8 minute read
8 Hours / Daily service
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.
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.
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2.2.Check oil level, before start 1*
•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.
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.
1
2
2.4.Check fuel level, before start 13*
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.
2.5.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
Rear 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
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: lower mark Hot oil, 80 °C: 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!
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
• When refilling, do not overfill! • Use only brake fluid as specified in the specification sheet, chapter 6!
- 410251 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 -
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.
7.Parking brake
7.1.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). 3.Increase the engine speed slowly.
D 1st gear
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).
D 1st gear
2.Depress the brake pedal. 4.Set the gear selector in 1st gear and select high gear range.
5.Increase the engine speed slowly.
OFF 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.
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).
2.Stop the engine.
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. 5.Check for brake fluid leakage at master cylinders, pipes and hoses.
ON 6.Start the engine and release the parking brake.
OFF
3.Depress brake pedal firmly and listen for leaks in the air system.
OFF
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.
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.
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.
3.Check that the exhaust sound changes. 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).
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.
2.Apply the engine and retarder brake by setting the engine/retarder brake switch to pos. II and release the throttle pedal.
3.Check that the exhaust sound changes. 4.Check the indicator light for function, both engine and retarder brake and note the braking power.
5.Depress the throttle pedal again and notify that both the engine and retarder brake goes off (i.e no braking power and the indicator lights switches off).
