.1. Check brake fluid levels, before start 60* Two containers in the engine compartment (left hand side) and two containers on rear chassis.

• The containers shall be min. 2/3 filled (see marks).

Fill up with correct brake fluid, if necessary.

• If the containers have to be filled up with brake fluid almost monthly, check the brake system for leaks and/ or worn brake linings. Replace brake linnings if necessary.

• Experiences has shown that if the brake fluid containers are filled up from minimum to maximum 3 times, the brake linnings could have reached the min. thickness.

Therefore, if the level in the containers decreases, the brake linings must be checked /replaced (see 500 hours service for procedure).

CAUTION • •

- 410251

When refilling, do not overfill!

Use only brake fluid as specified in the specification sheet, chapter 6!

6. Lubrication Grease lubrication points until pure grease is forced out of the components. Wipe off.

6.1. Articulation turning ring, Up to serial no. 410251 there are 5 lubricators 50* From serial no. 410252 (SERIES II) there is 1 lubricator 50* Lubricators located on the distribution block.

410252 -

* Numbers refer to positions on the lubrication schedule, chapter 6 132

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hourr of operation or daily.

6.2. Tip hinges, 2 lubricators 51* One lubricator on each tip hinge.

6.3. Tandem bearings, 2 lubricators 52* One lubricator on rear end of each tandem housing.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

133

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

7. Parking brake 7.1. Check braking (holding) capacity, before operation

ON

D1st gear

1. Apply the parking brake (indicator light) and make sure that the system pressure is at normal operating pressure which is between 7.0 - 7.8 bar (see air pressure gauge, in chapter 3).

3. Increase the engine speed slowly.

2. Set the gear selector in 1st gear and select high gear range.

4. The parking brake must be able to keep the dump truck stationary at engine speeds up to 1600 rpm. If not, check parking brake system and contact your Moxy Dealer.

8. Service brake (main brake) 8.1. Check braking (holding) capacity, before operation

ON

1. Apply the parking brake (indicator light) and make sure that the system pressure is at normal operating pressure which is between 7.0 - 7.8 bar (see air pressure gauge, in chapter 3).

D1st gear

4. Set the gear selector in 1st gear and select high gear range.

2. Depress the brake pedal.

5. Increase the engine speed slowly.

3. Release the parking brake.

6. The service brake must be able to keep the dump truck stationary at engine speed up to 1200 rpm. If not, check the brake system and contact your Moxy Dealer.

OFF

* Numbers refer to positions on the lubrication schedule, chapter 6 134

Operating & Maintenance Manual

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

8.2. Check function, before operation

ON

1. Apply the parking brake (indicator light) and make sure that the system pressure is at normal operating pressure which is between 7.0 - 7.8 bar (see air pressure gauge, in chapter 3).

5. Check for brake fluid leakage at master cylinders, pipes and hoses.

2. Stop the engine.

6. Start the engine and release the parking brake.

ON

OFF

OFF

3. Depress brake pedal firmly and listen for leaks in the air system.

7. Drive the dump truck slowly on firm, level ground and depress the brake pedal firmly.

8. Check that the braking effect is good and equal.

4. Also check that the brake fluid warning light (chapter 3) does not illuminate and the air pressure gauge (chapter 3) for large pressure drop.

9. Steering 9.1. 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.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

135

7. Maintenance

8 Hours / Daily Service To be performed every 8 hours of operation or daily.

10. Engine brake 10.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

4. Check the indicator light for function and note the braking power.

2. Apply the engine brake by setting the engine brake switch to pos. I and release the throttle pedal.

5. Depress the throttle pedal again and note that the engine brake goes off (i.e no braking power, exhaust sound changes and the indicator light switches off).

3. Check that the exhaust sound changes.

11. Engine and retarder brake 11.1. Check function, before operation 1. Drive the dump truck forwards at approx 10-15 km/h with lock-up engaged.

4. Check the indicator light for function, both engine and retarder brake and note the braking power.

2. Apply the engine and retarder brake by setting the engine/retarder brake switch to pos. II and release the throttle pedal.

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).

3. Check that the exhaust sound changes.

* Numbers refer to positions on the lubrication schedule, chapter 6 136

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

1. Engine 1.1. Check batteries 11*

• Checking of batteries shall also be carried out after the first 8 hours of operation.

10 - 15 mm

1. Open right hand side fender cover (key for opening the cover is to be found in the cab, near the fire extinguisher) 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.

1.2. Check battery terminals for tightness and corrosion Clean if necessary, apply acid-free vaseline on the terminals and retighten the clamps.

2. Cab ventilation 2.1. Clean prefilter 70* 1. Open 2 clamps and remove the cover (1).

2. Remove the prefilter (2), and clean it with compressed air.

• Replace if necessary 2 1

3. Reassamble the opposite way.

4. Adjust the check interval if another requirement is experienced.

NOTE Never start driving without prefilter. The heater could in worsc case get damaged.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

137

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

2.2. 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 operating the air conditioner for 10 minutes.

3. Tyres 3.1. 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 can cause damage and serious personal injury.

* Numbers refer to positions on the lubrication schedule, chapter 6 138

Operating & Maintenance Manual

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

4. Lubrication Grease following lubrication points until pure grease is forced out of the component. Wipe off.

4.1.

Articulation bearings, 2 lubricators 53* Turn the dump truck completely to the right for easy access to the lubricators on the bearing hinge.

4.2.

Steering cylinder bearings, 4 lubricators 54* 2 lubricators on each cylinder (one at each end).

Check the complete length of cylinder rods for scratches and other damage.

4.3.

Tip cylinder bearings, 4 lubricators 55* 2 lubricators on each cylinder (one at each end).

Raise the body to check all cylinder pistons for scratches and other damage.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

139

7. Maintenance

40 Hours / Weekly Service To be performed every 40 hours of operation or weekly.

4.4.

Tailgate arm hinge (optional), 2 lubricators 56* One lubricator on the inner side of each tailgate arm hinge.

5. Continue with all items in 8 Hours / Daily Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 140

Operating & Maintenance Manual

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

Quick drain plug

1. Remove the oil pan drain plug and drain the oil when the engine is hot.

Access through the drain hole in engine belly plate (1).

• If a quick drain plug is fitted: Remove the cap on the drain plug, install the draining hose (tool kit) and drain the oil.

2. Clean magnet on plug.

3. Reinstall the plug when all oil is drained.

• Plug torque: 80 Nm. • If quick drain plug is fitted: Remove the draining hose and reinstall the cap.

4. Reinstall the cover for drain hole in engine belly plate.

5. Fill oil through filler (2). Do not overfill!

2

6. Check oil level on dip stick (3).

CAUTION The oil may be hot! Wear protective gloves and eye protection.

3

1.2. Clean centrifugal cleaner 2* (at the same time as oil change, item 1.1) See next page about how to clean the centrifugal cleaner.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

141

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1. 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.

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.

* Numbers refer to positions on the lubrication schedule, chapter 6 142

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

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.

9. Place the O-ring in the rotor cover.

• The o-ring must be not be damaged.

Change if necessary.

10. Assemble the rotor.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

143

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

11. Tighten rotor nut firmly by hand.

12. Reinstall the rotor.

• Check that it rotates easily.

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.

* Numbers refer to positions on the lubrication schedule, chapter 6 144

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

1.3. Replace oil filter 3* (at the same time as oil change, item 1.1) 1. Remove the old filter and discard it according to enviromental requirements.

2. Oil the rubber gasket on the new genuine filter.

3. Fit the new genuine filter.

4. Tighten the filter by hand as tight as possible.

5. 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 the circulation obstructed!

