8 minute read
2000 Hours Service
FLYWHEEL
Cylinder numbering
TDC position No. 6 cylinder TDC position No. 1 cylinder
FLYWHEEL
Intake valve
Exhaust valve
The readings can only be taken from underneath 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 seeinstruction sign on one of the rocker covers. Valves should be adjusted when the engine is cold, at least 30 minutes after operation. Rocker cover gaskets must be changed if necessary. •Tightening torque: 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 Inlet and exhaust 2 Inlet 3 Exhaust 4 Inlet 5 Exhaust
3.Set no. 6 cylinder to TDC (Top Dead Centre) by turning the engine one revolution in its direction of rotation. 4.Adjust the following valves:
Cylinder 2 Exhaust 3 Inlet 4 Exhaust 5 Inlet 6 Inlet and exhaust
WARNING
Block the starter device when working on the engine! If the engine starts out of control, there is a SERIOUS RISK OF INJURY!
Coolant:
Water + Anti-freeze or Water + Anti-corrosive
(see text)
1.3.Check the coolant, at least once a year 5*
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)
1.3.1Check 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.
gnizeerF tniop °( )C -itn A e zeerf
81 - % 0 3 L 51
42 - % 5 3 L 5.71
03 - % 0 4 L 02
83 - % 5 4 L 5.22
04 - % 0 5 L 52
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.
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.
• 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.
NOTE
1.3.3Coolant 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.
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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. 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. 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
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
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!
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Brake fluid reservoir
Master cylinder bleeding plug
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. b.Depress the brake pedal and open bleeder plugs ( ) .
Close bleeders before fluid flow stops. c.Refill brake fluid during the bleeding process. d.Bleed until brake fluid appears to be free of air. e.Bleeder torque: 2,9 Nm. • 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
• 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.
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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) 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. 6.Check the rubber bellow for wear and damages. •Replace parts if necessary. 7.Reassemble the opposite way. 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. 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.