Use only genuine filter!

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

145

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

2. Transmission 2.1

Replace the filter element 21* • Replacement of filter element shall also be carried out after the first 100 hours of operation.

1. Clean well around the filter housing. The filter is to be found on left hand side in the engine compartment.

2. Place a suitable container beneath the draining hose to catch spillage.

3. Unscrew filter housing.

4. Check for wear particles in the oil.

5. Change O-ring. Check backing ring for damage.

6. Replace the filter element with a new one.

7. Clean the housing and apply oil or grease to threads and o-rings.

8. Fill housing half full with clean oil.

9. Screw filter housing back into place.

• Torque: 141 Nm. 10. Disconnect the hose (1) at the transmission filter.

Transmission oil pump

11. Raise the end of the hose, and fill the hose with oil (2).

1

12. Connect the hose.

En gin e

13. Start engine and let it idle for 2-3 minutes.

Check for leaks.

Transmission filter

2

Transmission oil pump Transmission filter

* Numbers refer to positions on the lubrication schedule, chapter 6 146

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

2.2

Clean breather 23* 1. Tilt the cab, procedure described chapter 2, safety instructions.

2. The breather is located on the top of the transmission (left hand side).

3. Remove the mud and dirt around the breather.

4. Remove the breather and clean it with diesel oil or flushing oil.

5. Reinstall the breather.

6. Lower the cab, procedure described chapter 2, safety instructions.

3. Drive line 3.1. 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* 1. Remove the rear belly plate.

2. Use a hexagonal key to unscrew the upper filling/level plug.

• Plug torque: 80 Nm. 3. Reinstall the rear belly plate.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

147

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

2. Rear differential 31* Use a hexagonal key to unscrew the filling/level plug at the rear of housing.

• Plug torque: 80 Nm.

3. Tandem housings 32* Use a hexagonal key (1) to unscrew the level plugs (2) on the inside of the housings.

• 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 6 148

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

Service brake

4. Brake system 4.1. Check lining thickness

• Checking of brake lining thickness shall also be carried out after the first 250 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 application. After checking the brake linings for the first 250 hours, consider whether or not the brake linings should be checked more often, based on lining wear.

• Also if there often (monthly) have to be filled up with brake fluid, the brake linings must be checked and if necessary replaced (see 8 hours/daily service).

If the linings have to be replaced, be aware that overflow of brake fluid in the reservoirs can occur.

To avoid this, open the bleeder plug before the old lining is pushed back to give space for the new one.

Parking brake

2. Parking brake: Lift body and apply the body support. Check thickness of linings through inspection hole on one of the sides of the caliper. Change when approaching limit.

• After replacement perform adjustment, see next page.

Standard lining thickness: Service brakes: Parking brake:

22.0 mm 18.0 mm

Min. thickness:

3.5 mm.

3.5 mm.

Service brakes: Parking brake:

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

149

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

4.2. How to adjust the parking brake.

To be performed after replacement of parking brake linings.

1. Apply the parking brake and make sure that the system pressure is at normal operating pressure which is between 7.0 - 7.8 bare (see air pressure gauge, in chapter 3).

1

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.

2

7. Turn the adjusting screw anticlockwise until a total clearance of 1.5 mm (2) is obtained between outer lining and disk. (Measure at centre of lining when sliding caliper max. outwards.)

3

8. Place a wrench on the adjusting screw (3), and apply the parking brake in the cab several times. Look out of the rear window to follow the wrench and when no further rotation on the adjusting screw is observed, the brake is correctly adjusted.

9. Remove the wrench and check function and effect.

5. Wheels 5.1

Check wheel nuts torque.

Torque setting 450 Nm. Wheel spanner in the tool box.

* Numbers refer to positions on the lubrication schedule, chapter 6 150

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

6. Cab ventilation

- 410251 2

1

6.1. Air conditioner system, test operation 1. Start the engine.

2. Press down the air conditioner switch, set the fan switch to position 3 (see also chapter 3) and open all nozzles.

3. Check that the temperature in the cab decreases.

410252 2

• 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

1

WARNING •

If the air conditioning system does not work properly, contact your Moxy Dealer in all cases!

•

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 unconciousness. 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 overpressure 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 once per year.

•

See also chapter 2, safety instructions

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

151

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, below the cover for fuseboxes and transmission controller).

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.

1

5. Reassamble the opposite way.

6. Adjust the check interval if another requirement is experienced.

2

* Numbers refer to positions on the lubrication schedule, chapter 6 152

Operating & Maintenance Manual

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

7. Automatic central lubrication 7.1. Refill the reservoir, the reservoir must 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.

Located inside the cover

4. Fill the reservoir up to the maximum level indicated on the reservoir.

5. Remove the filler hose and fit the dust cap.

7.2. Check the system • Check the pump for damage and leakage.

Filler coupling

• 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.

•

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 doors and fender hatches and the cab rear hinges.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

153

7. Maintenance

500 Hours Service Maintenance to be performed every 500 hours of operation.

8. Lubrication Grease lubrication points until pure grease is forced out of the components.

8.1. Door and fender hatches, 4 lubricators 57* There are 2 lubricators on the door and 2 lubricators on right hand side fender (one per hinge).

8.2. Cab rear hinges, 2 lubricator 58 * There is one lubricator on each side of the cab.

8.3. Suspension legs, 4 lubricators 59* The lubricators are located on the distribution block.

9. Continue with all items in 40 Hours Service. * Numbers refer to positions on the lubrication schedule, chapter 6 154

Operating & Maintenance Manual

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* The filter consist of one filter unit.

1. Wash the filter externally and unscrew it, wrench in toolkit. Discard the filter according to environmental requirements.

2. Fit the new genuine filter and tighten it by hand.

• Never use tools to tighten the filter! The filter may be damaged and the fuel flow hampered.

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 Operating & Maintenance Manual

155

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.2

Bleed fuel system:

1 2

1. Turn the starter switch to pos. I so that the fuel shut-off valve opens.

3

2. Undo the connection on the fuel filter outlet (1) (upwards).

3. Pump with the hand pump (3) until bubble-free fuel flows out of the opened connection.

4. Tighten the connection on the filter.

5. Remove overflow valve (2) from the fuel shut-off valve's outlet.

6. Pump with the hand pump until bubble-free fuel flows out of the opened overflow valve.

7. Tighten the overflow valve and pump with the hand pump additional 10 strokes.

If the engine is difficult to start after bleeding: 1. Open the overflow valve again and pump with the hand pump until bubble-free fuel flows out.

2. Close the overflow valve firmly and start the engine.

WARNING The engine may be hot! Use gloves when pumping with the hand pump to avoid burning your hands.

2.3. Check batteries 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 6 156

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

The first belt circuit

2.4. Check poly-V belt condition

• Checking of poly-V belt condition shall also be carried out after the first 8 and 100 hours of operation.

1. The first belt circuit: • Stop the engine to inspect the poly-V belt (1).

• Change the belt (1) if damaged or worn.

• Check that the automatic belt tensioner (2) is in proper working order and keeps the V-belt correctly tensioned.

2. The second belt circuit.

• The second belt circuit has to be adjusted manually.

• It shall be tensioned to 15 - 20 Nm as shown on illustration.

The second belt circuit

2.5. Air filter 10* Up to serial number 410251.

NOTE For cleaning/replacement of air filter from serial no.

410252 (SERIES II), see page 159.

Up to serial no. 410251, the air filter is located in the fender on right hand side of the dump truck.

Unscrew the steps on right hand side fender.

continue overleaf

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

157

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Outer element (- 410251) : Clean element every 1000th hour of operation or if the air filter warning light illuminates at full load on the engine.

Replace it after 6 times of cleaning, or at least once a year.

Prefilter

1. Loosen all clamps and remove the prefilter (1).

1

2. Remove outer element (2).

Do not remove inner element when cleaning outer element!

3. Clean prefilter and inside of filter housing with compressed air.

4

4. Direct dry compressed air (less than 7 bar) to the element from inside along its folds, then direct it from the outside along its folds, and then from inside again.

Outer element 2

5. Check that the element is clean and undamaged, and reinstall it.

6. Reinstall the prefilter, and fasten all the clamps.

Turn the prefilter so that the dust cap (4) is pointed downwards (max angle: 20°).

7. Reinstall the steps.

Inner element (- 410251): Replace element every 3rd replacement of the outer element, or at least every 3rd year.

Inner element 3

1. Loosen all clamps and remove the prefilter (1).

2. Remove outer element (2). Then remove inner element (3).

3. Cover the air inlet port.

4. Clean prefilter and inside of filter housing with compressed air.

5. Remove cover on the inlet air port.

6. Install a new inner element into the housing.

7. Install a new or cleaned outer element.

8. Reinstall the prefilter, and fasten all the clamps.

Turn the prefilter so that the dust cap (4) is pointed downwards (max angle: 20°).

9. Reinstall the steps

CAUTION • • •

• • • • •

Do not attempt to reinstall a cleaned inner element.

Do not clean or replace the element when the engine is running.

Replace the element if small holes or thinner parts are found on the element when it is checked with an electric bulb after cleaning.

If the element is usable, wrap it and store it a dry place.

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 replaced.

* Numbers refer to positions on the lubrication schedule, chapter 6 158

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

2.5. Air filter 10* From serial number 410252 (SERIES II).

From serial number 410252, 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.

Outer element (410252 -): 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

Fig. 2

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).

• 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).

Fig. 3

6. Never carry on using a damaged outer element. In case of doubt, always fit a new outer element.

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

159

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Servicing the dust cap (410252- ) The dust cap require very little maintenance.

Possible dust packs to be removed by squeezing the cap (fig. 5).

Fig. 5

Inner element (410252- ): • Replace element every 5th cleaning of the outer element, or at the latest after 2 year.

• 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.

1. Loosen all clamps and remove the cover.

2. Remove outer element.

Fig. 6

3. Remove the inner element; Use a suitable tool (e.g. screw driver) to push through the seal of the inner element from the inside to the outside and pull both the straps upwards (fig. 6).

4. Use both straps to take hold of the inner element and then pull out with a light turning movement (fig. 7).

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 downwards (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 6 160

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

3. Fuel tank 3.1. Drain condensation, at least once a year 13* It is an advantage to do this procedure after the dump truck has been stationary for a while (e.g. weekend) if possible.

1. The drain cock is to be found on the left hand side of the the fuel tank, behind the cab.

2. Place a suitable container to catch spillage.

3. Remove blanking plug and install draining hose (tool kit).

4. Open the drain cock.

5. Drain until water/sediment-free fuel comes out.

6. Close the drain cock.

7. Remove the draining hose and reinstall the blanking plug.

NOTE If a large amount of dirt and contamination has collected into the tank: • Drain all fuel.

• Remove the flange for the hoses and clean inside of the tank.

1

4. Transmission 4.1. Change oil 20* Clean strainer 22* at least once a year

• Changing transmission oil 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 (1).

4. Remove the rear belly plate.

5. Unscrew drain plug (2), at the bottom of the transmission and drain the oil into a suitable container.

2

6. Clean the drain plug with magnetic insert, replace seal if necessary and reinstall the plug.

• Tightening torque: 80 Nm.

continued overleaf

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

161

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Clean stranier: 7. The strainer is located on the right hand side of the drain plug.

8. Remove the bolts and washers (3).

9. Remove the cover (4) and the spring (5).

10. Remove the strainer (6) and clean it with diesel oil or flushing oil.

11. The strainer must be replaced if it is damaged.

12. Procedure for reinstall the strainer :

6

To check and confirm that the strainer is being installed into the strainer mounting section properly, apply a gauge (a scale etc.) on the end face of the block (mating surface to the cover) to make sure the tip end of the strainer bolt is not projecting beyond the end face of the block, see figure 1.

5 4 3

NOTE It is very important that the strainer is installed properly, if the cover (4) is installed while the strainer (6) is not installed to the strainer mounting section properly and completely, the tip end of the strainer may be damaged and the strainer structure may break.

13. Put the O-ring on the block.

14. Reinstall the spring.

Depress the cover by hand to let it come to close contact with the end face of the block

15. Depress the cover by hand to let it come to close contact with the end face of the block, see figure 2.

16. Securely holding the cover in close contact with the end face of the block, install the bolts and washers, see figure 3.

Tightening torque: 98 - 123 Nm 17. Reinstall the rear belly plate.

Check and make sure that the end face of the block and the cover are in close contact

* Numbers refer to positions on the lubrication schedule, chapter 6 162

Operating & Maintenance Manual

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Fill new oil: 18. Fill new oil according to the transmission oil list and oil specification sheet (chapter 6) through the dip stick tube.

19. Insert the dip stick again and turn handle clockwise to tighten the sealing.

Fill hose with oil: 20. Open the bonnet.

21. Disconnect the hose (7) at the transmission filter.

22. Raise the end of the hose, and fill the hose with oil (8).

23. Connect the hose.

continued overleaf

Transmission oil pump

7

En gin e

8

Transmission filter

Transmission oil pump Transmission filter

NOTE •

•

From serial no. 410234 it is not necessary to carry out items 20-23 in regards to the introdcution of a new hydraulic pump.

If the hydraulic pump on the transmission is modified according to Moxy Service/Parts Information no.

20/2000 on older dump trucks than serial no. 410234, then it is not necessary to carry out items 20- 23.

Contact your Moxy Dealer if you have questions about hydraulic pump modifications.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

163

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

Check: 24. Start engine and let it idle for 2-3 minutes.

25. When the engine is started, check oil level (9) (see daily maintenance, for procedure) at low idle. Both too low and too high level can cause serious internal damage!

9

26. Warm up the oil and check for leaks. Recheck 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 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 6 164

Operating & Maintenance Manual

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. Remove the rear belly plate.

2. Open level / filling plug (1), special spanner in tool kit.

3. Unscrew drain plug (2).

4. Drain the oil into a suitable container.

1

2

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. 8. Reinstall the rear belly plate.

CAUTION Be aware of possible internal pressure when the oil is hot! Oil can spurt out when opening the drain plug.

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.

1

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.

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.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

165

7. Maintenance

1000 Hours Service Maintenance to be performed every 1000 hours of operation.

7. Front reduction gears 7.1. 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. Recheck 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.

8. Electrical system 8.1. 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

9. Continue with all items in 500 Hours Service.

* Numbers refer to positions on the lubrication schedule, chapter 6 166

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1. Engine 1.1. Check fuel injectors, at least once a year Contact Moxy Dealer for checking of the fuel injectors.

1.2. Check/adjust valve clearance

• Checking/adjusting valve clearance shall also be carried out after the first 500 hours of operation.

Adjust if necessary: • Inlet: 0,45 mm • Exhaust: 0,80 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.

FLYWHEEL Cylinder numbering TDC position No. 6 cylinder

TDC position No. 1 cylinder

Rocker cover gaskets must be changed if necessary.

• Tightening torque: 25 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

1 2 3 4 5

Inlet and exhaust Inlet Exhaust Inlet 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

FLYWHEEL

2 3 4 5 6

Exhaust Inlet Exhaust Inlet Inlet and exhaust

Intake valve Exhaust valve

The readings can only be taken from underneath

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

167

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1.3. 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)

1.3.1 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 6 168

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

Freezing point (° C)

Anti - freeze

- 18

30%

15 L

- 24

35%

17.5 L

- 30

40%

20 L

- 38

45%

22.5 L

- 40

50%

25 L

1.3.2 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 anti-freeze protection down to -18 °C. If more protection is required, see the table for calculating the necessary amount of glycol. The amount of glycol (anti-freeze) 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 designations: • BASF Glysantin G48

• Always fill up the anti-freeze if the 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 or 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 at least every 4th year.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

169

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

1.3.3 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 that 5% by volume or exceed 30% by volume.

NOTE • • • •

Anti-corrosive must not be mixed with glycol.

Mixing or over concentration can cause sludging and reduced cooling capacity.

Any coolant filter must not contain inhibitor.

The coolant should be changed when the cooling system is cleaned. Every 4000 hours or at least every 4th year.

1.4. Replace air dryer, at least once a year 12* 1. Release air pressure in dryer through air draining point.

2. The air dryer is to be found on left hand side in the engine compartment.

3. Remove the old air dryer element.

4. Install the new air dryer element.

5. Start engine end check for air leaks.

* Numbers refer to positions on the lubrication schedule, chapter 6 170

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

2. Hydraulic system 2.1. Change oil 40* 1. The drain plugs both for the main reservoir and the emergency steering reservoir (1) are to be found under the hydraulic tank.

2. Place a suitable container to catch spillage.

3. Remove the cap from both drain plugs.

1

4. Install the draining hose with nipple (tool kit) to the first drain plug and drain the oil into the container.

5. Install the draining hose to the second drain plug and drain the oil into the container 6. Remove the draining hose and reinstall both caps.

2

7. Fill new oil through the oil filler (2), according to the oil specification sheet (chapter 6).

2.2

Replace breather element 42* • Unscrew the old element on the hydraulic tank.

• Check the o-ring for deterioration, apply oil and screw on a new element.

CAUTION Both breather and filter must be replaced if the hydraulic filter warning light illuminates.

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

171

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

2.3. Replace hydraulic oil filter, must be replaced if the hydraulic filter warning light illuminates 43*.

•

Replacement of hydraulic filter shall also be carried out after the first 100 hours of operation.

1. Clean well around the filter housing. The filter is to be found on left hand side in the engine compartment.

2. Place a suitable container beneath the draining hose to catch spillage.

3. Unscrew filter housing.

4. Check for wear particles in the oil.

5. Change O-ring. Check backing ring for damage.

6. Replace the filter element with a new one.

7. Clean the housing and apply oil or grease to threads and o-rings.

8. Fill housing half full with clean oil.

9. Screw filter housing back into place.

• Torque: 141 Nm. 10. Start engine and check for leaks.

11. Check that the hydraulic filter warning light does not light at normal operating temperatures.

CAUTION Both breather and filter must be replaced if the hydraulic filter warning light illuminates.

Pay special attention to cleanliness when working with the hydraulic system! Contamination can give steering disturbance and reduce safety.

3. Brake system 3.1. 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 condtions or similar environment that may affect the brake system!

* Numbers refer to positions on the lubrication schedule, chapter 6 172

Operating & Maintenance Manual

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

3.2. Change brake fluid, at least once a year 60* 1. Apply the parking brake and stop the engine.

2. Put wheel chocks under the wheel to avoid spontaneous rolling.

4. Drain the old fluid from all circuits, pipes included (1).

5. Refill with new brake fluid (2) acc. to Oil Specification Sheet (chapter 6).

6. Bleed the brake circuits, one at a time: a. First bleed the master cylinder (3) and then the calipers (4). Fit a transparent hose to the bleeders and collect the spillage fluid in a container.

2

b. Depress the brake pedal and open bleeder plugs ( ) .

Close bleeders before fluid flow stops.

3

c. Refill brake fluid during the bleeding process. d. Bleed until brake fluid appears to be free of air.

1

e. Bleeder torque: 2,9 Nm.

•

4

Alternatively, other suitable equipment for bleeding the brake circuits can be used.

7. Fill up to correct reservoir level, see filling capacities (chapter 6).

8. Perform brake function test and check for leakage.

WARNING Brake fluid reservoir

• •

Master cylinder bleeding plug

•

Contact your Moxy Dealer for performing the fluid replacement.

Always follow the applicable governmental regulations for work on the brake system.

Make sure that the parking brake is on and put wheel chocks under the wheels before performing brake fluid replacement.

* Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

173

7. Maintenance

2000 Hours Service Maintenance to be performed every 2000 hours of operation.

4. Parking brake 4.1. Check breather, at least once a year 1. Loosen the circlip (1).

2. Remove cover plate (2).

3. Take out the breather element (3).

4. Remove the sealing (4) 4 3

5. Check if the breather element is clogged or damaged.

Clean the breather element and the other parts with solvent or cleaning fluid. Dry with compressed air.

2

6. Check the rubber bellow for wear and damages.

• Replace parts if necessary.

7. Reassemble the opposite way.

1

Adjust the check interval according to the surroundings (dusty/muddy conditions, etc.)

5. Tandem housings 5.1. Change oil 32*

• Change of tandem housing oil shall also be carried out after the first 500 hours of operation.

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.

1

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.

CAUTION Be aware of possible internal pressure when the oil is hot!

Oil can spurt out when opening the drain plug.

2

6. Continue with all items in 1000 Hours Service. * Numbers refer to positions on the lubrication schedule, chapter 6 174

Operating & Maintenance Manual

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

1. Cooling system If necessary, the cooling system should be cleaned more often.

1.1. External cleaning, at least every 4th year 5* 1. Clean externally the radiator fins and hoses.

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.

1.2

Internal cleaning, at least every 4th year 5* Removing deposits 1. If possible, run the engine until it is warm and then drain the cooling system, see changing coolant, item 1.4

1

2. Remove the thermostats (1).

3. Fill the system with clean, hot water mixed with one of the commercially available radiator cleaners based on sulphamin acid and containing dispersing agents. Follow the manufacturer's instructions (on the packaging) for mix ratios and cleaning times.

4. Run the engine for the specified time.

5. Drain the cooling system by removing a low hose or pipe (2). Do not use the drain cocks, the loosened deposits can clog them!

6. Refit the hose which was used as drain hose.

7 Fill the system again with hot water and run the engine for about 20 -30 minutes.

8. Drain the water from the cooling system in the usual way, use the drain cocks.

9. Refit the thermostats.

10.Fill the system with coolant as described in the specifications in item 1.3 at 2000 hours service.

2

WARNING When handling cleaners for the cooling system: Study the warning on the packaging. * Numbers refer to positions on the lubrication schedule, chapter 6 Operating & Maintenance Manual

175

7. Maintenance

4000 Hours Service Maintenance to be performed every 4000 hours of operation.

1.3. Charge air cooler 5* 1

1. Drain the coolant from the engine, see changing coolant, item 1.4.

2. Detach the intake manifold from the turbo.

3. Detach the charge air cooler's inlet and outlet connections.

2

4. Unbolt the charge air cooler assembly from the intake manifold. The charge air element is integrated into the housing.

Take care not to damage the element's water connections.

3 4

5. Clean the outside of the element. Use a paraffin-based engine cleaner.

6. Change gasket (3).

1.

2.

3.

4.

7. Bolt the charge air cooler back in place. Tighten the bolts to 42 Nm.

Charge air cooler housing with element O-ring Gasket Intake manifold

8. Refit inlet and outlet connections with new O-rings.

9. Refit the delivery pipe clamps.

10. Connect the intake manifold from the turbo.

11. Fill coolant as described in the specifications in item 1.3 at 2000 hours service.

1.4

Change coolant, at least every 4th year 5* 1. Remove the filler cap (1) from the expansion tank.

1

2. Drain the coolant in two places: • the "lowest point" on the engine block (2), right hand side.

• the "lowest point" of the cooling system (3), under the oil cooler on left hand side. The engine belly plate must be removed to reach the drain cock.

3. Close the cocks.

4. Fill with correct mixture, pre-mixed coolant through the expansion tank filler hole. See item 1.3 at 2000 hours service.

2

3

2. Continue with all items in 2000 Hours Service. * Numbers refer to positions on the lubrication schedule, chapter 6 176

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 housings.

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

177

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 6 178

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8. Technical Data

Technical Data

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179

8. Technical Data

Contents

8. Technical data .......................................................... 179 - 192 Measurements ........................................................... 181 Engine ........................................................................ 182 Transmission ............................................................. 182 Hydraulic system ....................................................... 183 Air system .................................................................. 183 Tyre pressures ........................................................... 183 Electrical system ........................................................ 184 Metering conversion table ......................................... 186 Tool kit content ........................................................... 186 Performance chart ..................................................... 187 Engine and retarder brake chart ............................... 188 Torque limit tables ..................................................... 189 Reference information (fill in table) .......................... 189 Consumable parts ..................................................... 189 Product signs ............................................................. 190 Periodic service (fill in table) ..................................... 191

180

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8. Technical Data

Measurements Machine dimensions (mm): ..................................... MT36 Total length ................................................................ 10330 Total width ................................................................. 3210 Total height ................................................................ 3700 (cab) Total height , loaded .................................................. 3643 (cab) Overhang, front .......................................................... 2870 Overhang, rear ........................................................... 1265 Wheelbase ................................................................. 4340/1855 Body upper height (rear edge) ................................... 3065 Body floor height (rear edge) ..................................... 2200 Total height, raised body ........................................... 6235 Ground clearance, raised body ................................. 685 Min. ground clearance ............................................... 575 (rear) Min. ground clearance, loaded .................................. 519 (rear) Turning radius (ISO 7457) ......................................... 9,0 Body tipping angle ..................................................... 70° Steering angle, both sides ......................................... 45° Standard tyre dimension ............................................ 26.5R25 Tyre load/speed index ............................................... 193B (2-stars)

Machine weights (kg): Empty weight .............................................................. 26500 Gross weight .............................................................. 59200 Maximum payload ...................................................... 32700

Weight distribution (kg): Front axle, empty ....................................................... 13300 Rear axle, empty ........................................................ 13200 Body capacity (m³): Struck ......................................................................... 16.0 (16.8*) Heaped, SAE 2:1 ....................................................... 20.0 (21.5*)

Machine speed (km/h): Forward speeds 6 - low gear range ........................... 6 - 9 - 12 - 17 - 24 - 34 Forward speeds 6 - high gear range ......................... 10 - 15 - 20 - 28 - 39 - 55 Reverse speed 2 - low gear range ........................... 5 - 8 Reverse speed 2 - high gear range ........................... 9 - 14 Towing load on hooks (kN): Front ........................................................................... 180 (each) Rear ............................................................................ 250 Sound power level, dB(A): According to ISO 6395 (external) ............................. 112

Sound pressure level, dB(A): According to ISO 6394 (in cab) ................................. 73

Ambient operating temperature (°C): Min. (-) ........................................................................ 20 Max. (+) ...................................................................... 40

The measurements are valid for a standard, unloaded machine if nothing else is given. *= with top tail gate fitted Operating & Maintenance Manual

181

8. Technical Data

Engine Water cooled, 4-stroke, direct injected diesel engine with turbo charger and intercooler Type ........................................................................... Scania DI 12 40 A (- 410251) DI 12 51 A (410252 -) Cylinder volume ........................................................ 11.70 litres Bore x stroke .............................................................. 127 x 154 mm No. of cylinders .......................................................... 6 (in line) Power rating (ISO 3046) at 2200 rpm ........................ 294 kW (400 hp) 1 kW = hp Power rating (ISO 9249) at 2200 rpm ........................ 285 kW (388 hp) 1,36 Max. torque ................................................................ 1750 Nm at 1300 rpm Engine speed, low idle ............................................... 650 + 50 rpm Engine speed, high idle ............................................. 2400 ± 50 rpm Max. allowed engine speed ....................................... 2600 rpm Oil capacity (min./max.) ............................................. 30/34 litres Oil pressure, warm engine at 2200 rpm .................... 3.0-6.0 bar Oil pressure, warm engine at 800 rpm ...................... min. 0.7 bar Specific oil consumption ............................................ 0.3 g/kWh Coolant volume .......................................................... 50 litres (approx.)

Normal temperature ................................................... 70-93 oC Thermostats (double) ................................................. 75 oC Max. system pressure ................................................ 0.5 bar Compression ratio ...................................................... 17 : 1 Firing order ................................................................. 1-5-3-6-2-4 Engine rotation, seen from rear ................................. Counterclockwise Valve clearance (cold engine) ................................... 0.45 mm, inlet valves .............................................................................. 0.80 mm, exhaust valves Pump timing (see rocker cover sign) ......................... 18o before TDC Opening pressure, injectors ....................................... 300 bar

Transmission Automatic transmission. Integrated in the gearbox: torque converter, automatic lock-up clutch, retarder brake and lockable inter axle differential.

Type ........................................................................... Komatsu KTF 6140 No. of forward gears .................................................. 6 No. of reverse gears .................................................. 2 Oil capacity ................................................................ 79 litres (approx.)

Normal temperature ................................................... 80-110 oC Max. permitted temp. when using retarder brake ...... 120 oC (short period only) Lock-up clutch ............................................................ in all gears (except 1st gear of reverse) Lock-up in/out ............................................................ acc. to engaged mode Inter axle diff. distribution .......................................... 1/3 to front axle, 2/3 to rear axle, lockable

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8. Technical Data

Hydraulic system Applied for steering and work equipment. The steering circuit has priority above the work circuit. The main and emergency steering pumps are fitted on the transmission.

Tank capacity ............................................................. 135 litres (approx.)

Normal oil temperature .............................................. 40-90 oC (at tank) Filter ........................................................................... Full flow pressure filter w/ indicator Main pumps (two) ...................................................... Gear pump, engine speed dependent Pump delivery ............................................................ 300 l/min at 2100 rpm Emergency steering pump ......................................... Piston pump, ground driven, speed dependent Pump delivery ............................................................ Max. 50 l/min Pressure setting- main safety valves: Tipping circuit - up ..................................................... 150 bar Tipping circuit - down ................................................. 45 bar End stop for tip cylinders ........................................... 145 bar (shock valve) Steering circuit ........................................................... 175 bar Tipping cylinders ........................................................ 2 x 3-stage, double acting on the third stage Tipping time ............................................................... 15 sec.

Steering cylinders ...................................................... 2 x double acting w/ 1 piston Steering wheel turns .................................................. Approx. 5

Air system Applied for brakes, tip control, differential lock and driver seat. The air dryer is fitted with heater, thermostat and silencer.

System pressure ........................................................ 7.0-7.8 bar Safety valve (compressor) ......................................... 19.0 bar Safety valve, supply circuit ........................................ 9.3 bar Low pressure indication (buzzer) .............................. Below 5.0 bar Air tanks ..................................................................... 5 (2x 30 L, 1x 20 L, 1x 10 L and 1x 3 L) Air compressor ........................................................... Piston, 2 cylinders, single acting Heater element, air dryer ........................................... 100 W Thermostat range, air dryer ....................................... 7-29 oC

Tyre pressures Basic pressure for cold tyres (based on max. load and max. speed):

Type Bridgestone VLT ** Michelin XADN/XADT Good Year GP2B/GP4B/RL-2+

Front bar (psi) 4.25 (62) 3.50 (51) 3.50 (51)

Rear bar (psi) 4.50 (65) 4.0 (58) 3.90 (57)

Regarding tyre pressure: Contact your Moxy Dealer or tyre supplier to get further information.

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183

8. Technical Data

Electrical system System voltage .......................................................... 24 V Battery ........................................................................ 2x 12 V, 230 Ah Grounding .................................................................. Negative earth cable Alternator .................................................................... 28 V, 65 A Starter motor .............................................................. 6.7 kW (9.1 hp) Fuses: The fuses are located in the fuse boxes located under the panel behind the driver's seat. 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.

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88

89

MT36 serial no. 410002 and up

92

FUSE BOXES AND RELAYS 90

60 1A / 5A • Radio

91

60

61

62

63

64

1A

1A

1A

1A

1A

2B

2B

2B

2B

2B

3C

3C

3C

3C

3C

4D

4D

4D

4D

4D

5E

5E

5E

5E

5E

6F

6F

6F

6F

6F

61 1A / 5A • Brake light s *

62

63

1A /10A

1A / 10A

• Low beam

• Reverse light

• Cab light 2B / 5A • Aut omat ic cent ral

2B / 5A

64 1A / 15A • Start er

• Reverse alarm 2B / 10A

• Transmission controller • High beam

lubricat ion

2B / 10A • Working light (backwards)

2B / 15A • Wiper / washer • Horn

• Start er 3C / 5A • Rot ating beacon

3C / 5A • Engine cont roller

• Switch light s

3C / 10A • Side light s • Switch light s

3C / 10A • Working light , roof

3C / 15A • Heater

(backwards)

• High beam f lash 4D / 5A • Gear display

4D / 10A • Tipping system

• Inst ruments

4D / 10A • Air dryer • Heated driver's seat

4D / 10A 4D / 15A • Working light , sun visor • Engine cont roller (f orwards)

• Low pressure alarm • Parking brake alarm 5E / 5A • Side light , lef t h.s.

5E / 10A • Cont roller, head light s

5E / 10A • Light er

• Light , gear selector

• Direct ion indicat ors

• Radio

5E / 10A • Heated mirrors

5E

6F / 10A • Hazard light

6F

-

• Engine compart ment light

6F / 5A • Side light , right h.s.

6F / 10A • Transmission controller

6F / 10A -

-

• Inst rument light s

* = For serial no. 410002 through 410047, and s/n 410049 the brake lights are connected to fuse 62-5E.

184

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8. Technical Data

Relays: The relays are located under the panel behind the driver's seat (together with the fuse boxes).

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88

89

MT36 serial no. 410002 and up

92

FUSE BOXES AND RELAYS 90

91

60

61

62

63

64

1A

1A

1A

1A

1A

2B

2B

2B

2B

2B

3C

3C

3C

3C

3C

4D

4D

4D

4D

4D

5E

5E

5E

5E

5E

6F

6F

6F

6F

6F

65 • Engine cont roller

66

67

68

69

-

-

-

-

70 • Reverse light

71 72 • Work. light (backwards) • Working light , roof (backwards)

73 74 • Working light , sun visor • Low beam (f orwards)

75 • High beam

76 77 78 • Transm. Cont roller (" cut" ) • Transm. Controller (" N" ) • Parking brake alarm

79 • Parking brake alarm

80 • Power supply relay

81 • Heat er

82 • Engine cont roller

83 • Start er

84 • Heat ed mirrors

85 • Air dryer

86 • Tipping system

87 • Tipping syst em

88 89 • Transm. Cont roller (" H/ L" • Direct ion indicat ors

91 • Parking brake alarm

92 • Wiper / washer

• Hazard light

• Heat ed driver's seat 90 • Low pressure alarm

Bulbs: Light ........................................................................... Watts Head lights (H4) ......................................................... 75/70 Side lights in head light .............................................. 4 Direction indicators .................................................... 21 Stop lights .................................................................. 21 Licence plate lights .................................................... 5 Work light on roof ....................................................... 70 Reverse light .............................................................. 70 Rotating beacon (H1) ................................................. 70 Rear lights .................................................................. 5 Engine compartment light .......................................... 18 Cab light ..................................................................... 5 Instrument lights ......................................................... 1.2 Warning/indicator lights ............................................. 1.2 Switch lights ............................................................... 1.2

Socket P 45t BA 9s BA 15s BA 15s S 8,5 Pk 22s Pk 22s P 14,5s BA 15s S 8,5 S 8,5 W2x4,6d W2x4,6d

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185

8. Technical Data

Metering conversion table Length:

1m 1 km

= =

1.094 yd 1000 m

= =

3.281 ft 0.621 mile

=

39.37 in

Volume:

1 dm3 1 dm3 1 m3

= = =

1 litre 0.0353 ft3 35.32 ft3

= =

0.264 gal (US) 61.02 in3

=

0.220 gal (UK)

Weight:

1 kg = 1000 kg =

2.20 lb 1 ton (metric)

= =

35.27 oz 0.984 ton (UK) =

0.902 ton (US)

Power:

1 hp

=

0.746 kW

=

1.015 hk.

Torque:

10 Nm =

1.02 kpm

=

7.38 lbf ft (pound-force foot)

=

14.5 p.s.i.

2

Pressure:

1 bar

=

1.02 kp/cm

Temperature:

o

= =

5/9 x (oF- 32) (9/5 x oC)+32

C F

o

Speed:

1 km/h =

=

0.62 mph

Tool kit content

Operation manual Driver instruction Parts catalogue

Arm, hydraulic pump (tiltable cab) - only High Line Draining hose

Tool kit content (optional) Hex. socket 19 mm Hex. bit front hub Diagonal wrench

186

Wheel-spanner Arm, wheel-spanner Grease gun

Operating & Maintenance Manual

100 kPa

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 perfomance: 1. Read from vehicle weight (A) up to the percentage grade (B).

2. From this point, read horizontally to the curve highest speed range (C).

Rimpull (kp x 1000)

3. Then down to maximum speed (D).

Travel speed (km/h)

Operating & Maintenance Manual

Weight (kg x 1000)

187

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 grade (B) (Rolling resistance is not included in the percentage grade).

2. From this point, read horizontally to the curve with highest speed range (C).

Brake capacity (kp x 1000)

3. Then down to maximum speed (D).

Travel speed (km/h)

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Operating & Maintenance Manual

Weight (kg x 1000)

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

Dim./Class

8.8

Fine Metric Threads

10.9

12.9

Dim./Class

8.8

10.9

12.9

M8 M10 M12

24 47 81

33 65 114

40 79 136

M8 x 1 M10 x 1.25 M10 x 1

25 48 49

35 68 70

42 81 84

M14 M16 M18

128 197 275

181 277 386

217 333 463

M12 x 1.5 M12 x 1.25 M14 x 1.5 M16 x 1.5

83 85 135 204

117 120 190 287

140 144 228 344

M20 M22 M24

385 518 665

541 728 935

649 874 1120

M27 M30 M33 M36

961 1310 1770 2280

1350 1840 2480 3210

1620 2210 2980 3850

M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2

294 408 546 696

413 574 768 979

496 688 921 1170

1000 1390 1860 2350

1410 1950 2610 3310

1690 2340 3130 3970

M27 x 2 M30 x 2 M33 x 2 M36 x 3

Reference information Machine model:

Serial no.:

Prod. year:

In operation:

Engine s/no.:

Transm. s/no.:

Dealer:

Consumeable parts Part no.

Q'ty

Description

Operating & Maintenance Manual

189

8. Technical Data

Product signs

190

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

191

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.:

192

Operating & Maintenance Manual

9. Index

Index

Operating & Maintenance Manual

193

9. Index

194

Operating & Maintenance Manual

9. Index

Index 1000 Hours Service ........................................................ 155 2000 Hours Service ........................................................ 167 40 Hours Service ............................................................ 137 4000 Hours Service ........................................................ 175 500 Hours Service .......................................................... 141 8 Hours Service .............................................................. 127 Air conditioner system .................................. 138, 151, 153 Air conditioning system hazard prevention ...................... 18 Air dryer .......................................................................... 170 Air filter ................................................................... 157, 159 Air filter warning light ........................................................ 49 Air pressure gauge, front service brakes ......................... 44 Air pressure gauge, rear service brakes .......................... 44 Air system ....................................................................... 183 Articulation lock ................................................................ 28 Ashtray .............................................................................. 74 Automatic central lubrication .......................................... 153 Automatic central lubrication indicator light ..................... 56 Batteries ................................................................. 137, 156 Battery charge warning light ............................................ 49 Battery hazard prevention ................................................ 17 Battery power aid ............................................................ 106 Bearings ......................................................................... 178 Before operation ............................................................... 88 Bleed fuel system ........................................................... 156 Body capacity ................................................................. 181 Body support .................................................................... 26 Brake fluid ....................................................................... 173 Brake fluid warning light ................................................... 46 Brake lines ...................................................................... 172 Brake pedal ...................................................................... 63 Brake system ................................................ 132, 149, 172 Brakes ........................................................................ 20, 93 Braking/stopping the dump truck ...................................... 94 Breather element ............................................................ 171 Bulbs ............................................................................... 185 Cab and engine compartment light .................................. 53 Cab certification ................................................................ 30 Cab light ........................................................................... 74 Cab ventilation ........................................................ 67, 137 Central lubrication ................................................... 56, 153 Centrifugal cleaner ......................................................... 141 Change brake fluid ......................................................... 173 Change coolant .............................................................. 176 Change oil, engine ......................................................... 141 Change oil, front differential ........................................... 165 Change oil, front reduction gears ................................... 166 Change oil, hydraulic system ......................................... 171 Change oil, rear differential ............................................ 165 Change oil, tandem housings ........................................ 174 Change oil, transmission ................................................ 161 Charge air cooler ............................................................ 176 Check batteries ...................................................... 137, 156 Check battery terminals .................................................. 137 Check brake fluid levels ................................................. 132 Check braking (holding) capacity .................................. 134 Check cab ventilation filter element ............................... 137

Check clearance of bearings ......................................... 178 Check coolant level ........................................................ 129 Check driver's seat ......................................................... 127 Check fuel injectors ........................................................ 167 Check fuel level .............................................................. 129 Check function, engine and retarder brake ................... 136 Check function, engine brake ........................................ 136 Check function, main brake ............................................ 135 Check function, steering ................................................. 135 Check glycol content in the coolant ............................... 169 Check lining thickness ................................................... 149 Check of the centrifugal cleaner .................................... 130 Check oil level, drive line ............................................... 147 Check oil level, engine ................................................... 128 Check oil level, front differential ..................................... 147 Check oil level, front reduction gears ............................. 148 Check oil level, hydraulic system ................................... 131 Check oil level, rear differential ...................................... 148 Check oil level, tandem housings .................................. 148 Check oil level, transmission .......................................... 131 Check parking brake breather ....................................... 174 Check poly-V belts condition .......................................... 157 Check protection against corrosion in the coolant ......... 170 Check the appearance of the coolant ............................ 168 Check the coolant ........................................................... 168 Check tyre pressures ...................................................... 138 Check wheel nuts torque ................................................ 150 Check wiring ................................................................... 166 Check/adjust valve clearance ........................................ 167 Checks after stopping the engine .................................. 100 Cigarette lighter ................................................................ 66 Clean breather ............................................................... 147 Clean centrifugal cleaner ............................................... 141 Clean strainer ................................................................. 161 Clothing and personal protection items ........................... 12 Cold weather .................................................................. 104 Column switch .................................................................. 60 Consumeable parts ........................................................ 189 Controls ............................................................................ 59 Coolant .................................................................. 168, 176 Cooling system ............................................................... 175 Correct tyre pressures .................................................... 102 Daily Service .................................................................. 127 Dangerous loads .............................................................. 21 Difference in tyre diameter ............................................. 102 Differentials ....................................................................... 96 Direction light indicator ..................................................... 51 Do not go close to high-voltage cables ............................ 17 Drain air tanks ................................................................ 130 Drain condensation, fuel tank ........................................ 161 Drive line ............................................................... 147, 177 Driver's seat ............................................................. 71, 155 Dropbox High - low gear .................................................. 90 Dump truck knowledge ..................................................... 11 Dump truck transportation ................................................ 29 Electrical system .................................................... 166, 184 Electrically heated driver's seat switch ............................. 56 Emergency braking .......................................................... 95

Operating & Maintenance Manual

195

9. Index

Emergency exit .......................................................... 14, 66 Emergency steering ......................................................... 19 Emergency steering warning light ................................... 46 Engine ............................... 128, 137, 141, 155, 167, 182 Engine and retarder brake ............................................. 136 Engine and retarder brake capacity chart ...................... 188 Engine and retarder brake mode ..................................... 90 Engine and retarder brake operation ............................... 93 Engine and retarder brake switch .................................... 58 Engine bonnet .................................................................. 24 Engine brake ........................................................... 93, 136 Engine brake indicator ..................................................... 51 Engine controller .............................................................. 47 Engine coolant temperature gauge ................................. 41 Engine coolant temperature warning light ....................... 47 Engine, general condition check .................................... 128 Engine oil pressure gauge ............................................... 41 Engine oil pressure warning light .................................... 47 Engine oils ...................................................................... 121 Engine overspeed ............................................................ 20 Engine revolution counter and hour meter ...................... 42 Exhaust heating ................................................................ 21 Exhaust system ............................................................... 178 Expansion tank coolant level ........................................... 19 External air filling ............................................................ 107 External cleaning, cooling system ................................. 175 External door opener/lock ................................................ 72 Filling capacities ............................................................. 120 Filling fuel or oil ................................................................ 18 Fire extinguisher ............................................................... 13 Fire prevention ................................................................. 15 Fire prevention for fuel and oil ......................................... 13 First 100 hours .................................................................. 80 First 250 hours .................................................................. 81 First 500 hours .................................................................. 81 First 8 hours ...................................................................... 80 First aid kit ......................................................................... 13 FOPS ................................................................................ 14 Foreword ............................................................................ 5 Front differential ....................................................... 96, 165 Front reduction gears ...................................................... 166 Front service brakes warning light ................................... 46 Fuel filter ......................................................................... 155 Fuel gauge ....................................................................... 42 Fuel injectors .................................................................. 167 Fuel tank ......................................................................... 161 Fuses .............................................................................. 184 Gear display ..................................................................... 42 Gear position 3 ................................................................. 89 Gear position 4 ................................................................. 89 Gear position 5 ................................................................. 89 Gear position D ................................................................. 89 Gear position L ................................................................. 89 Gear position N ................................................................. 89 Gear selector .................................................................... 64 Gear shift program ............................................................ 90 Gear shifting ..................................................................... 89 General condition check, drive line ................................ 177 General condition check, engine ................................... 128 General condition check, tanks ...................................... 177 General condition check, transmission .......................... 177

196

General description ............................................................ 7 General precautions ......................................................... 11 General safety check, driver's seat ................................. 155 Getting on and off the dump truck .................................... 12 Hazard light switch ........................................................... 55 High and low gear switch ................................................. 54 High beam indicator ......................................................... 51 High gear .......................................................................... 90 High gear indicator ........................................................... 49 High pressure ................................................................... 29 High temperatures ............................................................ 13 High-voltage cables ......................................................... 17 Hoisting ............................................................................. 28 How to adjust the parking brake .................................... 150 Hydraulic filter warning light ............................................. 50 Hydraulic oil filter ............................................................ 172 Hydraulic system ................................. 131, 171, 178, 183 Important operating instructions ....................................... 98 Indicator lights .................................................................. 45 Inspect the hydraulic hoses ........................................... 178 Inspect brake lines ......................................................... 172 Instructor seat ................................................................... 72 Instruments ....................................................................... 40 Intended use ....................................................................... 7 Inter axle differential ......................................................... 96 Inter-axle differential lock ................................................. 54 Inter-axle differential lock indicator .................................. 51 Internal cleaning, cooling system ................................... 175 Internal door opener ......................................................... 72 Introduction ......................................................................... 7 Labels ............................................................................... 30 Lifting ................................................................................ 28 Loading ........................................................................... 100 Long term storage .......................................................... 105 Low gear ........................................................................... 90 Low gear indicator ............................................................ 50 Lubricants ....................................................................... 115 Lubrication .................................................... 132, 139, 154 Lubrication, articulation bearings ................................... 139 Lubrication, articulation turning ring .............................. 132 Lubrication, cab rear hinges .......................................... 154 Lubrication, door and fender hatches ............................ 154 Lubrication schedule ...................................................... 117 Lubrication, steering cylinder bearings .......................... 139 Lubrication, tailgate arm hinge ....................................... 140 Lubrication, tandem bearings ........................................ 133 Lubrication, tip cylinder bearings ................................... 139 Lubrication, tip hinges .................................................... 133 Lubrication,suspension legs .......................................... 154 Machine dimensions ...................................................... 181 Machine speed ............................................................... 181 Machine turning ................................................................ 19 Machine weights ............................................................ 181 Main light switch ............................................................... 53 Main warning light, engine failure .................................... 47 Main warning light, transmission failure .......................... 49 Maintenance ................................................................... 123 Maintenance precautions ............................................... 125 Maintenance table .......................................................... 126

Operating & Maintenance Manual

9. Index

Manual release of parking brake ................................... 108 Measurements ................................................................ 181 Metering conversion table .............................................. 186 Mirror heating switch ........................................................ 56 Normal operation .............................................................. 92 Oil filter, engine ............................................................... 145 Oil specification sheet .................................................... 119 Operating Controls ........................................................... 37 Operating hints ................................................................. 91 Operating Instructions ...................................................... 83 Operating the dump truck ................................................. 88 Operation of brakes .......................................................... 20 Operator's cab .................................................................. 15 Optional accessories ........................................................ 14 Other cab equipment ........................................................ 71 Parking brake ........................................ 93, 134, 150, 174 Parking brake indicator .................................................... 46 Parking brake lever .......................................................... 65 Parking brake warning light ............................................. 46 Parking the dump truck ..................................................... 99 Performance chart .......................................................... 187 Periodic service .............................................................. 191 Precautions before starting the engine ............................ 15 Precautions for mirrors, windows and lights .................... 16 Precautions for optional accessories ............................... 14 Precautions when handling at high temperatures ........... 13 Product signs .................................................................. 190 Proper maintenance ....................................................... 103 Protection against falling objects ..................................... 14 Radio/Cassette player ...................................................... 75 Rear differential ....................................................... 96, 165 Rear service brakes warning light ................................... 46 Reference information .................................................... 189 Refrigerant ........................................................................ 18 Relays ............................................................................. 185 Replace air dryer ............................................................ 170 Replace breather element ............................................. 171 Replace fuel filter ............................................................ 155 Replace hydraulic oil filter .............................................. 172 Replace oil filter .............................................................. 145 Replace transmisson filter element ................................ 146 Retarder brake ........................................................ 93, 136 Retarder brake capacity chart ........................................ 188 Retarder brake indicator .................................................. 51 Retarder brake mode ....................................................... 90 Retarder brake switch ...................................................... 58 Retractable roller sunblind on front window .................... 74 Reversing (back-up) operations ...................................... 92 Roll-over protection .......................................................... 14 ROPS ................................................................................ 14 Rotating beacon switch .................................................... 53 Rules to follow when filling fuel or oil ............................... 18 Running-in operation ....................................................... 79 Running-in period ............................................................ 77 Running-in services ......................................................... 80 Safety at the worksite ........................................................ 15 Safety check, exhaust system ........................................ 178 Safety equipment .............................................................. 73

Safety information ............................................................... 6 Safety Instructions .............................................................. 9 Safety labels ..................................................................... 30 Safety rules ....................................................................... 11 Service brake ........................................................... 93, 134 Service position ................................................................ 27 Side window ..................................................................... 73 Specified loading ............................................................ 103 Speedometer .................................................................... 43 Starter switch .................................................................... 65 Starting in cold weather .................................................... 87 Starting the engine ........................................................... 86 Steering ................................................................... 95, 135 Steering column ............................................................... 62 Stopping the engine ......................................................... 99 Switches ........................................................................... 52 Tandem housings ........................................................... 174 Tanks .............................................................................. 177 Technical Data ................................................................ 179 Test switch for brake warning light ................................... 55 Throttle pedal .................................................................... 63 Tiltable cab ....................................................................... 25 Tip control lever ................................................................ 65 Tipping ............................................................................ 101 Tipping system switch ...................................................... 55 Tool kit content ................................................................ 186 Top tailgate ....................................................................... 23 Torque limits for bolts ...................................................... 189 Towing the dump truck ................................................... 107 Transit, long distance drive-away on road ..................... 103 Transmission .............................. 131, 146, 161, 177, 182 Transmission controller .................................................... 43 Transmission filter element ............................................. 146 Transmission oil list ........................................................ 121 Transmission oil temperature gauge ................................ 41 Transportation ................................................................... 29 Travelling on slopes ......................................................... 20 Troubleshooting .............................................................. 109 Tyre filling point ............................................................... 108 Tyre handling .................................................................. 102 Tyre pressures ....................................................... 102, 183 Tyres ............................................................................... 138 Unauthorised modification ............................................... 12 Up, down and crossgradient travel .................................. 97 Valve clearance .............................................................. 167 Ventilation for enclosed areas .......................................... 16 Volt meter .......................................................................... 44 Wading ............................................................................. 21 Walk around check ......................................................... 127 Warming up period ........................................................... 89 Warning / indicator lights .................................................. 45 Warning triangle ............................................................... 13 Weekly Service ............................................................... 137 Weight distribution .......................................................... 181 Welding ............................................................................. 22 Wheel chocks ................................................................... 27 Wheels ............................................................................ 150 When starting the engine ................................................. 16 Worker protection rules, refrigerant .................................. 18

Operating & Maintenance Manual

197

9. Index

Working lights on cab roof ................................................ 53 Working lights on the sun visor ........................................ 53 Yearly recommended maintenance ............................... 177

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Operating & Maintenance Manual